Hypertherm ArcGlide THC User manual

ArcGlide®THC
Torch Height Control
Instruction Manual
806450 | Revision 5 | English

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ArcGlide
Instruction Manual
806450
Revision 5
English
March 2015
Hypertherm Inc.
Hanover, NH 03755 USA

Hypertherm Inc.
Etna Road, P.O. Box 5010
Hanover, NH 03755 USA
603-643-3441 Tel (Main Office)
603-643-5352 Fax (All Departments)
[email protected] (Main Office Email)
800-643-9878 Tel (Technical Service)
[email protected] (Technical Service Email)
800-737-2978 Tel (Customer Service)
[e-mail] (Customer Service Email)
866-643-7711 Tel (Return Materials Authorization)
877-371-2876 Fax (Return Materials Authorization)
[email protected] (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

ArcGlide THC Instruction Manual 806450 5
Contents
Safety ....................................................................................................................................... SC-13
Recognize safety information ...............................................................................................................................................SC-13
Follow safety instructions ......................................................................................................................................................SC-13
Electrical hazards ....................................................................................................................................................................SC-13
Electric shock can kill ............................................................................................................................................................SC-14
Cutting can cause fire or explosion ....................................................................................................................................SC-15
Fire prevention .................................................................................................................................................................SC-15
Explosion prevention ......................................................................................................................................................SC-15
Toxic fumes can cause injury or death ...............................................................................................................................SC-16
Grounding safety ....................................................................................................................................................................SC-17
Static electricity can damage circuit boards ....................................................................................................................SC-17
A plasma arc can cause injury and burns .........................................................................................................................SC-18
Compressed gas equipment safety ...................................................................................................................................SC-18
Gas cylinders can explode if damaged .............................................................................................................................SC-18
Arc rays can burn eyes and skin .........................................................................................................................................SC-19
Pacemaker and hearing aid operation ...............................................................................................................................SC-20
Noise can damage hearing ...................................................................................................................................................SC-20
A plasma arc can damage frozen pipes ............................................................................................................................SC-20
Dry dust collection information ............................................................................................................................................SC-21
Laser radiation .........................................................................................................................................................................SC-22
Additional safety information ................................................................................................................................................SC-22
Warning labels ........................................................................................................................................................................SC-23
Symbols and marks ................................................................................................................................................................SC-25
Product Stewardship ...........................................................................................................SC-27
Introduction ..............................................................................................................................................................................SC-27
National and local safety regulations ..................................................................................................................................SC-27
Certification test marks .........................................................................................................................................................SC-27

6ArcGlide THC Instruction Manual 806450
Contents
Differences in national standards .......................................................................................................................................SC-27
Safe installation and use of shape cutting equipment ...................................................................................................SC-27
Procedures for periodic inspection and testing ..............................................................................................................SC-27
Qualification of test personnel .............................................................................................................................................SC-28
Residual current devices (RCDs) .......................................................................................................................................SC-28
Higher-level systems ..............................................................................................................................................................SC-28
Environmental Stewardship .............................................................................................. SC-29
Introduction ..............................................................................................................................................................................SC-29
National and local environmental regulations ...................................................................................................................SC-29
The RoHS directive ................................................................................................................................................................SC-29
Proper disposal of Hypertherm products ..........................................................................................................................SC-29
The WEEE Directive ..............................................................................................................................................................SC-29
The REACH regulation ..........................................................................................................................................................SC-29
Proper handling and safe use of chemicals .....................................................................................................................SC-30
Fumes emission and air quality ...........................................................................................................................................SC-30
Electromagnetic Compatibility (EMC) ............................................................................ SC-31
Introduction ..............................................................................................................................................................................SC-31
Installation and use .................................................................................................................................................................SC-31
Assessment of area ................................................................................................................................................................SC-31
Methods of reducing emissions ..........................................................................................................................................SC-31
Mains supply ....................................................................................................................................................................SC-31
Maintenance of cutting equipment .....................................................................................................................................SC-31
Cutting cables .........................................................................................................................................................................SC-31
Equipotential bonding ....................................................................................................................................................SC-31
Earthing of the workpiece .............................................................................................................................................SC-31
Screening and shielding .......................................................................................................................................................SC-32
Warranty .................................................................................................................................. SC-33
Attention ...................................................................................................................................................................................SC-33
General .....................................................................................................................................................................................SC-33
Patent indemnity .....................................................................................................................................................................SC-33
Limitation of liability ................................................................................................................................................................SC-33
National and local codes ......................................................................................................................................................SC-33
Liability cap ..............................................................................................................................................................................SC-33
Insurance ..................................................................................................................................................................................SC-34
Transfer of rights .....................................................................................................................................................................SC-34
1 Specifications .............................................................................................................................. 35
Introduction .................................................................................................................................................................................... 35

ArcGlide THC Instruction Manual 806450 7
Contents
ArcGlide control module ..................................................................................................................................................... 36
Lifter assembly ....................................................................................................................................................................... 36
Human machine interface (HMI) ........................................................................................................................................ 37
Plasma interface board ........................................................................................................................................................ 37
Industrial Ethernet switch .................................................................................................................................................... 37
Specifications ................................................................................................................................................................................ 38
ArcGlide system .................................................................................................................................................................... 38
ArcGlide control module (090054) .................................................................................................................................. 39
Lifter assembly (090053) ................................................................................................................................................... 40
Optional HMI (090055) ...................................................................................................................................................... 43
Discrete plasma interface board (141094) .................................................................................................................... 44
Hypernet plasma interface board (141162) ................................................................................................................... 45
Ethernet switch ...................................................................................................................................................................... 46
ArcGlide communication ............................................................................................................................................................ 48
Hypernet communication .................................................................................................................................................... 48
Discrete communication ...................................................................................................................................................... 50
Mixed communication .......................................................................................................................................................... 51
Serial communication ........................................................................................................................................................... 51
2 Installation .................................................................................................................................... 53
Hardware setup ............................................................................................................................................................................. 53
Claims ...................................................................................................................................................................................... 53
Installation requirements ..................................................................................................................................................... 54
Placement of system components .................................................................................................................................... 54
Recommended grounding and shielding practices .............................................................................................................. 55
Introduction ............................................................................................................................................................................ 55
Types of grounding ............................................................................................................................................................... 55
Grounding practices ............................................................................................................................................................ 55
System description for a Hypernet configuration .................................................................................................................. 59
System description for a discrete configuration .................................................................................................................... 60
ArcGlide communication configuration examples ................................................................................................................. 61
Install the lifter ................................................................................................................................................................................ 77
Connect the ohmic wire from HPRXD plasma systems .............................................................................................. 79
Connect the ohmic wire to other plasma systems ........................................................................................................ 80
Ground the lifter .................................................................................................................................................................... 80
Extended torch sleeve option ............................................................................................................................................. 81
Install the optional pneumatic breakaway ....................................................................................................................... 82
Install the control module ............................................................................................................................................................ 84
Modify Retract Delay Time for an HT2000 plasma system ........................................................................................ 85
Ground the control module ................................................................................................................................................ 86
Install the optional HMI ................................................................................................................................................................ 87

8ArcGlide THC Instruction Manual 806450
Contents
Ground the HMI ............................................................................................................................................................................ 89
Install the plasma interface board in a plasma system ......................................................................................................... 90
Discrete plasma interface board (141094) .................................................................................................................... 90
Hypernet plasma interface board (141162) .................................................................................................................. 91
Connect Hypernet cables ........................................................................................................................................................... 92
Connect discrete cables ............................................................................................................................................................. 95
Ground all cables with circular connectors .................................................................................................................... 95
Control module cable connections .................................................................................................................................. 95
Cables ............................................................................................................................................................................................. 97
Power cable ........................................................................................................................................................................... 97
Lifter interface cable ............................................................................................................................................................. 98
Hypernet and HMI interface cable .................................................................................................................................. 100
Optional operator console I/O cable ............................................................................................................................. 101
Optional operator console I/O signals ................................................................................................................... 103
ArcGlide control module CNC interlock kit (228594) ............................................................................................... 104
CNC I/O cable .................................................................................................................................................................... 105
CNC discrete I/O ............................................................................................................................................................... 108
Plasma interface I/O cable ............................................................................................................................................... 110
Plasma discrete I/O ............................................................................................................................................................ 113
Non-serial plasma interface cable .................................................................................................................................. 115
Serial plasma interface cable ........................................................................................................................................... 116
ArcGlide discrete interface signal examples ........................................................................................................................ 117
Inputs ..................................................................................................................................................................................... 117
Relay outputs ....................................................................................................................................................................... 118
ArcGlide setup in Phoenix™ software .................................................................................................................................... 119
Set up ArcGlide and Hypernet ........................................................................................................................................ 119
ArcGlide axis setup ............................................................................................................................................................ 120
ArcGlide axis setup parameters ...................................................................................................................................... 121
Gains ............................................................................................................................................................................. 121
Speeds .......................................................................................................................................................................... 122
Mechanical ................................................................................................................................................................... 123
Miscellaneous .............................................................................................................................................................. 124
Assign an ArcGlide THC to a station ............................................................................................................................ 125
3 Operation .................................................................................................................................... 127
Operator controls ....................................................................................................................................................................... 127
Control module .................................................................................................................................................................... 127
Lifter ....................................................................................................................................................................................... 128
HMI ......................................................................................................................................................................................... 129
Daily operations .......................................................................................................................................................................... 130
Startup procedure .............................................................................................................................................................. 130

ArcGlide THC Instruction Manual 806450 9
Contents
Automatic diagnostic tests ............................................................................................................................................... 130
Verify workpiece sensing .................................................................................................................................................. 130
Shutdown procedure ......................................................................................................................................................... 130
ArcGlide THC operating modes ............................................................................................................................................. 131
Manual mode ....................................................................................................................................................................... 131
Automatic modes ................................................................................................................................................................ 131
Voltage Control Off mode ......................................................................................................................................... 132
Set Arc Voltage mode ................................................................................................................................................ 132
Sample Voltage mode ................................................................................................................................................ 132
Initial height sense ...................................................................................................................................................................... 133
Performing a first IHS on the ArcGlide .......................................................................................................................... 133
Operating the control module .................................................................................................................................................. 135
Screen 0 – Idle Park .......................................................................................................................................................... 136
Screen 1 – ArcGlide control state ................................................................................................................................. 136
Screen 2 – Options ........................................................................................................................................................... 137
Screen 3 – Inputs from the CNC .................................................................................................................................... 138
Screen 4 – Outputs to the CNC .................................................................................................................................... 138
Screen 5 – Inputs from the lifter control board ........................................................................................................... 139
Screen 6 – Outputs from the lifter control board ........................................................................................................ 139
Screen 7 – Inputs from the operator console .............................................................................................................. 140
Screen 8 – Outputs to the operator console ............................................................................................................... 140
Screen 9 – Inputs from the plasma system .................................................................................................................. 141
Screen 10 – Outputs to the plasma system ................................................................................................................ 141
Screen 11 – Last errors .................................................................................................................................................... 142
Screen 12 – Total lifter operating time .......................................................................................................................... 142
Operating the HMI ...................................................................................................................................................................... 143
HMI screen hierarchy ......................................................................................................................................................... 144
Main screen .......................................................................................................................................................................... 146
Setup screen ........................................................................................................................................................................ 147
Diagnostics screen ............................................................................................................................................................. 148
Installation Data screen ..................................................................................................................................................... 153
Manual mode ....................................................................................................................................................................... 155
Lifter Disabled mode .......................................................................................................................................................... 155
ArcGlide operating parameters ............................................................................................................................................... 156
THC mode ............................................................................................................................................................................ 157
Cut chart values .................................................................................................................................................................. 157
Options .................................................................................................................................................................................. 158
Automatically-set parameters ........................................................................................................................................... 158
Plasma cutting tips ..................................................................................................................................................................... 161
Cut quality issues ................................................................................................................................................................ 161
Basic steps to improve cut quality .................................................................................................................................. 164

10 ArcGlide THC Instruction Manual 806450
Contents
4 Maintenance .............................................................................................................................. 169
Introduction .................................................................................................................................................................................. 169
Lifter routine maintenance ........................................................................................................................................................ 169
Carriage ................................................................................................................................................................................ 169
Sealing strip ......................................................................................................................................................................... 171
Cable connections ............................................................................................................................................................. 171
System grounding .............................................................................................................................................................. 171
Calibrate arc voltage .................................................................................................................................................................. 172
Flow of ArcGlide operations .................................................................................................................................................... 174
Basic flow for all ArcGlide operating states ................................................................................................................. 177
Common machine-cutting faults ............................................................................................................................................. 178
Update ArcGlide firmware ........................................................................................................................................................ 180
Download through Phoenix software ............................................................................................................................. 180
Download from a laptop .................................................................................................................................................... 180
Operator tests ............................................................................................................................................................................. 181
Problems and solutions ............................................................................................................................................................. 182
Troubleshooting routines .......................................................................................................................................................... 185
Hypertherm CNC will not communicate with HPR plasma system ........................................................................ 185
Error 19 – Excess plate contact ..................................................................................................................................... 186
Error 21 – Ohmic tip sense .............................................................................................................................................. 188
Error message troubleshooting .............................................................................................................................................. 191
Error message displays ..................................................................................................................................................... 191
ArcGlide errors .................................................................................................................................................................... 191
Printed circuit board (PCB) block diagram for a Hypernet configuration ..................................................................... 209
Printed circuit board (PCB) block diagram for a discrete configuration ....................................................................... 210
ArcGlide PCBs ........................................................................................................................................................................... 211
HMI processor board (228581) ...................................................................................................................................... 211
HMI 7-segment display interface board (228582) ..................................................................................................... 214
THC control interface board (228577) ......................................................................................................................... 215
THC processor board (228578) .................................................................................................................................... 220
Discrete plasma interface board (141094) .................................................................................................................. 224
Hypernet plasma interface board (141162) ................................................................................................................ 228
Lifter interface board (228580) ....................................................................................................................................... 231
5 Parts List ..................................................................................................................................... 235
Lifter parts .................................................................................................................................................................................... 235
Lifter motor and slide parts ...................................................................................................................................................... 237
Control module parts ................................................................................................................................................................. 238
HMI parts ...................................................................................................................................................................................... 239
Plasma interface boards ........................................................................................................................................................... 240

ArcGlide THC Instruction Manual 806450 11
Contents
6 Wiring Diagrams ....................................................................................................................... 241
Wiring diagram symbols ........................................................................................................................................................... 242
1 – Lifter interface board (141097) ....................................................................................................................................... 245
2 – THC control interface board (141088) ......................................................................................................................... 246
3 – THC Processor board (141091) ..................................................................................................................................... 247
4 – HMI processor board (141082) ...................................................................................................................................... 248
A ArcGlide THC Serial Communication Protocol ................................................................ 249
Overview ....................................................................................................................................................................................... 249
ArcGlide THC Operation .......................................................................................................................................................... 249
Serial Protocol ............................................................................................................................................................................. 249
ArcGlide THC Responses ................................................................................................................................................ 250
Calculating the Checksum ............................................................................................................................................... 250
ArcGlide Commands and Examples ...................................................................................................................................... 251
Setup Commands ...................................................................................................................................................................... 252
Operating Commands ............................................................................................................................................................... 255
ArcGlide THC Extended Commands .................................................................................................................................... 260
ArcGlide THC to Command THC error conversions ......................................................................................................... 266
B ArcGlide THC Serial Communication Installation ........................................................... 269
Introduction .................................................................................................................................................................................. 269
Kit 228846 (Command THC replacement) .................................................................................................................. 269
Kit 228851 (New ArcGlide installation) ........................................................................................................................ 270
Specifications .............................................................................................................................................................................. 270
Limitations ............................................................................................................................................................................. 271
RS-422 serial protocol ...................................................................................................................................................... 271
Serial communication configurations ..................................................................................................................................... 272
Replacing a Command THC ............................................................................................................................................ 272
System description for a serial configuration ....................................................................................................................... 274
ArcGlide THC replacement for Command THC ......................................................................................................... 274
ArcGlide THC in a new installation ................................................................................................................................ 275
Connect serial cables ................................................................................................................................................................ 276
Connecting cables for a Command THC replacement ............................................................................................. 276
Connecting cables in a new serial system .................................................................................................................... 278
Cables ........................................................................................................................................................................................... 280
Plasma I/O split cable (Z) (223253) .............................................................................................................................. 280
Adjusting ArcGlide parameters with the HMI ....................................................................................................... 283
Plasma board adapter cable (223260) ......................................................................................................................... 284
Plasma I/O split cable (Y) (223262) .............................................................................................................................. 285

12 ArcGlide THC Instruction Manual 806450
Contents

Safety and Compliance SC-13
Safety
RECOGNIZE SAFETY
INFORMATION
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.
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.
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.
• 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.

SC-14 Safety and Compliance
Safety
ELECTRIC SHOCK CAN KILL
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.

Safety and Compliance SC-15
Safety
CUTTING CAN CAUSE FIRE OR EXPLOSION
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.
WARNING
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.
WARNING
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.
WARNING
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.

SC-16 Safety and Compliance
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.

Safety and Compliance SC-17
Safety
GROUNDING 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.
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.
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.

SC-18 Safety and Compliance
Safety
COMPRESSED GAS EQUIPMENT
SAFETY
GAS CYLINDERS CAN
EXPLODE IF DAMAGED
• 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 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.

Safety and Compliance SC-19
Safety
ARC RAYS CAN BURN EYES AND SKIN
Arc current
(amps)
Minimum
protective shade
number
(ANSIZ49.1:2005)
Suggested shade
number for
comfort
(ANSI Z49.1:2005)
OSHA 29CFR
1910.133(a)(5)
Europe
EN168:2002
Less than 40 A 5589
41 to 60 A 6689
61 to 80 A 8889
81 to 125 A 8989
126 to 150 A 89810
151 to 175 A 89811
176 to 250 A 89812
251 to 300 A 89813
301 to 400 A 912913
401 to 800 A 10 14 10 N /A
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.

SC-20 Safety and Compliance
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.
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.
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.
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.