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THC ArcGlide
User Manual
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Hypertherm THC ArcGlide User Manual

ArcGlide® THC
Torch Height Control
Instruction Manual
806450 | Revision 5 | English
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ArcGlide, EDGE, HPR, HSD, Hypernet, MAXPRO200, Phoenix, Powermax, Sensor, and Hypertherm are trademarks of Hypertherm Inc. and may be registered in the United States and other countries. All other trademarks are the property of their respective holders.
© 2015 Hypertherm Inc.
ArcGlide
Instruction Manual
806450
Revision 5
English
March 2015
Hypertherm Inc.
Hanover, NH 03755 USA
Hypertherm Inc.
Etna Road, P.O. Box 5010 Hanover, NH 03755 USA 603-643-3441 Tel (Main Office) 603-643-5352 Fax (All Departments) info@hypertherm.com (Main Office Email)
800-643-9878 Tel (Technical Service)
technical.service@hypertherm.com (Technical Service Email)
800-737-2978 Tel (Customer Service)
customer.service@hypertherm.com (Customer Service Email)
866-643-7711 Tel (Return Materials Authorization) 877-371-2876 Fax (Return Materials Authorization)
return.materials@hypertherm.com (RMA email)
Hypertherm Plasmatechnik GmbH
Technologiepark Hanau Rodenbacher Chaussee 6 D-63457 Hanau-Wolfgang, Deutschland 49 6181 58 2100 Tel 49 6181 58 2134 Fax
49 6181 58 2123 (Technical Service)
Hypertherm (S) Pte Ltd.
82 Genting Lane Media Centre Annexe Block #A01-01 Singapore 349567, Republic of Singapore 65 6841 2489 Tel 65 6841 2490 Fax
65 6841 2489 (Technical Service)
Hypertherm (Shanghai) Trading Co., Ltd.
Unit 301, South Building 495 ShangZhong Road Shanghai, 200231 PR China 86-21-60740003 Tel 86-21-60740393 Fax
Hypertherm Europe B.V.
Vaartveld 9 4704 SE Roosendaal, Nederland 31 165 596907 Tel 31 165 596901 Fax 31 165 596908 Tel (Marketing)
31 165 596900 Tel (Technical Service) 00 800 4973 7843 Tel (Technical Service)
Hypertherm Japan Ltd.
Level 9, Edobori Center Building 2-1-1 Edobori, Nishi-ku Osaka 550-0002 Japan 81 6 6225 1183 Tel 81 6 6225 1184 Fax
Hypertherm Brasil Ltda.
Rua Bras Cubas, 231 – Jardim Maia Guarulhos, SP - Brasil CEP 07115-030 55 11 2409 2636 Tel 55 11 2408 0462 Fax
Hypertherm México, S.A. de C.V.
Avenida Toluca No. 444, Anexo 1, Colonia Olivar de los Padres Delegación Álvaro Obregón México, D.F. C.P. 01780 52 55 5681 8109 Tel 52 55 5683 2127 Fax
Hypertherm Korea Branch
#3904 Centum Leaders Mark B/D, 1514 Woo-dong, Haeundae-gu, Busan Korea, 612-889 82 51 747 0358 Tel 82 51 701 0358 Fax
Contents
Safety ....................................................................................................................................... SC-13
Recognize safety information ...............................................................................................................................................SC-13
Follow safety instructions ......................................................................................................................................................SC-13
Electrical hazards ....................................................................................................................................................................SC-13
Electric shock can kill ............................................................................................................................................................SC-14
Cutting can cause fire or explosion ....................................................................................................................................SC-15
Fire prevention .................................................................................................................................................................SC-15
Explosion prevention ......................................................................................................................................................SC-15
Toxic fumes can cause injury or death ...............................................................................................................................SC-16
Grounding safety ....................................................................................................................................................................SC-17
Static electricity can damage circuit boards ....................................................................................................................SC-17
A plasma arc can cause injury and burns .........................................................................................................................SC-18
Compressed gas equipment safety ...................................................................................................................................SC-18
Gas cylinders can explode if damaged .............................................................................................................................SC-18
Arc rays can burn eyes and skin .........................................................................................................................................SC-19
Pacemaker and hearing aid operation ...............................................................................................................................SC-20
Noise can damage hearing ...................................................................................................................................................SC-20
A plasma arc can damage frozen pipes ............................................................................................................................SC-20
Dry dust collection information ............................................................................................................................................SC-21
Laser radiation .........................................................................................................................................................................SC-22
Additional safety information ................................................................................................................................................SC-22
Warning labels ........................................................................................................................................................................SC-23
Symbols and marks ................................................................................................................................................................SC-25
Product Stewardship ...........................................................................................................SC-27
Introduction ..............................................................................................................................................................................SC-27
National and local safety regulations ..................................................................................................................................SC-27
Certification test marks .........................................................................................................................................................SC-27
ArcGlide THC Instruction Manual 806450 5
Contents
Differences in national standards .......................................................................................................................................SC-27
Safe installation and use of shape cutting equipment ...................................................................................................SC-27
Procedures for periodic inspection and testing ..............................................................................................................SC-27
Qualification of test personnel .............................................................................................................................................SC-28
Residual current devices (RCDs) .......................................................................................................................................SC-28
Higher-level systems ..............................................................................................................................................................SC-28
Environmental Stewardship .............................................................................................. SC-29
Introduction ..............................................................................................................................................................................SC-29
National and local environmental regulations ...................................................................................................................SC-29
The RoHS directive ................................................................................................................................................................SC-29
Proper disposal of Hypertherm products ..........................................................................................................................SC-29
The WEEE Directive ..............................................................................................................................................................SC-29
The REACH regulation ..........................................................................................................................................................SC-29
Proper handling and safe use of chemicals .....................................................................................................................SC-30
Fumes emission and air quality ...........................................................................................................................................SC-30
Electromagnetic Compatibility (EMC) ............................................................................ SC-31
Introduction ..............................................................................................................................................................................SC-31
Installation and use .................................................................................................................................................................SC-31
Assessment of area ................................................................................................................................................................SC-31
Methods of reducing emissions ..........................................................................................................................................SC-31
Mains supply ....................................................................................................................................................................SC-31
Maintenance of cutting equipment .....................................................................................................................................SC-31
Cutting cables .........................................................................................................................................................................SC-31
Equipotential bonding ....................................................................................................................................................SC-31
Earthing of the workpiece .............................................................................................................................................SC-31
Screening and shielding .......................................................................................................................................................SC-32
Warranty ..................................................................................................................................SC-33
Attention ...................................................................................................................................................................................SC-33
General .....................................................................................................................................................................................SC-33
Patent indemnity .....................................................................................................................................................................SC-33
Limitation of liability ................................................................................................................................................................SC-33
National and local codes ......................................................................................................................................................SC-33
Liability cap ..............................................................................................................................................................................SC-33
Insurance ..................................................................................................................................................................................SC-34
Transfer of rights .....................................................................................................................................................................SC-34
1 Specifications .............................................................................................................................. 35
Introduction .................................................................................................................................................................................... 35
6 ArcGlide THC Instruction Manual 806450
Contents
ArcGlide control module ..................................................................................................................................................... 36
Lifter assembly ....................................................................................................................................................................... 36
Human machine interface (HMI) ........................................................................................................................................ 37
Plasma interface board ........................................................................................................................................................ 37
Industrial Ethernet switch .................................................................................................................................................... 37
Specifications ................................................................................................................................................................................ 38
ArcGlide system .................................................................................................................................................................... 38
ArcGlide control module (090054) .................................................................................................................................. 39
Lifter assembly (090053) ................................................................................................................................................... 40
Optional HMI (090055) ...................................................................................................................................................... 43
Discrete plasma interface board (141094) .................................................................................................................... 44
Hypernet plasma interface board (141162) ................................................................................................................... 45
Ethernet switch ...................................................................................................................................................................... 46
ArcGlide communication ............................................................................................................................................................ 48
Hypernet communication .................................................................................................................................................... 48
Discrete communication ...................................................................................................................................................... 50
Mixed communication .......................................................................................................................................................... 51
Serial communication ........................................................................................................................................................... 51
2 Installation .................................................................................................................................... 53
Hardware setup ............................................................................................................................................................................. 53
Claims ...................................................................................................................................................................................... 53
Installation requirements ..................................................................................................................................................... 54
Placement of system components .................................................................................................................................... 54
Recommended grounding and shielding practices .............................................................................................................. 55
Introduction ............................................................................................................................................................................ 55
Types of grounding ............................................................................................................................................................... 55
Grounding practices ............................................................................................................................................................ 55
System description for a Hypernet configuration .................................................................................................................. 59
System description for a discrete configuration .................................................................................................................... 60
ArcGlide communication configuration examples ................................................................................................................. 61
Install the lifter ................................................................................................................................................................................ 77
Connect the ohmic wire from HPRXD plasma systems .............................................................................................. 79
Connect the ohmic wire to other plasma systems ........................................................................................................ 80
Ground the lifter .................................................................................................................................................................... 80
Extended torch sleeve option ............................................................................................................................................. 81
Install the optional pneumatic breakaway ....................................................................................................................... 82
Install the control module ............................................................................................................................................................ 84
Modify Retract Delay Time for an HT2000 plasma system ........................................................................................ 85
Ground the control module ................................................................................................................................................ 86
Install the optional HMI ................................................................................................................................................................ 87
ArcGlide THC Instruction Manual 806450 7
Contents
Ground the HMI ............................................................................................................................................................................ 89
Install the plasma interface board in a plasma system ......................................................................................................... 90
Discrete plasma interface board (141094) .................................................................................................................... 90
Hypernet plasma interface board (141162) .................................................................................................................. 91
Connect Hypernet cables ........................................................................................................................................................... 92
Connect discrete cables ............................................................................................................................................................. 95
Ground all cables with circular connectors .................................................................................................................... 95
Control module cable connections .................................................................................................................................. 95
Cables ............................................................................................................................................................................................. 97
Power cable ........................................................................................................................................................................... 97
Lifter interface cable ............................................................................................................................................................. 98
Hypernet and HMI interface cable .................................................................................................................................. 100
Optional operator console I/O cable ............................................................................................................................. 101
Optional operator console I/O signals ................................................................................................................... 103
ArcGlide control module CNC interlock kit (228594) ............................................................................................... 104
CNC I/O cable .................................................................................................................................................................... 105
CNC discrete I/O ............................................................................................................................................................... 108
Plasma interface I/O cable ............................................................................................................................................... 110
Plasma discrete I/O ............................................................................................................................................................ 113
Non-serial plasma interface cable .................................................................................................................................. 115
Serial plasma interface cable ........................................................................................................................................... 116
ArcGlide discrete interface signal examples ........................................................................................................................ 117
Inputs ..................................................................................................................................................................................... 117
Relay outputs ....................................................................................................................................................................... 118
ArcGlide setup in Phoenix™ software .................................................................................................................................... 119
Set up ArcGlide and Hypernet ........................................................................................................................................ 119
ArcGlide axis setup ............................................................................................................................................................ 120
ArcGlide axis setup parameters ...................................................................................................................................... 121
Gains ............................................................................................................................................................................. 121
Speeds .......................................................................................................................................................................... 122
Mechanical ................................................................................................................................................................... 123
Miscellaneous .............................................................................................................................................................. 124
Assign an ArcGlide THC to a station ............................................................................................................................ 125
3 Operation .................................................................................................................................... 127
Operator controls ....................................................................................................................................................................... 127
Control module .................................................................................................................................................................... 127
Lifter ....................................................................................................................................................................................... 128
HMI ......................................................................................................................................................................................... 129
Daily operations .......................................................................................................................................................................... 130
Startup procedure .............................................................................................................................................................. 130
8 ArcGlide THC Instruction Manual 806450
Contents
Automatic diagnostic tests ............................................................................................................................................... 130
Verify workpiece sensing .................................................................................................................................................. 130
Shutdown procedure ......................................................................................................................................................... 130
ArcGlide THC operating modes ............................................................................................................................................. 131
Manual mode ....................................................................................................................................................................... 131
Automatic modes ................................................................................................................................................................ 131
Voltage Control Off mode ......................................................................................................................................... 132
Set Arc Voltage mode ................................................................................................................................................ 132
Sample Voltage mode ................................................................................................................................................ 132
Initial height sense ...................................................................................................................................................................... 133
Performing a first IHS on the ArcGlide .......................................................................................................................... 133
Operating the control module .................................................................................................................................................. 135
Screen 0 – Idle Park .......................................................................................................................................................... 136
Screen 1 – ArcGlide control state ................................................................................................................................. 136
Screen 2 – Options ........................................................................................................................................................... 137
Screen 3 – Inputs from the CNC .................................................................................................................................... 138
Screen 4 – Outputs to the CNC .................................................................................................................................... 138
Screen 5 – Inputs from the lifter control board ........................................................................................................... 139
Screen 6 – Outputs from the lifter control board ........................................................................................................ 139
Screen 7 – Inputs from the operator console .............................................................................................................. 140
Screen 8 – Outputs to the operator console ............................................................................................................... 140
Screen 9 – Inputs from the plasma system .................................................................................................................. 141
Screen 10 – Outputs to the plasma system ................................................................................................................ 141
Screen 11 – Last errors .................................................................................................................................................... 142
Screen 12 – Total lifter operating time .......................................................................................................................... 142
Operating the HMI ...................................................................................................................................................................... 143
HMI screen hierarchy ......................................................................................................................................................... 144
Main screen .......................................................................................................................................................................... 146
Setup screen ........................................................................................................................................................................ 147
Diagnostics screen ............................................................................................................................................................. 148
Installation Data screen ..................................................................................................................................................... 153
Manual mode ....................................................................................................................................................................... 155
Lifter Disabled mode .......................................................................................................................................................... 155
ArcGlide operating parameters ............................................................................................................................................... 156
THC mode ............................................................................................................................................................................ 157
Cut chart values .................................................................................................................................................................. 157
Options .................................................................................................................................................................................. 158
Automatically-set parameters ........................................................................................................................................... 158
Plasma cutting tips ..................................................................................................................................................................... 161
Cut quality issues ................................................................................................................................................................ 161
Basic steps to improve cut quality .................................................................................................................................. 164
ArcGlide THC Instruction Manual 806450 9
Contents
4 Maintenance .............................................................................................................................. 169
Introduction .................................................................................................................................................................................. 169
Lifter routine maintenance ........................................................................................................................................................ 169
Carriage ................................................................................................................................................................................ 169
Sealing strip ......................................................................................................................................................................... 171
Cable connections ............................................................................................................................................................. 171
System grounding .............................................................................................................................................................. 171
Calibrate arc voltage .................................................................................................................................................................. 172
Flow of ArcGlide operations .................................................................................................................................................... 174
Basic flow for all ArcGlide operating states ................................................................................................................. 177
Common machine-cutting faults ............................................................................................................................................. 178
Update ArcGlide firmware ........................................................................................................................................................ 180
Download through Phoenix software ............................................................................................................................. 180
Download from a laptop .................................................................................................................................................... 180
Operator tests ............................................................................................................................................................................. 181
Problems and solutions ............................................................................................................................................................. 182
Troubleshooting routines .......................................................................................................................................................... 185
Hypertherm CNC will not communicate with HPR plasma system ........................................................................ 185
Error 19 – Excess plate contact ..................................................................................................................................... 186
Error 21 – Ohmic tip sense .............................................................................................................................................. 188
Error message troubleshooting .............................................................................................................................................. 191
Error message displays ..................................................................................................................................................... 191
ArcGlide errors .................................................................................................................................................................... 191
Printed circuit board (PCB) block diagram for a Hypernet configuration ..................................................................... 209
Printed circuit board (PCB) block diagram for a discrete configuration ....................................................................... 210
ArcGlide PCBs ........................................................................................................................................................................... 211
HMI processor board (228581) ...................................................................................................................................... 211
HMI 7-segment display interface board (228582) ..................................................................................................... 214
THC control interface board (228577) ......................................................................................................................... 215
THC processor board (228578) .................................................................................................................................... 220
Discrete plasma interface board (141094) .................................................................................................................. 224
Hypernet plasma interface board (141162) ................................................................................................................ 228
Lifter interface board (228580) ....................................................................................................................................... 231
5 Parts List ..................................................................................................................................... 235
Lifter parts .................................................................................................................................................................................... 235
Lifter motor and slide parts ...................................................................................................................................................... 237
Control module parts ................................................................................................................................................................. 238
HMI parts ...................................................................................................................................................................................... 239
Plasma interface boards ........................................................................................................................................................... 240
10 ArcGlide THC Instruction Manual 806450
Contents
6 Wiring Diagrams ....................................................................................................................... 241
Wiring diagram symbols ........................................................................................................................................................... 242
1 – Lifter interface board (141097) ....................................................................................................................................... 245
2 – THC control interface board (141088) ......................................................................................................................... 246
3 – THC Processor board (141091) ..................................................................................................................................... 247
4 – HMI processor board (141082) ...................................................................................................................................... 248
A ArcGlide THC Serial Communication Protocol ................................................................ 249
Overview ....................................................................................................................................................................................... 249
ArcGlide THC Operation .......................................................................................................................................................... 249
Serial Protocol ............................................................................................................................................................................. 249
ArcGlide THC Responses ................................................................................................................................................ 250
Calculating the Checksum ............................................................................................................................................... 250
ArcGlide Commands and Examples ...................................................................................................................................... 251
Setup Commands ...................................................................................................................................................................... 252
Operating Commands ............................................................................................................................................................... 255
ArcGlide THC Extended Commands .................................................................................................................................... 260
ArcGlide THC to Command THC error conversions ......................................................................................................... 266
B ArcGlide THC Serial Communication Installation ........................................................... 269
Introduction .................................................................................................................................................................................. 269
Kit 228846 (Command THC replacement) .................................................................................................................. 269
Kit 228851 (New ArcGlide installation) ........................................................................................................................ 270
Specifications .............................................................................................................................................................................. 270
Limitations ............................................................................................................................................................................. 271
RS-422 serial protocol ...................................................................................................................................................... 271
Serial communication configurations ..................................................................................................................................... 272
Replacing a Command THC ............................................................................................................................................ 272
System description for a serial configuration ....................................................................................................................... 274
ArcGlide THC replacement for Command THC ......................................................................................................... 274
ArcGlide THC in a new installation ................................................................................................................................ 275
Connect serial cables ................................................................................................................................................................ 276
Connecting cables for a Command THC replacement ............................................................................................. 276
Connecting cables in a new serial system .................................................................................................................... 278
Cables ........................................................................................................................................................................................... 280
Plasma I/O split cable (Z) (223253) .............................................................................................................................. 280
Adjusting ArcGlide parameters with the HMI ....................................................................................................... 283
Plasma board adapter cable (223260) ......................................................................................................................... 284
Plasma I/O split cable (Y) (223262) .............................................................................................................................. 285
ArcGlide THC Instruction Manual 806450 11
Contents
12 ArcGlide THC Instruction Manual 806450

Safety

RECOGNIZE SAFETY INFORMATION

The symbols shown in this section are used to identify potential hazards. When you see a safety symbol in this manual or on your machine, understand the potential for personal injury, and follow the related instructions to avoid the hazard.

FOLLOW SAFETY INSTRUCTIONS

Read carefully all safety messages in this manual and safety labels on your machine.
• Keep the safety labels on your machine in good condition. Replace missing or damaged labels immediately.
• Learn how to operate the machine and how to use the controls properly. Do not let anyone operate it without instruction.
• Keep your machine in proper working condition. Unauthorized modifications to the machine may affect safety and machine service life.
DANGER WARNING CAUTION
Hypertherm uses American National Standards Institute guidelines for safety signal words and symbols. A signal word DANGER or WARNING is used with a safety symbol. DANGER identifies the most serious hazards.
• DANGER and WARNING safety labels are located on your machine near specific hazards.
• DANGER safety messages precede related instructions in the manual that will result in serious injury or death if not followed correctly.
• WARNING safety messages precede related instructions in this manual that may result in injury or death if not followed correctly.
• CAUTION safety messages precede related instructions in this manual that may result in minor injury or damage to equipment if not followed correctly.

ELECTRICAL HAZARDS

• Only trained and authorized personnel may open this equipment.
• If the equipment is permanently connected, turn it off, and lock out/tag out power before the enclosure is opened.
• If power is supplied to the equipment with a cord, unplug the unit before the enclosure is opened.
• Lockable disconnects or lockable plug covers must be provided by others.
• Wait 5 minutes after removal of power before entering the enclosure to allow stored energy to discharge.
Safety and Compliance SC-13
• If the equipment must have power when the enclosure is open for servicing, arc flash explosion hazards may exist. Follow ALL local requirements (NFPA 70E in the USA) for safe work practices and for Personal Protective Equipment when servicing energized equipment.
• The enclosure shall be closed and the proper earth ground continuity to the enclosure verified prior to operating the equipment after moving, opening, or servicing.
• Always follow these instructions for disconnecting power before inspecting or changing torch consumable parts.
Safety
Touching live electrical parts can cause a fatal shock or severe burn.
• Operating the plasma system completes an electrical circuit between the torch and the workpiece. The workpiece and anything touching the workpiece are part of the electrical circuit.
• Never touch the torch body, workpiece or the water in a water table when the plasma system is operating.
Electric shock prevention
All Hypertherm plasma systems use high voltage in the cutting process (200 to 400 VDC are common). Take the following precautions when operating this system:
• Wear insulated gloves and boots, and keep your body and clothing dry.
• Do not stand, sit or lie on – or touch – any wet surface when using the plasma system.
• Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground. If you must work in or near a damp area, use extreme caution.
• Provide a disconnect switch close to the power supply with properly sized fuses. This switch allows the operator to turn off the power supply quickly in an emergency situation.
• When using a water table, be sure that it is correctly connected to earth ground.
• Install and ground this equipment according to the instruction manual and in accordance with national and local codes.
• Inspect the input power cord frequently for damage or cracking of the cover. Replace a damaged power cord immediately. Bare wiring can kill.
• Inspect and replace any worn or damaged torch leads.
• Do not pick up the workpiece, including the waste cutoff, while you cut. Leave the workpiece in place or on the workbench with the work cable attached during the cutting process.
• Before checking, cleaning or changing torch parts, disconnect the main power or unplug the power supply.
• Never bypass or shortcut the safety interlocks.
• Before removing any power supply or system enclosure cover, disconnect electrical input power. Wait 5 minutes after disconnecting the main power to allow capacitors to discharge.
• Never operate the plasma system unless the power supply covers are in place. Exposed power supply connections present a severe electrical hazard.
• When making input connections, attach proper grounding conductor first.
• Each Hypertherm plasma system is designed to be used only with specific Hypertherm torches. Do not substitute other torches which could overheat and present a safety hazard.

ELECTRIC SHOCK CAN KILL

SC-14 Safety and Compliance

CUTTING CAN CAUSE FIRE OR EXPLOSION

Safety

Fire prevention

• Be sure the area is safe before doing any cutting. Keep a fire extinguisher nearby.
• Remove all flammables within 35 feet (10 m) of the cutting area.
• Quench hot metal or allow it to cool before handling or before letting it touch combustible materials.
• Never cut containers with potentially flammable materials inside – they must be emptied and properly cleaned first.
• Ventilate potentially flammable atmospheres before cutting.
• When cutting with oxygen as the plasma gas, an exhaust ventilation system is required.

Explosion prevention

• Do not use the plasma system if explosive dust or vapors may be present.
• Do not cut pressurized cylinders, pipes, or any closed container.
• Do not cut containers that have held combustible materials.
WAR N ING
Explosion Hazard
Argon-Hydrogen and Methane
Hydrogen and methane are flammable gases that present an explosion hazard. Keep flames away from cylinders and hoses that contain methane or hydrogen mixtures. Keep flames and sparks away from the torch when using methane or argon-hydrogen plasma.
WAR N ING
Hydrogen Detonation with
Aluminum Cutting
• Do not cut aluminum underwater or with water touching the underside of the aluminum.
• Cutting aluminum underwater or with the water touching the underside of the aluminum can result in an explosive condition that can detonate during plasma cutting operations.
WAR N ING
Explosion Hazard
Underwater Cutting with Fuel Gases
• Do not cut under water with fuel gases containing hydrogen.
• Cutting under water with fuel gases containing hydrogen can result in an explosive condition that can detonate during plasma cutting operations.
Safety and Compliance SC-15
Safety

TOXIC FUMES CAN CAUSE INJURY OR DEATH

The plasma arc by itself is the heat source used for cutting. Accordingly, although the plasma arc has not been identified as a source of toxic fumes, the material being cut can be a source of toxic fumes or gases that deplete oxygen.
Fumes produced vary depending on the metal that is cut. Metals that may release toxic fumes include, but are not limited to, stainless steel, carbon steel, zinc (galvanized), and copper.
In some cases, the metal may be coated with a substance that could release toxic fumes. Toxic coatings include, but are not limited to, lead (in some paints), cadmium (in some paints and fillers), and beryllium.
Gases produced by plasma cutting vary based on the material to be cut and the method of cutting, but may include ozone, oxides of nitrogen, hexavalent chromium, hydrogen, and other substances if such are contained in or released by the material being cut.
Caution should be taken to minimize exposure to fumes produced by any industrial process. Depending upon the chemical composition and concentration of the fumes (as well as other factors, such as ventilation), there may be a risk of physical illness, such as birth defects or cancer.
It is the responsibility of the equipment and site owner to test the air quality in the area where the equipment is used and to ensure that the air quality in the workplace meets all local and national standards and regulations.
The air quality level in any relevant workplace depends on site-specific variables such as:
• Table design (wet, dry, underwater).
• Material composition, surface finish, and composition of coatings.
• Volume of material removed.
• Duration of cutting or gouging.
• Size, air volume, ventilation and filtration of the work area.
• Personal protective equipment.
• Number of welding and cutting systems in operation.
• Other site processes that may produce fumes.
If the workplace must conform to national or local regulations, only monitoring or testing done at the site can determine whether the site is above or below allowable levels.
To reduce the risk of exposure to fumes:
• Remove all coatings and solvents from the metal before cutting.
• Use local exhaust ventilation to remove fumes from the air.
• Do not inhale fumes. Wear an air-supplied respirator when cutting any metal coated with, containing, or suspected to contain toxic elements.
• Assure that those using welding or cutting equipment, as well as air-supplied respiration devices, are qualified and trained in the proper use of such equipment.
• Never cut containers with potentially toxic materials inside. Empty and properly clean the container first.
• Monitor or test the air quality at the site as needed.
• Consult with a local expert to implement a site plan to ensure safe air quality.
SC-16 Safety and Compliance

GROUNDING SAFETY

Safety
Work cable Attach the work cable securely to the
workpiece or the work table with good metal-to-metal contact. Do not connect it to the piece that will fall away when the cut is complete.
Work table Connect the work table to an earth ground, in accordance with appropriate national and local electrical codes.

STATIC ELECTRICITY CAN DAMAGE CIRCUIT BOARDS

Use proper precautions when handling printed circuit boards:
• Store PC boards in anti-static containers.
• Wear a grounded wrist strap when handling PC boards.
Input power
• Be sure to connect the power cord ground wire to the ground in the disconnect box.
• If installation of the plasma system involves connecting the power cord to the power supply, be sure to connect the power cord ground wire properly.
• Place the power cord’s ground wire on the stud first, then place any other ground wires on top of the power cord ground. Fasten the retaining nut tightly.
• Tighten all electrical connections to avoid excessive heating.
Safety and Compliance SC-17
Safety

COMPRESSED GAS EQUIPMENT SAFETY

• Never lubricate cylinder valves or regulators with oil or grease.
• Use only correct gas cylinders, regulators, hoses and fittings designed for the specific application.
• Maintain all compressed gas equipment and associated parts in good condition.
• Label and color-code all gas hoses to identify the type of gas in each hose. Consult applicable national and local codes.

GAS CYLINDERS CAN EXPLODE IF DAMAGED

Gas cylinders contain gas under high pressure. If damaged, a cylinder can explode.
• Handle and use compressed gas cylinders in accordance with applicable national and local codes.
• Never use a cylinder that is not upright and secured in place.
• Keep the protective cap in place over valve except when the cylinder is in use or connected for use.
• Never allow electrical contact between the plasma arc and a cylinder.
• Never expose cylinders to excessive heat, sparks, slag or open flame.
• Never use a hammer, wrench or other tool to open a stuck cylinder valve.

A PLASMA ARC CAN CAUSE INJURY AND BURNS

Instant-on torches
Plasma arc comes on immediately when the torch switch is activated.
The plasma arc will cut quickly through gloves and skin.
• Keep away from the torch tip.
• Do not hold metal near the cutting path.
• Never point the torch toward yourself or others.
SC-18 Safety and Compliance

ARC RAYS CAN BURN EYES AND SKIN

Eye protection Plasma arc rays produce intense
visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin.
• Use eye protection in accordance with applicable national and local codes.
• Wear eye protection (safety glasses or goggles with side shields, and a welding helmet) with appropriate lens shading to protect your eyes from the arc’s ultraviolet and infrared rays.
Skin protection Wear protective clothing to protect against burns caused by ultraviolet light, sparks, and hot metal.
• Gauntlet gloves, safety shoes and hat.
• Flame-retardant clothing to cover all exposed areas.
• Cuffless trousers to prevent entry of sparks and slag.
• Remove any combustibles, such as a butane lighter or matches, from your pockets before cutting.
Cutting area Prepare the cutting area to reduce reflection and transmission of ultraviolet light:
• Paint walls and other surfaces with dark colors to reduce reflection.
• Use protective screens or barriers to protect others from flash and glare.
• Warn others not to watch the arc. Use placards or signs.
Safety
Minimum
Arc current
(amps)
protective shade
number
(ANSIZ49.1:2005)
Less than 40 A
41 to 60 A
61 to 80 A
81 to 125 A
126 to 150 A
151 to 175 A
176 to 250 A
251 to 300 A
301 to 400 A
401 to 800 A
5589 6689 8889 8989 89810 89811 89812 89813 912913
10 14 10 N /A
Safety and Compliance SC-19
Suggested shade
number for
comfort
OSHA 29CFR
1910.133(a)(5)
EN168:2002
(ANSI Z49.1:2005)
Europe
Safety

PACEMAKER AND HEARING AID OPERATION

Pacemaker and hearing aid operation can be affected by magnetic fields from high currents.
Pacemaker and hearing aid wearers should consult a doctor before going near any plasma arc cutting and gouging operations.

NOISE CAN DAMAGE HEARING

Cutting with a plasma arc can exceed acceptable noise levels as defined by local codes in many applications. Prolonged exposure to excessive noise can damage hearing. Always wear proper ear protection when cutting or gouging, unless sound pressure level measurements taken at the installed site have verified personal hearing protection is not necessary per relevant international, regional, and local codes.
Significant noise reduction can be obtained by adding simple engineering controls to cutting tables such as barriers or curtains positioned between the plasma arc and the workstation; and/or locating the workstation away from the plasma arc. Implement administrative controls in the workplace to restrict access, limit operator exposure time, screen off noisy working areas and/or take measures to reduce reverberation in working areas by putting up noise absorbers.
To reduce magnetic field hazards:
• Keep both the work cable and the torch lead to one side, away from your body.
• Route the torch leads as close as possible to the work cable.
• Do not wrap or drape the torch lead or work cable around your body.
• Keep as far away from the power supply as possible.
Use ear protectors if the noise is disruptive or if there is a risk of hearing damage after all other engineering and administrative controls have been implemented. If hearing protection is required, wear only approved personal protective devices such as ear muffs or ear plugs with a noise reduction rating appropriate for the situation. Warn others in the area of possible noise hazards. In addition, ear protection can prevent hot splatter from entering the ear.

A PLASMA ARC CAN DAMAGE FROZEN PIPES

Frozen pipes may be damaged or can burst if you attempt to thaw them with a plasma torch.
SC-20 Safety and Compliance

DRY DUST COLLECTION INFORMATION

Safety
At some sites, dry dust can represent a potential explosion hazard.
The U.S. National Fire Protection Association’s 2007 edition of NFPA standard 68, “Explosion Protection by Deflagration Venting,” provides requirements for the design, location, installation, maintenance, and use of devices and systems to vent combustion gases and pressures after any deflagration event. Consult with the manufacturer or installer of any dry dust collection system for applicable requirements before you install a new dry dust collection system or make significant changes in the process or materials used with an existing dry dust collection system.
Consult your local “Authority Having Jurisdiction” (AHJ) to determine whether any edition of NFPA 68 has been “adopted by reference” in your local building codes.
Refer to NFPA68 for definitions and explanations of regulatory terms such as deflagration, AHJ, adopted by reference, the Kst value, deflagration index, and other terms.
Note 1 – Hypertherm’s interpretation of these new requirements is that unless a site-specific evaluation has been completed to determine that all dust generated is not combustible, the 2007 edition of NFPA 68 requires the use of explosion vents designed to the worst-case Kst value (see annex F) that could be generated from dust so that the explosion vent size and type can be designed. NFPA 68 does not specifically identify plasma cutting or other thermal cutting processes as requiring deflagration venting systems, but it does apply these new requirements to all dry dust collection systems.
Note 2 – Users of Hypertherm manuals should consult and comply with all applicable federal, state, and local laws and regulations. Hypertherm does not, by the publication of any Hypertherm manual, intend to urge action that is not in compliance with all applicable regulations and standards, and this manual may never be construed as doing so.
Safety and Compliance SC-21
Safety

LASER RADIATION

Exposure to the laser output can result in serious eye injury. Avoid direct eye exposure.
For your convenience and safety, on Hypertherm products that use a laser, one of the following laser radiation labels has been applied on the product near where the laser beam exits the enclosure. The maximum output (mV), wavelength emitted (nM) and, if appropriate, the pulse duration is also provided.
Additional laser safety instructions:
• Consult with an expert on local laser regulations. Laser safety training may be required.
• Do not allow untrained persons to operate the laser. Lasers can be dangerous in the hands of untrained users.
• Do not look into the laser aperture or beam at any time.
• Position the laser as instructed to avoid unintentional eye contact.
• Do not use the laser on reflective workpieces.
• Do not use optical tools to view or reflect the laser beam.
• Do not disassemble or remove the laser or aperture cover.

ADDITIONAL SAFETY INFORMATION

1. ANSI Standard Z49.1, Safety in Welding and Cutting, American Welding Society, 550 LeJeune Road P.O. Box 351020, Miami, FL 33135
2. ANSI Standard Z49.2, Fire Prevention in the Use of Cutting and Welding Processes, American National Standards Institute 1430 Broadway, New York, NY 10018
3. ANSI Standard Z87.1, Safe Practices for Occupation and Educational Eye and Face Protection, American National Standards Institute, 1430 Broadway, New York, NY 10018
4. AWS F4.1, Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances, American Welding Society 550 LeJeune Road, P.O. Box 351040, Miami, FL 33135
5. AWS F5.2, Recommended Safe Practices for Plasma Arc Cutting, American Welding Society 550 LeJeune Road, P.O. Box 351040, Miami, FL 33135
• Modifying the laser or product in any way can increase the risk of laser radiation.
• Use of adjustments or performance of procedures other than those specified in this manual may result in hazardous laser radiation exposure.
• Do not operate in explosive atmospheres, such as in the presence of flammable liquids, gases, or dust.
• Use only laser parts and accessories that are recommended or provided by the manufacturer for your model.
• Repairs and servicing MUST be performed by qualified personnel.
• Do not remove or deface the laser safety label.
6. CGA Pamphlet P-1, Safe Handling of Compressed Gases in Cylinders, Compressed Gas Association 1235 Jefferson Davis Highway, Arlington, VA 22202
7. CSA Standard W117.2, Code for Safety in Welding and Cutting, Canadian Standards Association Standard Sales 178 Rexdale Boulevard, Rexdale, Ontario M9W 1R3, Canada
8. NFPA Standard 51B, Cutting and Welding Processes, National Fire Protection Association 470 Atlantic Avenue, Boston, MA 02210
9. NFPA Standard 70–1978, National Electrical Code, National Fire Protection Association, 470 Atlantic Avenue, Boston, MA 02210
10. OSHA, Safety and Health Standards, 29FR 1910 U.S. Government Printing Office, Washington, D.C. 20402
11. AWS Safety and Health Fact Sheets, American Welding Society 550 LeJeune Road, P.O. Box 351040, Miami, FL 33135 www.aws.org/technical/facts/
SC-22 Safety and Compliance

WARNING LABELS

Read and follow these instructions, employer safety practices, and material safety data sheets. Refer to ANS Z49.1, “Safety in Welding, Cutting and Allied Processes” from American Welding Society (http://www.aws.org) and OSHA Safety and Health Standards, 29 CFR 1910 (http://www.osha.gov).
WARNING
1. Cutting sparks can cause explosion or fire.
1.1 Do not cut near flammables.
1.2 Have a fire extinguisher nearby and ready to use.
1.3 Do not use a drum or other closed container as a cutting table.
2. Plasma arc can injure and burn; point the nozzle away from yourself. Arc starts instantly when triggered.
2.1 Turn off power before disassembling torch.
2.2 Do not grip the workpiece near the cutting path.
2.3 Wear complete body protection.
3. Hazardous voltage. Risk of electric shock or burn.
3.1 Wear insulating gloves. Replace gloves when wet or damaged.
3.2 Protect from shock by insulating yourself from work and ground.
3.3 Disconnect power before servicing. Do not touch live parts.
4. Plasma fumes can be hazardous.
4.1 Do not inhale fumes.
4.2 Use forced ventilation or local exhaust to remove the fumes.
4.3 Do not operate in closed spaces. Remove fumes with ventilation.
6. Become trained.
Only qualified personnel should operate this
equipment. Use torches specified in the manual. Keep non-qualified personnel and children away.
5. Arc rays can burn eyes and injure skin.
5.1 Wear correct and appropriate protective equipment to protect head, eyes, ears, hands, and body. Button shirt collar. Protect ears from noise. Use welding helmet with the correct shade of filter.
7. Do not remove, destroy, or cover this label.
Replace if it is missing, damaged, or worn (PN 110584 Rev C).
Plasma cutting can be injurious to operator and persons in the work area. Consult manual before operating. Failure to follow all these safety instructions can result in death.
AVERTISSEMENT
Le coupage plasma peut être préjudiciable pour l’opérateur et les personnes qui se trouvent sur les lieux de travail. Consulter le manuel avant de faire fonctionner. Le non respect des ces instructions de sécurité peut entraîner la mort.
1. Les étincelles de coupage peuvent provoquer une explosion ou un incendie.
1.1 Ne pas couper près des matières inflammables.
1.2 Un extincteur doit être à proximité et prêt à être utilisé.
1.3 Ne pas utiliser un fût ou un autre contenant fermé comme table de coupage.
2. L’arc plasma peut blesser et brûler; éloigner la buse de soi. Il s’allume instantanément quand on l’amorce;
2.1 Couper l’alimentation avant de démonter la torche.
2.2 Ne pas saisir la pièce à couper de la trajectoire de coupage.
2.3 Se protéger entièrement le corps.
3. Tension dangereuse. Risque de choc électrique ou de brûlure.
3.1 Porter des gants isolants. Remplacer les gants quand ils sont humides ou endommagés.
3.2 Se protéger contre les chocs en s’isolant de la pièce et de la terre.
3.3 Couper l’alimentation avant l’entretien. Ne pas toucher les pièces sous tension.
4. Les fumées plasma peuvent être dangereuses.
4.1 Ne pas inhaler les fumées
4.2 Utiliser une ventilation forcée ou un extracteur local pour dissiper les fumées.
4.3 Ne pas couper dans des espaces clos. Chasser les fumées par ventilation.
5. Les rayons d’arc peuvent brûler les yeux et blesser la peau.
5.1 Porter un bon équipement de protection pour se protéger la tête, les yeux, les oreilles, les mains et le corps. Boutonner le col de la chemise. Protéger les oreilles contre le bruit. Utiliser un masque de soudeur avec un filtre de nuance appropriée.
6. Suivre une formation. Seul le personnel qualifié a le droit de faire
fonctionner cet équipement. Utiliser exclusivement les torches indiquées dans le manual. Le personnel non qualifié et les enfants doivent se tenir à l’écart.
7. Ne pas enlever, détruire ni couvrir cette étiquette.
La remplacer si elle est absente, endommagée ou usée (PN 110584 Rev C).
This warning label is affixed to some power supplies. It is important that the operator and maintenance technician understand the intent of these warning symbols as described.
Safety
Safety and Compliance SC-23
Safety
Warning labels
This warning label is affixed to some power supplies. It is important that the operator and maintenance technician understand the intent of these warning symbols as described. The numbered text corresponds to the numbered boxes on the label.
1. Cutting sparks can cause explosion or fire.
1.1 Do not cut near flammables.
1.2 Have a fire extinguisher nearby and ready to use.
1.3 Do not use a drum or other closed container as a cutting table.
2. Plasma arc can injure and burn; point the nozzle away from yourself. Arc starts instantly when triggered.
2.1 Turn off power before disassembling torch.
2.2 Do not grip the workpiece near the cutting path.
2.3 Wear complete body protection.
3. Hazardous voltage. Risk of electric shock or burn.
3.1 Wear insulating gloves. Replace gloves when wet or damaged.
3.2 Protect from shock by insulating yourself from work and ground.
3.3 Disconnect power before servicing. Do not touch live parts.
4. Plasma fumes can be hazardous.
4.1 Do not inhale fumes.
4.2 Use forced ventilation or local exhaust to remove the fumes.
4.3 Do not operate in closed spaces. Remove fumes with ventilation.
5. Arc rays can burn eyes and injure skin.
5.1 Wear correct and appropriate protective equipment to protect head, eyes, ears, hands, and body. Button shirt collar. Protect ears from noise. Use welding helmet with the correct shade of filter.
6. Become trained. Only qualified personnel should operate this equipment. Use torches specified in the manual. Keep non-qualified personnel and children away.
7. Do not remove, destroy, or cover this label. Replace if it is missing, damaged, or worn.
SC-24 Safety and Compliance
Safety
s

Symbols and marks

Your product may have one or more of the following markings on or near the data plate. Due to differences and conflicts in national regulations, not all marks are applied to every version of a product.
S mark
The S mark indicates that the power supply and torch are suitable for operations carried out in environments with increased hazard of electrical shock according to IEC 60974-1.
CSA mark
Products with a CSA mark meet the United States and Canadian regulations for product safety. The products were evaluated, tested, and certified by CSA-International. Alternatively, the product may have a mark by one of the other Nationally Recognized Testing Laboratories (NRTL) accredited in both the United States and Canada, such as UL or TÜV.
CE mark
The CE marking signifies the manufacturer’s declaration of conformity to applicable European directives and standards. Only those versions of products with a CE marking located on or near the data plate have been tested for compliance with the European Low Voltage Directive and the European Electromagnetic Compatibility (EMC) Directive. EMC filters needed to comply with the European EMC Directive are incorporated within versions of the product with a CE marking.
Eurasian Customs Union (CU) mark
CE versions of products that include an EAC mark of conformity meet the product safety and EMC requirements for export to Russia, Belarus, and Kazakhstan.
GOST-TR mark
CE versions of products that include a GOST-TR mark of conformity meet the product safety and EMC requirements for export to the Russian Federation.
C-Tick mark
CE versions of products with a C-Tick mark comply with the EMC regulations required for sale in Australia and New Zealand.
CCC mark
The China Compulsory Certification (CCC) mark indicates that the product has been tested and found compliant with product safety regulations required for sale in China.
UkrSEPRO mark
The CE versions of products that include a UkrSEPRO mark of conformity meet the product safety and EMC requirements for export to the Ukraine.
Serbian AAA mark
CE versions of products that include a AAA Serbian mark meet the product safety and EMC requirements for export to Serbia.
Safety and Compliance SC-25
Safety
SC-26 Safety and Compliance

Product Stewardship

Introduction

Hypertherm maintains a global Regulatory Management System to ensure that products comply with regulatory and environmental requirements.

National and local safety regulations

National and Local safety regulations shall take precedence over any instructions provided with the product. The product shall be imported, installed, operated and disposed of in accordance with national and local regulations applicable to the installed site.

Certification test marks

Certified products are identified by one or more certification test marks from accredited testing laboratories. The certification test marks are located on or near the data plate.
Each certification test mark means that the product and its safety-critical components conform to the relevant national safety standards as reviewed and determined by that testing laboratory. Hypertherm places a certification test mark on its products only after that product is manufactured with safety-critical components that have been authorized by the accredited testing laboratory.
Once the product has left the Hypertherm factory, the certification test marks are invalidated if any of the following occurs:
• The product is modified in a manner that creates a hazard or non-conformance with the applicable standards.
• Safety-critical components are replaced with unauthorized spare parts.
• Any unauthorized assembly, or accessory that uses or generates a hazardous voltage is added.
• There is any tampering with a safety circuit or other feature that is designed into the product as part of the certification, or otherwise.
CE marking constitutes a manufacturer’s declaration of conformity to applicable European directives and standards. Only those versions of Hypertherm products with a CE Marking located on or near the data plate have been tested for compliance with the European Low Voltage Directive and the European EMC Directive. EMC filters needed to comply with the European EMC Directive are incorporated within versions of the power supply with a CE Marking.
Certificates of compliance for Hypertherm products are available from the Downloads Library on the Hypertherm web site at
https://www.hypertherm.com
.

Differences in national standards

Nations may apply different performance, safety or other standards. National differences in standards include, but are not limited to:
•Voltages
• Plug and cord ratings
• Language requirements
• Electromagnetic compatibility requirements
These differences in national or other standards may make it impossible or impractical for all certification test marks to be placed on the same version of a product. For example, the CSA versions of Hypertherm’s products do not comply with European EMC requirements, and therefore do not have a CE marking on the data plate.
Countries that require CE marking or have compulsory EMC regulations must use CE versions of Hypertherm products with the CE marking on the data plate. These include, but are not limited to:
•Australia
• New Zealand
• Countries in the European Union
• Russia
It is important that the product and its certification test mark be suitable for the end-use installation site. When Hypertherm products are shipped to one country for export to another country; the product must be configured and certified properly for the end-use site.

Safe installation and use of shape cutting equipment

IEC 60974-9, titled Arc Welding Equipment – Installation and use, provides guidance in the safe installation and use of shape cutting equipment and the safe performance of cutting operations. The requirements of national and local regulations shall be taken into consideration during installation, including, but not limited to, grounding or protective earth connections, fuses, supply disconnecting device, and type of supply circuit. Read these instructions before installing the equipment. The first and most important step is the safety assessment of the installation.
The safety assessment must be performed by an expert, and determines what steps are necessary to create a safe environment, and what precautions should be adopted during the actual installation and operation.

Procedures for periodic inspection and testing

Where required by local national regulations, IEC 60974-4 specifies test procedures for periodic inspection and after repair or maintenance, to ensure electrical safety for plasma cutting power sources built in conformity with IEC 60974-1. Hypertherm performs the continuity of the protective circuit and insulation resistance tests in the factory as non-operating tests. The tests are performed with the power and ground connections removed.
Safety and Compliance SC-27
English
Product Stewardship
Hypertherm also removes some protective devices that would cause false test results. Where required by local national regulations, a label shall be attached to the equipment to indicate that it has passed the tests prescribed by IEC 60974-4. The repair report shall indicate the results of all tests unless an indication is made that a particular test has not been performed.

Qualification of test personnel

Electrical safety tests for shape cutting equipment can be hazardous and shall be carried out by an expert in the field of electrical repair, preferably someone also familiar with welding, cutting, and allied processes. The safety risks to personnel and equipment, when unqualified personnel are performing these tests, may be much greater than the benefit of periodic inspection and testing.
Hypertherm recommends that only visual inspection be performed unless the electrical safety tests are specifically required by local national regulations in the country where the equipment is installed.

Residual current devices (RCDs)

In Australia and some other countries, local codes may require the use of a Residual Current Devices (RCD) when portable electrical equipment is used in the workplace or at construction sites to protect operators from electrical faults in the equipment. RCDs are designed to safely disconnect the mains electrical supply when an imbalance is detected between the supply and return current (there is a leakage current to earth). RCDs are available with both fixed and adjustable trip currents between 6 to 40 milliamperes and a range of trip times up to 300 milliseconds selected for the equipment installation, application and intended use. Where RCDs are used, the trip current and trip time on RCDs should be selected or adjusted high enough to avoid nuisance tripping during normal operation of the plasma cutting equipment and low enough in the extremely unlikely event of an electrical fault in the equipment to disconnect the supply before the leakage current under a fault condition can pose a life threatening electrical hazard to operators.
To verify that the RCDs continue to function properly over time, both the trip current and the trip time should be tested periodically. Portable electrical equipment and RCDs used in commercial and industrial areas in Australia and New Zealand are tested to the Australian standard AS/NZS 3760. When you test the insulation of plasma cutting equipment to AS/NZS 3760, measure the insulation resistance according to Appendix B of the standard, at 250 VDC with the power switch in the ON position to verify proper testing and to avoid the false failure of the leakage current test. False failures are possible because the metal oxide varistors (MOVs) and electromagnetic compatibility (EMC) filters, used to reduce emissions and protect the equipment from power surges, may conduct up to 10 milliamperes leakage current to earth under normal conditions.
If you have any questions regarding the application or interpretation of any IEC standards described here, you are required to consult with an appropriate legal or other advisor familiar with the International Electrotechnical standards, and shall not rely on Hypertherm in any respect regarding the interpretation or application of such standards.

Higher-level systems

When a system integrator adds additional equipment; such as cutting tables, motor drives, motion controllers or robots; to a Hypertherm plasma cutting system, the combined system may be considered a higher-level system. A higher-level system with hazardous moving parts may constitute industrial machinery or robotic equipment, in which case the OEM or end-use customer may be subject to additional regulations and standards than those relevant to the plasma cutting system as manufactured by Hypertherm.
It is the responsibility of the end-use customer and the OEM to perform a risk assessment for the higher-level system, and to provide protection against hazardous moving parts. Unless the higher-level system is certified when the OEM incorporates Hypertherm products into it, the installation also may be subject to approval by local authorities. Seek advice from legal counsel and local regulatory experts if you are uncertain about compliance.
External interconnecting cables between component parts of the higher level system must be suitable for contaminants and movement as required by the final end use installation site. When the external interconnecting cables are subject to oil, dust, water, or other contaminants, hard usage ratings may be required.
When external interconnecting cables are subject to continuous movement, constant flexing ratings may be required. It is the responsibility of the end-use customer or the OEM to ensure the cables are suitable for the application. Since there are differences in the ratings and costs that can be required by local regulations for higher level systems, it is necessary to verify that any external interconnecting cables are suitable for the end-use installation site.
SC-28 Safety and Compliance
English

Environmental Stewardship

Introduction

The Hypertherm Environmental Specification requires RoHS, WEEE and REACH substance information to be provided by Hypertherm’s suppliers.
Product environmental compliance does not address the indoor air quality or environmental release of fumes by the end user. Any materials that are cut by the end user are not provided by Hypertherm with the product. The end user is responsible for the materials being cut as well as for safety and air quality in the workplace. The end user must be aware of the potential health risks of the fumes released from the materials being cut and comply with all local regulations.

National and local environmental regulations

National and local environmental regulations shall take precedence over any instructions contained in this manual.
The product shall be imported, installed, operated and disposed of in accordance with all national and local environmental regulations applicable to the installed site.
The European Environmental regulations are discussed later in The WEEE Directive.

The RoHS directive

Hypertherm is committed to complying with all applicable laws and regulations, including the European Union Restriction of Hazardous Substances (RoHS) Directive that restricts the use of hazardous materials in electronics products. Hypertherm exceeds RoHS Directive compliance obligations on a global basis.
Hypertherm continues to work toward the reduction of RoHS materials in our products, which are subject to the RoHS Directive, except where it is widely recognized that there is no feasible alternative.
Declarations of RoHS Conformity have been prepared for the current CE versions of Powermax plasma cutting systems manufactured by Hypertherm. There is also a “RoHS mark” on the Powermax CE versions below the “CE Marking” on the data plate of CE versions of Powermax series units shipped since 2006. Parts used in CSA versions of Powermax and other products manufactured by Hypertherm that are either out of scope or exempt from RoHS are continuously being converted to RoHS compliance in anticipation of future requirements.

Proper disposal of Hypertherm products

Hypertherm plasma cutting systems, like all electronic products, may contain materials or components, such as printed circuit boards, that cannot be discarded with ordinary waste. It is your responsibility to dispose of any Hypertherm product or component part in an environmentally acceptable manner according to national and local codes.
• In the United States, check all federal, state, and local laws.
• In the European Union, check the EU directives, national, and local laws. For more information, visit www.hypertherm.com/weee
• In other countries, check national and local laws.
• Consult with legal or other compliance experts when appropriate.
.

The WEEE Directive

On January 27, 2003, the European Parliament and the Council of the European Union authorized Directive 2002/96/EC or WEEE (Waste Electrical and Electronic Equipment).
As required by the legislation, any Hypertherm product covered by the directive and sold in the EU after August 13, 2005 is marked with the WEEE symbol. This directive encourages and sets specific criteria for the collection, handling, and recycling of EEE waste. Consumer and business-to-business wastes are treated differently (all Hypertherm products are considered business-to-business). Disposal instructions for the CE versions of Powermax plasma systems can be found at
www.hypertherm.com/weee
The URL is printed on the symbol-only warning label for each of these CE version Powermax series units shipped since 2006. The CSA versions of Powermax and other products manufactured by Hypertherm are either out of scope or exempt from WEEE.
.

The REACH regulation

The REACH regulation (1907/2006), in force since June1, 2007, has an impact on chemicals available to the European market. The REACH regulation requirements for component manufacturers states that the component shall not contain more than 0.1% by weight of the Substances of Very High Concern (SVHC).
Component manufacturers and other downstream users, such as Hypertherm, are obligated to obtain assurances from its suppliers that all chemicals used in or on Hypertherm products will have a European Chemical Agency (ECHA) registration number. To provide chemical information as required by the REACH regulation, Hypertherm requires suppliers to provide REACH declarations and identify any known use of REACH SVHC. Any use of SVHC in amounts exceeding 0.1% w/w of the parts has been eliminated. The MSDS contains a full disclosure of all substances in the chemical and can be used to verify REACH SVHC compliance.
The lubricants, sealants, coolants, adhesives, solvents, coatings and other preparations or mixtures used by Hypertherm in, on, for, or with its shape cutting equipment are used in very small quantities (except the coolant) and are commercially available with multiple sources that can and will be replaced in the event of a supplier problem associated with REACH Registration or REACH Authorization (SVHCs).
Safety and Compliance SC-29
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Environmental Stewardship

Proper handling and safe use of chemicals

Chemical Regulations in the USA, Europe, and other locations require that Material Safety Data Sheets (MSDS) be made available for all chemicals. The list of chemicals is provided by Hypertherm. The MSDS are for chemicals provided with the product and other chemicals used in or on the product. MSDS can be downloaded from the Downloads Library on the Hypertherm web site at https://www.hypertherm.com On the Search screen, insert MSDS in the document title and click on Search.
In the USA, OSHA does not require Material Safety Data Sheets for articles such as electrodes, swirl rings, retaining caps, nozzles, shields, deflectors and other solid parts of the torch.
Hypertherm does not manufacture or provide the materials that are cut and has no knowledge whether the fumes released from materials that are cut will pose a physical hazard or health risk. Please consult with your supplier or other technical advisor if you need guidance concerning the properties of the material you will cut using a Hypertherm product.
.

Fumes emission and air quality

Note: The following information on air quality is intended for general information only and should not be used as a substitute for reviewing and implementing applicable government regulations or legal standards in the country where the cutting equipment will be installed and operated.
In the USA, the National Institute for Occupational Safety and Health (NIOSH) Manual of Analytical Methods (NMAM) is a collection of methods for sampling and analyzing contaminants in workplace air. Methods published by others, such as OSHA, MSHA, EPA, ASTM, ISO or commercial suppliers of sampling and analytical equipment, may have advantages over NIOSH methods.
For example, ASTM Practice D 4185 is a standard practice for the collection, dissolution, and determination of trace metals in workplace atmospheres. The sensitivity, detection limit, and optimum working concentrations for 23 metals are listed in ASTM D 4185. An industrial hygienist should be used to determine the optimum sampling protocol, considering analytical accuracy, cost, and optimum sample number. Hypertherm uses a third party industrial hygienist to perform and interpret air quality testing results taken by air sampling equipment positioned at operator stations in Hypertherm buildings where plasma cutting tables are installed and operated.
Where applicable, Hypertherm also uses a third party industrial hygienist to obtain air and water permits.
If you are not fully aware and up to date on all applicable government regulations and legal standards for the installation site, you should consult a local expert prior to purchasing, installing, and operating the equipment.
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