Hypertherm EDGE Pro Ti User manual
Instruction Manual
807660 – Revision 3
EDGE®
Pro Ti
Shape Cutting Control
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ArcGlide, EDGE, HPR, HSD, Hypernet, Hypertherm, Phoenix, Powermax, and Sensor are trademarks of Hypertherm, Inc. and may be
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© 2018 Hypertherm, Inc.
EDGE Pro Ti CNC
Instruction Manual
807660 – Revision 3
English
September 2018
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)
800-643-9878 Tel (Technical Service)
800-737-2978 Tel (Customer Service)
866-643-7711 Tel (Return Materials Authorization)
877-371-2876 Fax (Return Materials Authorization)
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 Plasmatechnik GmbH
Sophie-Scholl-Platz 5
63452 Hanau
Germany
00 800 33 24 97 37 Tel
00 800 49 73 73 29 Fax
31 (0) 165 596900 Tel (Technical Service)
00 800 4973 7843 Tel (Technical Service)
Hypertherm (Singapore) Pte Ltd.
82 Genting Lane
Media Centre
Annexe Block #A01-01
Singapore 349567, Republic of Singapore
65 6841 2489 Tel
65 6841 2490 Fax
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 Europe B.V.
Vaartveld 9, 4704 SE
Roosendaal, Nederland
31 165 596907 Tel
31 165 596901 Fax
31 165 596908 Tel (Marketing)
31 (0) 165 596900 Tel (Technical Service)
00 800 4973 7843 Tel (Technical Service)
(Technical Service Email)
Hypertherm (Shanghai) Trading Co., Ltd.
B301, 495 ShangZhong Road
Shanghai, 200231
PR China
86-21-80231122 Tel
86-21-80231120 Fax
86-21-80231128 Tel (Technical Service)
(Technical Service Email)
South America & Central America: Hypertherm Brasil Ltda.
Rua Bras Cubas, 231 – Jardim Maia
Guarulhos, SP – Brasil
CEP 07115-030
55 11 2409 2636 Tel
Hypertherm Korea Branch
#3904. APEC-ro 17. Heaundae-gu. Busan.
Korea 48060
82 (0)51 747 0358 Tel
82 (0)51 701 0358 Fax
TechSupportAP[email protected]
(Technical Service Email)
Hypertherm Pty Limited
GPO Box 4836
Sydney NSW 2001, Australia
61 (0) 437 606 995 Tel
61 7 3219 9010 Fax
TechSupportAP[email protected]
(Technical Service Email)
Hypertherm (India) Thermal Cutting Pvt. Ltd
A-18 / B-1 Extension,
Mohan Co-Operative Industrial Estate,
Mathura Road, New Delhi 110044, India
91-11-40521201/ 2/ 3 Tel
91-11 40521204 Fax
HTIndia.info@hypertherm.com (Main Office Email)
TechSupportAP[email protected]
(Technical Service Email)
1/28/16
EDGE Pro Ti CNC Instruction Manual 807660 v
Contents
Safety .........................................................................................................................................................xi
Recognize safety information .............................................................................................................................................................xi
Inspect equipment before using ........................................................................................................................................................xi
Follow safety instructions ....................................................................................................................................................................xi
Responsibility for safety ......................................................................................................................................................................xi
A plasma arc can damage frozen pipes ..........................................................................................................................................xi
Static electricity can damage printed circuit boards ....................................................................................................................xi
Grounding safety .................................................................................................................................................................................xii
Electrical hazards .................................................................................................................................................................................xii
Electric shock can kill .........................................................................................................................................................................xii
Cutting can cause fire or explosion ................................................................................................................................................ xiii
Fire prevention ............................................................................................................................................................................. xiii
Explosion prevention .................................................................................................................................................................. xiii
Machine motion can cause injury .................................................................................................................................................... xiii
Compressed gas equipment safety ...............................................................................................................................................xiv
Gas cylinders can explode if damaged .........................................................................................................................................xiv
Toxic fumes can cause injury or death ...........................................................................................................................................xiv
A plasma arc can cause injury and burns ......................................................................................................................................xv
Arc rays can burn eyes and skin ......................................................................................................................................................xv
Pacemaker and hearing aid operation ............................................................................................................................................xv
Noise can damage hearing ...............................................................................................................................................................xvi
Dry dust collection information ........................................................................................................................................................ xvi
Laser radiation .................................................................................................................................................................................... xvii
Additional safety information ........................................................................................................................................................... xvii
Product Stewardship ..........................................................................................................................xix
Introduction .......................................................................................................................................................................................... xix
National and local safety regulations ............................................................................................................................................. xix
Certification test marks ..................................................................................................................................................................... xix
Differences in national standards .................................................................................................................................................... xix
vi EDGE Pro Ti CNC Instruction Manual 807660
Contents
Safe installation and use of shape cutting equipment ............................................................................................................... xix
Procedures for periodic inspection and testing .......................................................................................................................... xix
Qualification of test personnel .......................................................................................................................................................... xx
Residual current devices (RCDs) .................................................................................................................................................... xx
Higher-level systems .......................................................................................................................................................................... xx
Environmental Stewardship ............................................................................................................. xxi
Introduction .......................................................................................................................................................................................... xxi
National and local environmental regulations ............................................................................................................................... xxi
The RoHS directive ............................................................................................................................................................................ xxi
Proper disposal of Hypertherm products ..................................................................................................................................... xxi
The WEEE Directive .......................................................................................................................................................................... xxi
The REACH regulation ...................................................................................................................................................................... xxi
Proper handling and safe use of chemicals ................................................................................................................................ xxii
Fumes emission and air quality ...................................................................................................................................................... xxii
Electromagnetic Compatibility (EMC) .........................................................................................xxiii
Introduction ........................................................................................................................................................................................ xxiii
Installation and use ........................................................................................................................................................................... xxiii
Assessment of area .......................................................................................................................................................................... xxiii
Methods of reducing emissions .................................................................................................................................................... xxiii
Mains supply .............................................................................................................................................................................. xxiii
Maintenance of cutting equipment ............................................................................................................................................... xxiii
Cutting cables ................................................................................................................................................................................... xxiii
Equipotential bonding .............................................................................................................................................................. xxiii
Screening and shielding ................................................................................................................................................................. xxiv
Warranty ................................................................................................................................................ xxv
Attention .............................................................................................................................................................................................. xxv
General ................................................................................................................................................................................................ xxv
Patent indemnity ................................................................................................................................................................................ xxv
Limitation of liability ........................................................................................................................................................................... xxv
National and local codes ................................................................................................................................................................. xxv
Liability cap ........................................................................................................................................................................................ xxvi
Insurance ............................................................................................................................................................................................ xxvi
Transfer of rights ............................................................................................................................................................................... xxvi
Waterjet product warranty coverage ........................................................................................................................................... xxvi
Product ....................................................................................................................................................................................... xxvi
Parts coverage .......................................................................................................................................................................... xxvi
Specifications ........................................................................................................................................ 27
Main features of an automated cutting system ............................................................................................................................27
CNC ..............................................................................................................................................................................................29
Cutting table ................................................................................................................................................................................29
EDGE Pro Ti CNC Instruction Manual 807660 vii
Contents
Plasma system ............................................................................................................................................................................ 29
Control box .................................................................................................................................................................................. 29
Drive system ................................................................................................................................................................................ 29
Torch height control (THC) ..................................................................................................................................................... 29
Operator console ....................................................................................................................................................................... 30
Oxyfuel torch ............................................................................................................................................................................... 30
Marker ........................................................................................................................................................................................... 30
Overview .............................................................................................................................................................................................. 30
Features of the EDGE Pro Ti CNC ............................................................................................................................................... 31
Touchscreen ............................................................................................................................................................................... 31
Operator console ....................................................................................................................................................................... 31
Rear panel ................................................................................................................................................................................... 32
System specifications ....................................................................................................................................................................... 33
EDGE Pro Ti axis and I/O configuration ....................................................................................................................................... 35
Specifications for the Sensor Ti lifter ............................................................................................................................................ 36
Installation .............................................................................................................................................. 37
Upon receipt ....................................................................................................................................................................................... 37
Claims ........................................................................................................................................................................................... 37
Installation requirements .................................................................................................................................................................. 37
Gantry sizing for EDGE Pro Ti motors .................................................................................................................................. 37
Placement of system components ......................................................................................................................................... 38
Mounting the CNC ............................................................................................................................................................................ 39
Mounting hole patterns on the bottom of the CNC ........................................................................................................... 40
Mounting the THC ............................................................................................................................................................................. 41
Sensor™ Ti THC ......................................................................................................................................................................... 41
ArcGlide THC ............................................................................................................................................................................. 42
Configuration diagrams .................................................................................................................................................................... 49
X and Y axis configuration ............................................................................................................................................................... 51
The operator console ........................................................................................................................................................................ 51
Front panel I/O ........................................................................................................................................................................... 52
AC power ............................................................................................................................................................................................ 53
Power input ................................................................................................................................................................................. 53
Power cable ................................................................................................................................................................................ 53
Chassis grounding .................................................................................................................................................................... 54
Interface ports .................................................................................................................................................................................... 55
Hypernet®interface ................................................................................................................................................................... 55
LAN interface .............................................................................................................................................................................. 55
USB interface ............................................................................................................................................................................. 55
Serial ports .................................................................................................................................................................................. 55
System connections .......................................................................................................................................................................... 56
viii EDGE Pro Ti CNC Instruction Manual 807660
Contents
Cable shield grounds .................................................................................................................................................................56
Emergency stop (E-stop) connection ............................................................................................................................................57
Safety audit ..................................................................................................................................................................................57
Sample E-stop circuit ................................................................................................................................................................58
EDGE Pro Ti safety circuit ........................................................................................................................................................59
E-stop test circuit .......................................................................................................................................................................60
E-stop cable .................................................................................................................................................................................62
Motor connection ...............................................................................................................................................................................63
Axis configuration .......................................................................................................................................................................64
Motor (031143) ..........................................................................................................................................................................65
Regeneration circuit ...........................................................................................................................................................66
Motor cable ..........................................................................................................................................................................66
Encoder connection ...........................................................................................................................................................................68
Encoder cable .............................................................................................................................................................................69
I/O connection ....................................................................................................................................................................................71
I/O cable .......................................................................................................................................................................................72
Configuring I/O ...........................................................................................................................................................................73
Shared inputs ......................................................................................................................................................................73
Input modes .........................................................................................................................................................................74
I/O circuits ............................................................................................................................................................................74
I/O Setup screen ........................................................................................................................................................................76
Plasma connection .............................................................................................................................................................................77
Plasma connection for Powermax plasma systems ............................................................................................................78
Plasma connection for generic plasma systems .................................................................................................................80
Plasma interface assembly (228256) ....................................................................................................................................82
Plasma connection to HSD130 plasma systems ................................................................................................................85
Lifter interface ......................................................................................................................................................................................87
Lifter interface cable ..................................................................................................................................................................88
24 VDC auxiliary power connector ................................................................................................................................................89
Hypernet and LAN cable ..................................................................................................................................................................89
Operation ................................................................................................................................................ 91
Operating the CNC ...........................................................................................................................................................................91
Touch screen LCD .....................................................................................................................................................................91
Screen navigation .......................................................................................................................................................................91
Help ...............................................................................................................................................................................................92
View additional manuals ............................................................................................................................................................93
Show bookmarks ........................................................................................................................................................................94
Automated operations .......................................................................................................................................................................94
Align Wizard ................................................................................................................................................................................94
CutPro Wizard .............................................................................................................................................................................95
EDGE Pro Ti CNC Instruction Manual 807660 ix
Contents
Updating Phoenix software ............................................................................................................................................................. 95
Updating the software .............................................................................................................................................................. 95
Updating the Help ..................................................................................................................................................................... 95
Updating the cut charts ............................................................................................................................................................ 95
Maintenance and Diagnostics .......................................................................................................... 97
Introduction ......................................................................................................................................................................................... 97
Care and handling of the touchscreen ......................................................................................................................................... 97
Touchscreens, drops of water, and unintended motion ................................................................................................... 98
THC Slide Maintenance ................................................................................................................................................................... 98
Cleaning ....................................................................................................................................................................................... 98
Lubrication ................................................................................................................................................................................... 98
Diagnostic tests ................................................................................................................................................................................. 99
Machine interface tests ............................................................................................................................................................ 99
LAN and Hypernet tests .........................................................................................................................................................100
Serial test ...................................................................................................................................................................................101
USB test ....................................................................................................................................................................................102
E-stop test .................................................................................................................................................................................103
I/O test .......................................................................................................................................................................................105
Plasma and lifter tests .............................................................................................................................................................108
Operator panel test .................................................................................................................................................................109
Troubleshooting ...............................................................................................................................................................................110
Introduction ...............................................................................................................................................................................110
Common situations .................................................................................................................................................................111
Power up ............................................................................................................................................................................111
Display ................................................................................................................................................................................111
LED ......................................................................................................................................................................................111
Input failure ........................................................................................................................................................................112
Output failure ....................................................................................................................................................................112
Hypernet ............................................................................................................................................................................112
LAN connection ................................................................................................................................................................112
The regeneration circuit remains on for more than 25% of a single cut .............................................................112
Motion issues ....................................................................................................................................................................113
Serial communication issues .........................................................................................................................................113
The CNC is not recognizing a device in a USB port ...............................................................................................113
Cut quality or plasma performance issues .................................................................................................................113
The CNC feels excessively warm .................................................................................................................................113
Loading files ......................................................................................................................................................................114
Wireless troubleshooting .......................................................................................................................................................114
Component locations and information ........................................................................................................................................115
Operator control panel board (141058) ....................................................................................................................................116
xEDGE Pro Ti CNC Instruction Manual 807660
Contents
Motherboard (141110) ..................................................................................................................................................................118
Power distribution board (141153) ............................................................................................................................................119
4-axis MCC board (141191) .......................................................................................................................................................121
Utility and serial isolation board (141307) ................................................................................................................................124
Plasma interface board (141267) ............................................................................................................................................... 126
Relay I/O board (141278) ............................................................................................................................................................ 128
4-axis DC servo board (141281) ................................................................................................................................................ 135
Servo amplifier (228360) ...................................................................................................................................................... 139
Surge board (141287) ...................................................................................................................................................................140
Plasma interface assembly (228256) ......................................................................................................................................... 141
EDGE Pro Ti Parts List ......................................................................................................................143
EDGE Pro Ti CNC parts ................................................................................................................................................................ 143
Sensor Ti THC parts .......................................................................................................................................................................143
Interface assembly kits ................................................................................................................................................................... 143
Safety circuit kits ............................................................................................................................................................................. 144
Diagnostic kits .................................................................................................................................................................................. 144
Cables ................................................................................................................................................................................................144
Cable connector kits .......................................................................................................................................................................146
PCB kits ............................................................................................................................................................................................. 146
Additional kits ...................................................................................................................................................................................148
Wiring Diagrams .................................................................................................................................149
Wiring diagram symbols ................................................................................................................................................................150
EDGE Pro Ti system wiring ........................................................................................................................................................... 153
Motherboard ..................................................................................................................................................................................... 154
Power distribution board ............................................................................................................................................................... 155
Operator panel board ..................................................................................................................................................................... 156
Operator panel components .........................................................................................................................................................157
Utility and serial board .................................................................................................................................................................... 158
MCC board ....................................................................................................................................................................................... 159
I/O board ........................................................................................................................................................................................... 160
6-Axis servo board .......................................................................................................................................................................... 161
Surge board ...................................................................................................................................................................................... 162
ATX power supply ...........................................................................................................................................................................163
60 VDC power supply .................................................................................................................................................................... 164
Safety and compliance xi
Safety
RECOGNIZE SAFETY
INFORMATION
DANGER WARNING CAUTION
American National Standards Institute (ANSI) guidelines are used for
safety signal words and symbols. The 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.
INSPECT EQUIPMENT BEFORE USING
All cutting equipment must be inspected as required to make sure it is in
safe operating condition. When found to be incapable of reliable and
safe operation, the equipment must be repaired by qualified personnel
prior to its next use or withdrawn from service.
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
Carefully read 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.
RESPONSIBILITY FOR SAFETY
The person or entity responsible for the safety of the workplace must:
• Make sure that operators and their supervisors are trained in the safe
use of their equipment, the safe use of the process, and emergency
procedures.
• Make sure that all hazards and safety precautions identified herein
are communicated to and understood by workers before the start of
work.
• Designate approved cutting areas and establish procedures for safe
cutting.
• Be responsible for authorizing cutting operations in areas not
specifically designed or approved for such processes.
• Make sure that only approved equipment, such as torches and
personal protective equipment, are used.
• Select contractors who provide trained and qualified personnel, and
who have awareness of the risks involved, to do cutting.
• Tell contractors about flammable materials or hazardous conditions
that are specific to the site, or hazardous conditions that they may not
be aware of.
• Make sure that the quality and quantity of air for ventilation is such
that personnel exposures to hazardous contaminants are below the
allowable limits.
• Make sure that ventilation in confined spaces is sufficient to allow
adequate oxygen for life support, to prevent accumulation of
asphixiants or flammable explosive mixtures, to prevent
oxygen-enriched atmospheres, and to keep airborne contaminants in
breathing atmospheres below allowable limits.
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.
STATIC ELECTRICITY CAN DAMAGE PRINTED CIRCUIT BOARDS
Use proper precautions when handling printed circuit boards:
• Store printed circuit boards in anti-static containers.
• Wear a grounded wrist strap when handling printed circuit boards.
xii Safety and compliance
Safety
GROUNDING SAFETY
Work lead Attach the work lead securely to the workpiece or the
cutting table with good metal-to-metal contact. Do not connect it to
the piece that will fall away when the cut is complete.
Cutting table Connect the cutting table to an earth ground, in
accordance with appropriate national and local electrical regulations.
Input power
• Make 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, make 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. Tighten the
retaining nut.
• Tighten all electrical connections to avoid excessive heating.
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.
• Prior to operating the equipment after moving, opening, or servicing,
make sure to close the enclosure and make sure that there is proper
earth ground continuity to the enclosure.
• Always follow these instructions for disconnecting power before
inspecting or changing torch consumable parts.
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.
• In machine torch applications, never touch the torch body,
workpiece, or water in a water table when the plasma system is
operating.
Electric shock prevention
All 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 the work and ground using dry insulating
mats or covers big enough to prevent any physical contact with the
work or ground. If you must cut 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, make sure that it is correctly connected
to an earth ground.
• Install and ground this equipment according to the instruction
manual and in accordance with national and local regulations.
• 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 lead 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 a proper grounding
conductor first.
• Each plasma system is designed to be used only with specific
torches. Do not substitute other torches, which could overheat and
present a safety hazard.
Safety and compliance xiii
Safety
CUTTING CAN CAUSE FIRE OR EXPLOSION
Fire prevention
• Make sure the cutting 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 containers.
• 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
Explosion Hazard
Underwater Cutting with Fuel Gases
Containing Hydrogen
• Do not cut underwater with fuel gases containing hydrogen.
• Cutting underwater with fuel gases containing hydrogen can result
in an explosive condition that can detonate during plasma cutting
operations.
WARNING
Explosion Hazard
Hydrogen Detonation with Aluminum Cutting
When you use a plasma torch to cut aluminum alloys under water or
on a water table, a chemical reaction between the water and the
workpiece, parts, fine particles, or molten aluminum droplets
generates significantly more hydrogen gas than occurs with other
metals. This hydrogen gas may get trapped under the workpiece. If
exposed to oxygen or air, the plasma arc or a spark from any source
can ignite this trapped hydrogen gas, causing an explosion that may
result in death, personal injury, loss of property, or equipment damage.
Consult with the table manufacturer and other experts prior to cutting
aluminum to implement a risk assessment and mitigation plan that
eliminates the risk of detonation by preventing hydrogen
accumulation.
Also, make sure that the water table, fume extraction (ventilation), and
other parts of the cutting system have been designed with aluminum
cutting in mind.
Do not cut aluminum alloys underwater or on a water table
unless you can prevent the accumulation of hydrogen gas.
Note: With proper mitigation, most aluminum alloys can be plasma
cut on a water table. An exception is aluminum-lithium alloys. Never
cut aluminum-lithium alloys in the presence of water. Contact
your aluminum supplier for additional safety information regarding
hazards associated with aluminum-lithium alloys.
MACHINE MOTION CAN CAUSE INJURY
When an original equipment manufacturer (OEM) makes a cutting system by combining Hypertherm equipment with other equipment, the end-use
customer and the OEM are responsible for providing protection against the hazardous moving parts of this cutting system. However, we advise the
following to prevent operator injury and equipment damage:
• Read and follow the instruction manual provided by the OEM.
• Maintain a restricted-access area larger than the maximum
movement range of the cutting system’s moving parts.
• Where there is a risk of collision, do not allow personnel or
equipment near the cutting system’s moving parts.
• Avoid accidental contact with the CNC touchscreen or joystick.
Accidental contact can activate commands and result in
unintended motion.
• Do not service or clean the machinery during operation.
• If servicing is required, enable the safety interlock or disconnect
and lock out/tag out power to disable the motors and prevent
motion.
• Allow only qualified personnel to operate, maintain, and service the
machinery.
xiv 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 regulations.
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 regulations.
• Never use a cylinder that is not upright and secured in place.
• Keep the protective cap in place over the 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.
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.
The 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.
The 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 on 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 cutting area and to make sure 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 workplace.
• Personal protective equipment.
• Number of welding and cutting systems in operation.
• Other workplace 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
workplace 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.
• Make sure 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 make sure air
quality is safe.
Safety and compliance xv
Safety
A PLASMA ARC CAN CAUSE INJURY AND BURNS
Instant-on torches
A plasma arc ignites 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.
ARC RAYS CAN BURN EYES AND SKIN
Arc current
Minimum protective
shade number
(ANSIZ49.1:2012)
Suggested shade
number for comfort
(ANSI Z49.1:2012)
OSHA 29CFR
1910.133(a)(5)
Europe
EN168:2002
Less than 40 A 5 5 8 9
41 A to 60 A 6 6 8 9
61 A to 80 A 8 8 8 9
81 A to 125 A 8 9 8 9
126 A to 150 A 8 9 8 10
151 A to 175 A 8 9 8 11
176 A to 250 A 8 9 8 12
251 A to 300 A 8 9 8 13
301 A to 400 A 9 12 9 13
401Ato800A101410N/A
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 lead and the torch lead to one side, away from
your body.
• Route the torch leads as close as possible to the work lead.
• Do not wrap or drape the torch lead or work lead around your body.
• Keep as far away from the power supply as possible.
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
regulations.
• 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.
• Wear gauntlet gloves, safety shoes, and hat.
• Wear flame-retardant clothing to cover all exposed areas.
• Wear cuffless trousers to prevent entry of sparks and slag.
Also, 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.
xvi Safety and compliance
Safety
NOISE CAN DAMAGE HEARING
Cutting with a plasma arc can exceed acceptable noise levels as
defined by local regulations 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 site have verified personal hearing
protection is not necessary per relevant international, regional, and
local regulations.
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 and limit
operator exposure time, and screen off noisy areas and/or take
measures to reduce reverberation in cutting 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 equipment such as ear muffs
or ear plugs with a noise reduction rating appropriate for the
situation. Warn others near the cutting area of possible noise
hazards. In addition, ear protection can prevent hot splatter from
entering the ear.
DRY DUST COLLECTION INFORMATION
In some workplaces, dry dust can represent a potential explosion
hazard.
The U.S. National Fire Protection Association’s 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 standard 68 has been “adopted by
reference” in your local building codes.
Refer to NFPA standard 68 for definitions and explanations of
regulatory terms such as deflagration, AHJ, adopted by reference, the
Kst value, deflagration index, and other terms.
Note 1 – Unless a site-specific evaluation has been completed that
determines that none of the dust generated is combustible, then
NFPA standard 68 requires the use of explosion vents. Design the
explosion vent size and type to conform to the worst-case Kst value
as described in Annex F of NFPA standard 68. NFPA standard 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 should consult and comply with all applicable
national, state, and local regulations. Publications do not 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 xvii
Safety
LASER RADIATION
Exposure to the laser beam from a laser pointer can result in serious eye injury. Avoid direct eye exposure.
On products that use a laser pointer for alignment, 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, pulse duration are 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.
• 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.
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
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, 1 Batterymarch Park, Quincy, MA
02169-7471
9. NFPA Standard 70, National Electrical Code, National Fire
Protection Association, 1 Batterymarch Park, Quincy, MA
02169-7471
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/
xviii Safety and compliance
Safety
Safety and Compliance xix
Product Stewardship
Introduction
Hypertherm maintains a global Regulatory Management System to
ensure that products comply with regulatory and environmental
requirements.
National and local safety regulations
National and Local safety regulations shall take precedence over any
instructions provided with the product. The product shall be imported,
installed, operated and disposed of in accordance with national and local
regulations applicable to the installed site.
Certification test marks
Certified products are identified by one or more certification test marks
from accredited testing laboratories. The certification test marks are
located on or near the data plate.
Each certification test mark means that the product and its safety-critical
components conform to the relevant national safety standards as
reviewed and determined by that testing laboratory. Hypertherm places
a certification test mark on its products only after that product is
manufactured with safety-critical components that have been authorized
by the accredited testing laboratory.
Once the product has left the Hypertherm factory, the certification test
marks are invalidated if any of the following occurs:
• The product is modified in a manner that creates a hazard or
non-conformance with the applicable standards.
• Safety-critical components are replaced with unauthorized spare
parts.
• Any unauthorized assembly, or accessory that uses or generates a
hazardous voltage is added.
• There is any tampering with a safety circuit or other feature that is
designed into the product as part of the certification, or otherwise.
CE marking constitutes a manufacturer’s declaration of conformity to
applicable European directives and standards. Only those versions of
Hypertherm products with a CE Marking located on or near the data
plate have been tested for compliance with the European Low Voltage
Directive and the European EMC Directive. EMC filters needed to
comply with the European EMC Directive are incorporated within
versions of the power supply with a CE Marking.
Certificates of compliance for Hypertherm products are available from
the Documents Library on the Hypertherm web site at
www.hypertherm.com/docs.
Differences in national standards
Nations may apply different performance, safety or other standards.
National differences in standards include, but are not limited to:
•Voltages
• Plug and cord ratings
• Language requirements
• Electromagnetic compatibility requirements
These differences in national or other standards may make it impossible
or impractical for all certification test marks to be placed on the same
version of a product. For example, the CSA versions of Hypertherm’s
products do not comply with European EMC requirements, and therefore
do not have a CE marking on the data plate.
Countries that require CE marking or have compulsory EMC regulations
must use CE versions of Hypertherm products with the CE marking on
the data plate. These include, but are not limited to:
•Australia
• New Zealand
• Countries in the European Union
• Russia
It is important that the product and its certification test mark be suitable
for the end-use installation site. When Hypertherm products are shipped
to one country for export to another country; the product must be
configured and certified properly for the end-use site.
Safe installation and use of shape cutting
equipment
IEC 60974-9, titled Arc Welding Equipment – Installation and use,
provides guidance in the safe installation and use of shape cutting
equipment and the safe performance of cutting operations. The
requirements of national and local regulations shall be taken into
consideration during installation, including, but not limited to, grounding
or protective earth connections, fuses, supply disconnecting device, and
type of supply circuit. Read these instructions before installing the
equipment. The first and most important step is the safety assessment of
the installation.
The safety assessment must be performed by an expert, and determines
what steps are necessary to create a safe environment, and what
precautions should be adopted during the actual installation and
operation.
Procedures for periodic inspection and
testing
Where required by local national regulations, IEC 60974-4 specifies test
procedures for periodic inspection and after repair or maintenance, to
ensure electrical safety for plasma cutting power sources built in
conformity with IEC 60974-1. Hypertherm performs the continuity of the
protective circuit and insulation resistance tests in the factory as
non-operating tests. The tests are performed with the power and ground
connections removed.
xx Safety and Compliance
Product Stewardship
Hypertherm also removes some protective devices that would cause
false test results. Where required by local national regulations, a label
shall be attached to the equipment to indicate that it has passed the
tests prescribed by IEC 60974-4. The repair report shall indicate the
results of all tests unless an indication is made that a particular test has
not been performed.
Qualification of test personnel
Electrical safety tests for shape cutting equipment can be hazardous and
shall be carried out by an expert in the field of electrical repair, preferably
someone also familiar with welding, cutting, and allied processes. The
safety risks to personnel and equipment, when unqualified personnel are
performing these tests, may be much greater than the benefit of periodic
inspection and testing.
Hypertherm recommends that only visual inspection be performed unless
the electrical safety tests are specifically required by local national
regulations in the country where the equipment is installed.
Residual current devices (RCDs)
In Australia and some other countries, local codes may require the use of
a Residual Current Devices (RCD) when portable electrical equipment is
used in the workplace or at construction sites to protect operators from
electrical faults in the equipment. RCDs are designed to safely
disconnect the mains electrical supply when an imbalance is detected
between the supply and return current (there is a leakage current to
earth). RCDs are available with both fixed and adjustable trip currents
between 6 to 40 milliamperes and a range of trip times up to
300 milliseconds selected for the equipment installation, application and
intended use. Where RCDs are used, the trip current and trip time on
RCDs should be selected or adjusted high enough to avoid nuisance
tripping during normal operation of the plasma cutting equipment and
low enough in the extremely unlikely event of an electrical fault in the
equipment to disconnect the supply before the leakage current under a
fault condition can pose a life threatening electrical hazard to operators.
To verify that the RCDs continue to function properly over time, both the
trip current and the trip time should be tested periodically. Portable
electrical equipment and RCDs used in commercial and industrial areas
in Australia and New Zealand are tested to the Australian standard
AS/NZS 3760. When you test the insulation of plasma cutting
equipment to AS/NZS 3760, measure the insulation resistance
according to Appendix B of the standard, at 250 VDC with the power
switch in the ON position to verify proper testing and to avoid the false
failure of the leakage current test. False failures are possible because the
metal oxide varistors (MOVs) and electromagnetic compatibility (EMC)
filters, used to reduce emissions and protect the equipment from power
surges, may conduct up to 10 milliamperes leakage current to earth
under normal conditions.
If you have any questions regarding the application or interpretation of
any IEC standards described here, you are required to consult with an
appropriate legal or other advisor familiar with the International
Electrotechnical standards, and shall not rely on Hypertherm in any
respect regarding the interpretation or application of such standards.
Higher-level systems
When a system integrator adds additional equipment; such as cutting
tables, motor drives, motion controllers or robots; to a Hypertherm
plasma cutting system, the combined system may be considered a
higher-level system. A higher-level system with hazardous moving parts
may constitute industrial machinery or robotic equipment, in which case
the OEM or end-use customer may be subject to additional regulations
and standards than those relevant to the plasma cutting system as
manufactured by Hypertherm.
It is the responsibility of the end-use customer and the OEM to perform a
risk assessment for the higher-level system, and to provide protection
against hazardous moving parts. Unless the higher-level system is
certified when the OEM incorporates Hypertherm products into it, the
installation also may be subject to approval by local authorities. Seek
advice from legal counsel and local regulatory experts if you are uncertain
about compliance.
External interconnecting cables between component parts of the higher
level system must be suitable for contaminants and movement as
required by the final end use installation site. When the external
interconnecting cables are subject to oil, dust, water, or other
contaminants, hard usage ratings may be required.
When external interconnecting cables are subject to continuous
movement, constant flexing ratings may be required. It is the
responsibility of the end-use customer or the OEM to ensure the cables
are suitable for the application. Since there are differences in the ratings
and costs that can be required by local regulations for higher level
systems, it is necessary to verify that any external interconnecting cables
are suitable for the end-use installation site.
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