Hypertherm V9 User Manual
Phoenix™ Software Version 9 Series
Installation and Setup Manual
806410 | Revision 11 | English
© 2014 Hypertherm, Inc.
ArcGlide, COMMAND, EDGE Pro, EDGE Pro Ti, HPR, HSD, HyIntensity Fiber Laser, Hypernest, Hypernet, Hypertherm,
HyPrecision, MAXPRO, MicroEDGE Pro, Phoenix, Powermax, and Sensor are trademarks of Hypertherm, Inc. and may be registered
in the United States and other countries.
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Other trademarks are the property of their respective owners.
Phoenix Software® Version 9 Series
Installation and Setup Manual
806410
Revision 11
English
December 2014
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-15
Recognize safety information ...............................................................................................................................................SC-15
Follow safety instructions ......................................................................................................................................................SC-15
Electrical hazards ....................................................................................................................................................................SC-15
Electric shock can kill ............................................................................................................................................................SC-16
Cutting can cause fire or explosion ....................................................................................................................................SC-17
Fire prevention .................................................................................................................................................................SC-17
Explosion prevention ......................................................................................................................................................SC-17
Toxic fumes can cause injury or death ...............................................................................................................................SC-18
Grounding safety ....................................................................................................................................................................SC-19
Static electricity can damage circuit boards ....................................................................................................................SC-19
A plasma arc can cause injury and burns .........................................................................................................................SC-20
Compressed gas equipment safety ...................................................................................................................................SC-20
Gas cylinders can explode if damaged .............................................................................................................................SC-20
Arc rays can burn eyes and skin .........................................................................................................................................SC-21
Pacemaker and hearing aid operation ...............................................................................................................................SC-22
Noise can damage hearing ...................................................................................................................................................SC-22
A plasma arc can damage frozen pipes ............................................................................................................................SC-22
Dry dust collection information ............................................................................................................................................SC-23
Laser radiation .........................................................................................................................................................................SC-24
Additional safety information ................................................................................................................................................SC-24
Warning labels ........................................................................................................................................................................SC-25
Symbols and marks ................................................................................................................................................................SC-27
Product Stewardship ...........................................................................................................SC-29
Introduction ..............................................................................................................................................................................SC-29
National and local safety regulations ..................................................................................................................................SC-29
Certification test marks .........................................................................................................................................................SC-29
Phoenix 9.76.0 Installation and Setup Manual 806410 5
Contents
Differences in national standards .......................................................................................................................................SC-29
Safe installation and use of shape cutting equipment ...................................................................................................SC-30
Procedures for periodic inspection and testing ..............................................................................................................SC-30
Qualification of test personnel .............................................................................................................................................SC-30
Residual current devices (RCDs) .......................................................................................................................................SC-30
Higher-level systems ..............................................................................................................................................................SC-31
Environmental Stewardship .............................................................................................. SC-33
Introduction ..............................................................................................................................................................................SC-33
National and local environmental regulations ...................................................................................................................SC-33
The RoHS directive ................................................................................................................................................................SC-33
Proper disposal of Hypertherm products ..........................................................................................................................SC-33
The WEEE directive ...............................................................................................................................................................SC-33
The REACH regulation ..........................................................................................................................................................SC-34
Proper handling and safe use of chemicals .....................................................................................................................SC-34
Fumes emission and air quality ...........................................................................................................................................SC-34
Shrink-wrap License Agreement ...................................................................................... SC-35
1 System Tools ............................................................................................................................... 37
Introduction .................................................................................................................................................................................... 37
CNC performance information .................................................................................................................................................. 39
Back up the hard drive ................................................................................................................................................................ 40
Scan Hard Disk ............................................................................................................................................................................. 41
Antivirus .......................................................................................................................................................................................... 42
Defragment hard disk .................................................................................................................................................................. 43
Launch an External Program ...................................................................................................................................................... 43
Software installed on the CNC ................................................................................................................................................. 45
Phoenix software version number ..................................................................................................................................... 45
Phoenix setup files ........................................................................................................................................................................ 46
About setup files ................................................................................................................................................................... 46
Setup files from previous versions of Phoenix ............................................................................................................... 47
Save and load the setup file ............................................................................................................................................... 47
Save a setup file without using a password ........................................................................................................... 47
Save a setup file with a different name .................................................................................................................... 47
Load a setup file ............................................................................................................................................................ 48
Save and load default settings .......................................................................................................................................... 48
Save Default.ini .............................................................................................................................................................. 48
Load Default.ini .............................................................................................................................................................. 48
Reload factory settings ........................................................................................................................................................ 49
6 Phoenix 9.76.0 Installation and Setup Manual 806410
Contents
2 Machine Setup ............................................................................................................................ 51
Axis orientation and positive motion ......................................................................................................................................... 51
About axis assignments ............................................................................................................................................................... 55
Change the axis assignments with passwords ...................................................................................................................... 55
System axis screens ..................................................................................................................................................................... 58
Machine Setups screen ...................................................................................................................................................... 58
Transverse or Rail Axis ........................................................................................................................................................ 60
Using software travel limits ................................................................................................................................................. 63
Dual Gantry Axis .................................................................................................................................................................... 64
CBH Axis ................................................................................................................................................................................ 67
Rotate Axis ............................................................................................................................................................................. 69
Tilt Axis .................................................................................................................................................................................... 71
Transverse 2 Axis .................................................................................................................................................................. 74
Laser Mapping ............................................................................................................................................................................... 78
Setting Speeds ............................................................................................................................................................................. 79
CBH Speeds ......................................................................................................................................................................... 81
THC Speeds .......................................................................................................................................................................... 81
Tilt/Rotator Speeds .............................................................................................................................................................. 82
S-curve acceleration .................................................................................................................................................................... 82
S-curve setup ........................................................................................................................................................................ 84
Torch Height Disable ................................................................................................................................................................... 85
Configuring Ports ......................................................................................................................................................................... 87
Basic Configuration .............................................................................................................................................................. 87
Phoenix Link Configuration ................................................................................................................................................. 90
Command THC Port Designation ..................................................................................................................................... 91
RS-422 Connections to Command THC with 25-pin D-type Connector ...................................................... 91
Configuring I/O ............................................................................................................................................................................. 92
Digital Input Definitions ........................................................................................................................................................ 93
Digital Output Definitions .................................................................................................................................................... 97
THC I/O ................................................................................................................................................................................ 100
Speed Pot and Joystick Setup ................................................................................................................................................ 101
3 Torch Height Control Axis Setup ......................................................................................... 103
Sensor THC axis ......................................................................................................................................................................... 103
Initial height sense .............................................................................................................................................................. 103
Entering the slide length ................................................................................................................................................... 104
Assigning the Sensor THC to an axis and selecting an analog input .................................................................... 104
Setting speeds and acceleration .................................................................................................................................... 105
Assigning the Sensor THC as a lifter ............................................................................................................................. 106
Setting servo error tolerance and stall force tolerance .............................................................................................. 106
Phoenix 9.76.0 Installation and Setup Manual 806410 7
Contents
Sensor THC axis screen ........................................................................................................................................................... 108
Tuning the axis with gains ................................................................................................................................................. 109
Home settings for current-type drives ........................................................................................................................... 113
Tracking Mode ..................................................................................................................................................................... 113
Sensor THC I/O points ............................................................................................................................................................. 114
Watch Window setup ............................................................................................................................................................... 115
Sensor Ti axis setup ................................................................................................................................................................... 116
Machine Setups screen .................................................................................................................................................... 116
Speeds screen .................................................................................................................................................................... 116
Sensor THC Axis screen .................................................................................................................................................. 117
Station Configuration screen ........................................................................................................................................... 117
ArcGlide THC axis ..................................................................................................................................................................... 118
Gains ..................................................................................................................................................................................... 118
Speeds .................................................................................................................................................................................. 120
Mechanical ........................................................................................................................................................................... 121
Miscellaneous ...................................................................................................................................................................... 121
4 SERCOS setup ........................................................................................................................... 123
SERCOS III support .................................................................................................................................................................. 123
Drives ..................................................................................................................................................................................... 123
Bus couplers ........................................................................................................................................................................ 123
Cabling .................................................................................................................................................................................. 124
General recommendations ............................................................................................................................................... 124
Drive I/O ................................................................................................................................................................................ 124
Inline I/O bus coupler ........................................................................................................................................................ 125
Troubleshooting tips .......................................................................................................................................................... 125
SERCOS setup screen ..................................................................................................................................................... 126
SERCOS II support ................................................................................................................................................................... 127
Drives ..................................................................................................................................................................................... 127
I/O bus couplers and I/O modules ................................................................................................................................. 127
I/O bus couplers ................................................................................................................................................................. 127
I/O modules ......................................................................................................................................................................... 128
SERCSO II setup screen .................................................................................................................................................. 129
5 Station Setup ............................................................................................................................. 131
Overview ....................................................................................................................................................................................... 131
Generic and numbered I/O ...................................................................................................................................................... 131
Generic I/O .......................................................................................................................................................................... 131
Numbered I/O ...................................................................................................................................................................... 132
8 Phoenix 9.76.0 Installation and Setup Manual 806410
Contents
Enabling station I/O ................................................................................................................................................................... 132
Auto Select and Manual Select inputs and Station Enable LED output ................................................................ 132
Basic operating sequence ................................................................................................................................................ 133
Using manual mode as an override ................................................................................................................................ 133
Summary ............................................................................................................................................................................... 133
Station configuration screen .................................................................................................................................................... 136
Guidelines for using the Station Configuration screen ...................................................................................................... 136
Conflicting process .................................................................................................................................................................... 137
Example of a conflicting process .................................................................................................................................... 138
How a tool is associated with a station ......................................................................................................................... 140
Troubleshooting a conflicting process error ......................................................................................................................... 142
The settings look correct on the screen below .................................................................................................... 142
The cause of the error ................................................................................................................................................ 143
Troubleshooting steps ............................................................................................................................................................... 144
6 Special Setups .......................................................................................................................... 145
Status/Feature List ..................................................................................................................................................................... 147
Status/Message or Wizard List ............................................................................................................................................... 148
Soft Keys ...................................................................................................................................................................................... 149
7 Plasma Setup ............................................................................................................................. 151
Plasma 1 and Plasma 2 ............................................................................................................................................................. 151
Examples using Plasma 1 and Plasma 2 ....................................................................................................................... 152
Sample settings for a multiple-torch cutting system .................................................................................................. 153
Sample settings for two-torch cutting system ............................................................................................................. 154
Plasma cut sequence ................................................................................................................................................................ 155
Setting up inputs and outputs for plasma ............................................................................................................................. 157
Summary: setting up the plasma routine ............................................................................................................................... 158
I/O and diagnostics .................................................................................................................................................................... 159
HPR diagnostics ......................................................................................................................................................................... 159
Power Supply Inputs .......................................................................................................................................................... 160
Gas Console Inputs ........................................................................................................................................................... 161
Power Supply Outputs ...................................................................................................................................................... 162
Gas Console Outputs ....................................................................................................................................................... 163
Serial communication interface ............................................................................................................................................... 164
RS-422C connections to HPR CNC interface ........................................................................................................... 164
Phoenix 9.76.0 Installation and Setup Manual 806410 9
Contents
Powermax plasma supply ......................................................................................................................................................... 164
Selecting the Powermax in the Station Configuration screen ................................................................................. 164
Assigning the Powermax to a serial port ....................................................................................................................... 165
I/O selection for the Powermax ....................................................................................................................................... 166
Setting cut mode, gas pressure, and current from the CNC ................................................................................... 167
Powermax Diagnostic screen .......................................................................................................................................... 168
MAXPRO200 plasma supply ................................................................................................................................................... 169
Selecting the MAXPRO200 in the Station Configuration screen ........................................................................... 169
Assigning the MAXPRO200 to a serial port ................................................................................................................ 169
I/O selection for the MAXPRO200 ................................................................................................................................ 170
System error output ........................................................................................................................................................... 171
Watch Window setup for the MAXPRO200 ............................................................................................................... 172
Adjusting default cut chart settings from the CNC .................................................................................................... 173
MAXPRO200 Diagnostic screen .................................................................................................................................... 174
8 Diagnostics ................................................................................................................................. 177
Remote Help ................................................................................................................................................................................ 177
Load Additional Manuals ........................................................................................................................................................... 177
EDGE Pro Machine Interface Tests ....................................................................................................................................... 179
Serial Test ............................................................................................................................................................................. 180
USB Test .............................................................................................................................................................................. 181
I/O Test ................................................................................................................................................................................. 182
Axis Test ................................................................................................................................................................................ 184
THC Test .............................................................................................................................................................................. 186
LAN and Hypernet Tests ................................................................................................................................................... 187
Operator Interface Test ..................................................................................................................................................... 187
MicroEDGE Pro Machine Interface Tests ............................................................................................................................. 189
Serial Test ............................................................................................................................................................................. 190
USB Test .............................................................................................................................................................................. 191
I/O Test ................................................................................................................................................................................. 192
Axis Test ................................................................................................................................................................................ 194
THC Test .............................................................................................................................................................................. 195
LAN and Hypernet Tests ................................................................................................................................................... 197
Joystick and Speedpot Test ............................................................................................................................................. 197
I/O .................................................................................................................................................................................................. 199
Inputs ..................................................................................................................................................................................... 199
Outputs ................................................................................................................................................................................. 200
Expanded I/O ....................................................................................................................................................................... 201
10 Phoenix 9.76.0 Installation and Setup Manual 806410
Contents
Analog Input Diagnostics .......................................................................................................................................................... 202
Inputs ..................................................................................................................................................................................... 202
Analog Inputs ....................................................................................................................................................................... 202
Drives and Motors ...................................................................................................................................................................... 203
SERCOS Drives and Motors Test .......................................................................................................................................... 204
Using Norton Ghost Utility ........................................................................................................................................................ 204
Creating a Ghost Recovery File ...................................................................................................................................... 205
Retrieving an Image File .................................................................................................................................................... 206
9 Motion Control .......................................................................................................................... 207
Closed Loop Servo Control ..................................................................................................................................................... 207
Typical Velocity and Position Loop System .................................................................................................................. 208
Encoders ....................................................................................................................................................................................... 209
Following Error .................................................................................................................................................................... 210
Position and Servo Error ................................................................................................................................................... 210
Encoder Counts and Maximum Machine Speed ................................................................................................................. 210
Determining Maximum Machine Speed ......................................................................................................................... 210
Gain ............................................................................................................................................................................................... 211
Proportional Gain ................................................................................................................................................................ 211
Integral Gain ......................................................................................................................................................................... 211
Derivative Gain .................................................................................................................................................................... 211
Feedforward ......................................................................................................................................................................... 211
Velocity Gain ........................................................................................................................................................................ 212
Tuning Procedures ..................................................................................................................................................................... 212
Tuning for Velocity Drives ................................................................................................................................................. 212
Tuning for Current Drives .................................................................................................................................................. 213
Motion Tuning Watch Windows ............................................................................................................................................. 214
10 Motion Compensation ............................................................................................................. 217
Hardware and Software Requirements ................................................................................................................................. 217
Overview ....................................................................................................................................................................................... 217
Calculating Compensation Data ............................................................................................................................................. 218
Calculating Backlash Compensation ............................................................................................................................. 221
Capturing and Using Motion Data in Phoenix ...................................................................................................................... 222
Map Axes ...................................................................................................................................................................................... 225
Create the Motion Compensation Data File ......................................................................................................... 228
Load the Data File ...................................................................................................................................................................... 229
Turn on Motion Compensation ................................................................................................................................................ 229
Save the Setup File .................................................................................................................................................................... 230
Phoenix 9.76.0 Installation and Setup Manual 806410 11
Contents
11 Networking ................................................................................................................................. 231
Before You Begin ....................................................................................................................................................................... 231
Dynamic Host Configuration Protocol ........................................................................................................................... 231
Using the CNC in a Domain-based Network ............................................................................................................... 231
Administrator and User Accounts on the CNC ........................................................................................................... 232
About Network Connections ................................................................................................................................................... 232
Connecting the CNC to a Network (DHCP) ....................................................................................................................... 233
Connecting the CNC to a Network (non-DHCP) ............................................................................................................... 234
Connecting the CNC to a Workgroup .................................................................................................................................. 236
Mapping a Network Drive ......................................................................................................................................................... 238
Adding a Folder in Phoenix ...................................................................................................................................................... 240
12 Serial Ports ................................................................................................................................. 241
Control RS-232C DB-9 Pinout .............................................................................................................................................. 242
RS-232C Connections to Host PC with 9-pin D-type Connector ................................................................................ 242
RS-232C Connections to Host PC with 25-pin D-type Connector .............................................................................. 242
Control RS-422 DB-9 Pinout .................................................................................................................................................. 243
RS-422 Connections to Host PC with 9-pin D-type Connector ................................................................................... 243
RS-422 Connections to Host PC with 25-pin D-type Connector ................................................................................. 243
13 Phoenix Link .............................................................................................................................. 245
Files Menu .................................................................................................................................................................................... 246
Settings Menu ............................................................................................................................................................................. 247
Installation ..................................................................................................................................................................................... 248
Minimum System Requirements ...................................................................................................................................... 248
Software ................................................................................................................................................................................ 248
Change Master Folder ....................................................................................................................................................... 249
Operating Multiple Links ................................................................................................................................................... 251
Hardware ...................................................................................................................................................................................... 252
Operating Phoenix Link ............................................................................................................................................................. 252
Common Errors ........................................................................................................................................................................... 253
Error Messages ................................................................................................................................................................... 253
14 Aligning Plates .......................................................................................................................... 255
Notes about APA ........................................................................................................................................................................ 255
Sensing Sequence ..................................................................................................................................................................... 256
Five-Point Alignment .................................................................................................................................................................. 256
Three Point Alignment ............................................................................................................................................................... 257
Program Code ..................................................................................................................................................................... 257
Motion Path .......................................................................................................................................................................... 257
12 Phoenix 9.76.0 Installation and Setup Manual 806410
Contents
15 Oxyfuel Application .................................................................................................................. 259
Oxyfuel overview ......................................................................................................................................................................... 260
Two-torch oxyfuel system diagram ......................................................................................................................................... 261
Low preheat fuel gas options ................................................................................................................................................... 262
Oxyfuel cut sequence ................................................................................................................................................................ 262
Oxyfuel inputs .............................................................................................................................................................................. 266
Oxyfuel outputs ........................................................................................................................................................................... 267
Setting up oxyfuel ....................................................................................................................................................................... 269
Oxyfuel cut chart ......................................................................................................................................................................... 271
Controlling proportional gas regulators with analog outputs ........................................................................................... 272
Setting up analog outputs ........................................................................................................................................................ 273
Setting gas pressures from the CNC ............................................................................................................................ 274
Staged pierce for oxyfuel cutting ............................................................................................................................................ 276
16 Waterjet Application ................................................................................................................ 279
Waterjet system overview ......................................................................................................................................................... 280
Enabling the waterjet process on the CNC .................................................................................................................. 281
Selecting the waterjet pump model ................................................................................................................................ 282
Serial communications .............................................................................................................................................................. 282
Assigning a serial port ....................................................................................................................................................... 283
Sequence of operations ............................................................................................................................................................ 283
Waterjet I/O ................................................................................................................................................................................. 286
Automatically setting abrasive delays .................................................................................................................................... 287
Waterjet height control .............................................................................................................................................................. 287
Speeds for waterjet height control ................................................................................................................................. 288
Calibration ............................................................................................................................................................................ 289
Foot Sensor Up input ......................................................................................................................................................... 289
Initial height sense (IHS) ................................................................................................................................................... 289
Performing a first IHS ........................................................................................................................................................ 290
Skip IHS ................................................................................................................................................................................ 290
Low pressure piercing ............................................................................................................................................................... 290
Cutting a part ............................................................................................................................................................................... 291
Enabling a station ............................................................................................................................................................... 291
Setting the cut height without height control ............................................................................................................... 291
Cut speed calculator ................................................................................................................................................................. 292
Waterjet system messages ...................................................................................................................................................... 292
Phoenix 9.76.0 Installation and Setup Manual 806410 13
Contents
14 Phoenix 9.76.0 Installation and Setup Manual 806410
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-15
• 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-16 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 I NG
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 I NG
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 I NG
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-17
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-18 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-19
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-20 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
(ANSIZ49.1:2005)
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-21
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-22 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-23
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-24 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-25
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-26 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-27
Safety
SC-28 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:
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:
• 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
• 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.
Safety and Compliance SC-29
Product Stewardship
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.
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.
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.
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.
SC-30 Safety and Compliance
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