Hypertherm MAXPRO200 User manual

MAXPRO200®
Instruction Manual
807700 – Revision 1

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MAXPRO200
Instruction Manual
807700 – Revision 1
English
March 2013
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
07/18/12

MAXPRO200 Instruction Manual 807700 Revision 1 1
Contents
Safety ..........................................................................................................................................................9
Recognize safety information .............................................................................................................................................................9
Follow safety instructions ....................................................................................................................................................................9
Electrical hazards ..................................................................................................................................................................................9
Electric shock can kill ....................................................................................................................................................................... 10
Cutting can cause fire or explosion ............................................................................................................................................... 11
Fire prevention ............................................................................................................................................................................ 11
Explosion prevention ................................................................................................................................................................. 11
Toxic fumes can cause injury or death .......................................................................................................................................... 12
Grounding safety ............................................................................................................................................................................... 13
Static electricity can damage circuit boards ............................................................................................................................... 13
Compressed gas equipment safety .............................................................................................................................................. 14
Gas cylinders can explode if damaged ........................................................................................................................................ 14
A plasma arc can cause injury and burns .................................................................................................................................... 14
Arc rays can burn eyes and skin .................................................................................................................................................... 15
Pacemaker and hearing aid operation .......................................................................................................................................... 16
Noise can damage hearing .............................................................................................................................................................. 16
A plasma arc can damage frozen pipes ....................................................................................................................................... 16
Dry dust collection information ....................................................................................................................................................... 17
Laser radiation .................................................................................................................................................................................... 18
Symbols and marks ........................................................................................................................................................................... 19
Additional safety information ........................................................................................................................................................... 20
Warning labels ................................................................................................................................................................................... 20
Electromagnetic Compatibility (EMC) .............................................................................................23
Introduction ......................................................................................................................................................................................... 23
Installation and use ............................................................................................................................................................................ 23
Assessment of area ........................................................................................................................................................................... 23
Methods of reducing emissions ..................................................................................................................................................... 23
Mains supply ............................................................................................................................................................................... 23

2MAXPRO200 Instruction Manual 807700 Revision 1
Contents
Maintenance of cutting equipment .................................................................................................................................................24
Cutting cables .....................................................................................................................................................................................24
Equipotential bonding ................................................................................................................................................................24
Earthing of the workpiece .........................................................................................................................................................24
Screening and shielding ...................................................................................................................................................................24
Warranty .................................................................................................................................................. 25
Attention ...............................................................................................................................................................................................25
General .................................................................................................................................................................................................25
Patent indemnity .................................................................................................................................................................................26
Limitation of liability ............................................................................................................................................................................26
National and local codes ..................................................................................................................................................................26
Liability cap ..........................................................................................................................................................................................26
Insurance ..............................................................................................................................................................................................26
Transfer of rights .................................................................................................................................................................................26
Product Stewardship ........................................................................................................................... 27
Introduction ..........................................................................................................................................................................................27
National and local safety regulations .............................................................................................................................................27
Certification test marks .....................................................................................................................................................................27
Differences in national standards ...................................................................................................................................................27
Safe installation and use of shape cutting equipment ...............................................................................................................28
Procedures for periodic inspection and testing ..........................................................................................................................28
Qualification of test personnel .........................................................................................................................................................28
Residual current devices (RCDs) ...................................................................................................................................................28
Higher-level systems .........................................................................................................................................................................29
Environmental Stewardship .............................................................................................................. 31
Introduction ..........................................................................................................................................................................................31
National and local environmental regulations ...............................................................................................................................31
The RoHS directive ............................................................................................................................................................................31
Proper disposal of Hypertherm products .....................................................................................................................................31
The WEEE directive ...........................................................................................................................................................................31
The REACH regulation ......................................................................................................................................................................32
Proper handling and safe use of chemicals .................................................................................................................................32
Fumes emission and air quality .......................................................................................................................................................32
Specifications ........................................................................................................................................ 33
System description ............................................................................................................................................................................33
General .........................................................................................................................................................................................33
Power supply ...............................................................................................................................................................................33
Ignition console ...........................................................................................................................................................................33
Torch ..............................................................................................................................................................................................33
Gas system ..................................................................................................................................................................................33

MAXPRO200 Instruction Manual 807700 Revision 1 3
Contents
Cooling system ........................................................................................................................................................................... 35
System gas requirements ................................................................................................................................................................ 35
Power supply ...................................................................................................................................................................................... 36
Mechanized torches .......................................................................................................................................................................... 37
Straight torch – 428024 .......................................................................................................................................................... 37
Quick-disconnect torch – 428027 or 428028 .................................................................................................................. 38
Hand torches ...................................................................................................................................................................................... 39
90 degree hand torch – 420108 ........................................................................................................................................... 39
65 degree hand torch – 420107 ........................................................................................................................................... 40
Installation .............................................................................................................................................. 41
Upon receipt ....................................................................................................................................................................................... 41
Claims .................................................................................................................................................................................................. 41
Installation requirements .................................................................................................................................................................. 41
Noise levels ......................................................................................................................................................................................... 41
Placement of system components ................................................................................................................................................. 42
Recommended grounding and shielding practices ................................................................................................................... 44
Introduction ................................................................................................................................................................................. 44
Types of grounding .................................................................................................................................................................... 44
Grounding practices ................................................................................................................................................................. 44
Placement of the power supply ...................................................................................................................................................... 48
Torch lead connections .................................................................................................................................................................. 49
Work lead connections .................................................................................................................................................................. 52
Torch connections ........................................................................................................................................................................... 53
Connect the torch to the quick-disconnect receptacle ............................................................................................................ 54
Torch mounting and alignment ....................................................................................................................................................... 55
Mounting the torch .................................................................................................................................................................... 55
Torch alignment .......................................................................................................................................................................... 55
CNC interface cable ....................................................................................................................................................................... 56
Notes to CNC interface cable run list ................................................................................................................................... 56
Remote ON/OFF switch (provided by customer) ...................................................................................................................... 58
Power requirements .......................................................................................................................................................................... 60
General ......................................................................................................................................................................................... 60
Line disconnect switch ............................................................................................................................................................. 61
Main power cable .................................................................................................................................................................... 61
Connect the power ........................................................................................................................................................................... 62
Torch coolant requirements ............................................................................................................................................................ 63
Premixed coolant for standard operating temperatures ................................................................................................... 63
Custom Coolant mix for cold operating temperatures (below-12°C/10°F) ........................................................... 64
Custom Coolant mix for hot operating temperatures (above 38° C / 100° F) ............................................................ 65
Water purity requirements ....................................................................................................................................................... 65

4MAXPRO200 Instruction Manual 807700 Revision 1
Contents
Fill the power supply with coolant ..................................................................................................................................................66
Connect the supply gases ...............................................................................................................................................................67
Air/air cutting ...............................................................................................................................................................................67
N2/N2supply gas connection ..................................................................................................................................................67
O2/Air Supply gas hook up ......................................................................................................................................................67
Gas requirements ...............................................................................................................................................................................71
Setting the supply gas regulators ...........................................................................................................................................71
Gas regulators .....................................................................................................................................................................................72
Supply gas plumbing .........................................................................................................................................................................73
Supply gas hoses ...............................................................................................................................................................................74
Air .................................................................................................................................................................................................74
Oxygen ........................................................................................................................................................................................74
Nitrogen ......................................................................................................................................................................................74
Operation ................................................................................................................................................ 75
Daily start-up .......................................................................................................................................................................................75
Controls and indicators .....................................................................................................................................................................76
Power supply operation ....................................................................................................................................................................77
General .........................................................................................................................................................................................77
3-digit display functions ............................................................................................................................................................78
Choosing a cutting process .....................................................................................................................................................79
Handheld cutting ................................................................................................................................................................................80
Specifications ..............................................................................................................................................................................80
Consumable selection and gas settings ...............................................................................................................................80
Starting a cut ...............................................................................................................................................................................80
Piercing .........................................................................................................................................................................................81
Gouging ................................................................................................................................................................................................82
Specifications ..............................................................................................................................................................................82
Gouging safety ............................................................................................................................................................................82
Gouge a workpiece ....................................................................................................................................................................82
Gouging techniques ..................................................................................................................................................................83
Straight gouging .................................................................................................................................................................83
Side gouging .......................................................................................................................................................................84
Gouge profiles and metal removal rates ...............................................................................................................................85
Varying the gouge profile ..........................................................................................................................................................86
Cutting parameters ............................................................................................................................................................................86
Mechanized consumables ................................................................................................................................................................86
Hand held torch consumables ........................................................................................................................................................86
Hand held cutting and gouging consumable selection .....................................................................................................87
Mild steel ...............................................................................................................................................................................87
Stainless steel .....................................................................................................................................................................88

MAXPRO200 Instruction Manual 807700 Revision 1 5
Contents
Aluminum ............................................................................................................................................................................. 89
Install and inspect consumables .................................................................................................................................................... 90
Install consumables ................................................................................................................................................................... 90
Inspect consumables ................................................................................................................................................................ 91
Torch maintenance ............................................................................................................................................................................ 92
Routine maintenance ................................................................................................................................................................ 92
Quick-disconnect maintenance .............................................................................................................................................. 92
Maintenance kit .......................................................................................................................................................................... 92
Torch connections ..................................................................................................................................................................... 93
Quick-disconnect torch .................................................................................................................................................... 93
Straight torch ...................................................................................................................................................................... 93
Replace the torch water tube ................................................................................................................................................. 94
Common cutting faults ..................................................................................................................................................................... 95
Machine torch ............................................................................................................................................................................. 95
Hand torch ................................................................................................................................................................................... 95
Optimizing cut quality ....................................................................................................................................................................... 96
Tips for table and torch ............................................................................................................................................................ 96
Plasma setup tips ...................................................................................................................................................................... 96
Maximize the life of consumable parts .................................................................................................................................. 96
Additional factors of cut quality .............................................................................................................................................. 97
Cut angle ............................................................................................................................................................................. 97
Dross .................................................................................................................................................................................... 98
Straightness of the cut surface ....................................................................................................................................... 98
How to increase cutting speed ...................................................................................................................................... 98
Estimated kerf-width compensation ...................................................................................................................................... 99
Metric .................................................................................................................................................................................... 99
English ................................................................................................................................................................................100
Cut charts ..........................................................................................................................................................................................101
Maintenance ........................................................................................................................................119
Introduction .......................................................................................................................................................................................119
Preventive maintenance .................................................................................................................................................................119
Power supply status ........................................................................................................................................................................120
Sequence of operation and power supply status ....................................................................................................................121
PCB block diagram .........................................................................................................................................................................126
Error codes .......................................................................................................................................................................................127
Diagnostic functions .......................................................................................................................................................................128
Troubleshooting table .....................................................................................................................................................................129
Initial checks .....................................................................................................................................................................................137
Power measurement .......................................................................................................................................................................138

6MAXPRO200 Instruction Manual 807700 Revision 1
Contents
Power supply coolant system servicing ..................................................................................................................................... 139
Draining the coolant system .................................................................................................................................................. 139
Coolant flow test ...................................................................................................................................................................... 140
Coolant system filter replacement ....................................................................................................................................... 142
Air filter element replacement .......................................................................................................................................................143
Control board ................................................................................................................................................................................... 144
Control board LED list ............................................................................................................................................................ 144
Control board test points ....................................................................................................................................................... 144
Gas leak tests ................................................................................................................................................................................... 147
Start circuit ........................................................................................................................................................................................ 148
Operation ................................................................................................................................................................................... 148
Start circuit functional schematic ......................................................................................................................................... 148
Start circuit troubleshooting .................................................................................................................................................. 149
Pilot arc current levels .................................................................................................................................................................... 151
Transfer current ........................................................................................................................................................................ 151
Chopper tests .................................................................................................................................................................................. 152
Automatic chopper and current sensor tests during power-up .................................................................................... 152
Using a meter to measure open circuit voltage (OCV) ...........................................................................................153
Phase loss detection .............................................................................................................................................................. 154
Torch lead test ......................................................................................................................................................................... 155
Preventive maintenance ................................................................................................................................................................. 156
Introduction ............................................................................................................................................................................... 156
Preventive maintenance protocol ......................................................................................................................................... 156
The power supply .................................................................................................................................................................... 156
Cooling system ........................................................................................................................................................................ 157
Torch main body ...................................................................................................................................................................... 157
Gas flows .................................................................................................................................................................................. 157
Cable connections .................................................................................................................................................................. 158
Ignition enclosure ....................................................................................................................................................................158
System grounding ................................................................................................................................................................... 158
............................................................................................................................................................................................................. 158
Preventive Maintenance Master Schedule ................................................................................................................................159
Daily: ........................................................................................................................................................................................... 159
Weekly: ......................................................................................................................................................................................159
Semi-annually: .......................................................................................................................................................................... 159
Annually: .................................................................................................................................................................................... 159
Preventive Maintenance Protocol Checklist .............................................................................................................................. 160
Year 1 preventive maintenance (PM) kits .................................................................................................................................. 161
Maintenance kits parts list ..................................................................................................................................................... 161
Service parts replacement schedule .......................................................................................................................................... 161

MAXPRO200 Instruction Manual 807700 Revision 1 7
Contents
Parts List ...............................................................................................................................................165
Control panel ....................................................................................................................................................................................165
Power supply ....................................................................................................................................................................................166
Ignition enclosure ............................................................................................................................................................................172
Height control connection kits ......................................................................................................................................................173
Sensor THC connection kit – 428023 ...............................................................................................................................173
Sensor PHC connection kit – 428022 ..............................................................................................................................173
Wire groups and harnesses ..........................................................................................................................................................173
USB cables for software updates ................................................................................................................................................173
Cable for USB update – 223291 ........................................................................................................................................173
Cable for USB update – 223273 ........................................................................................................................................173
Power supply gas hose kit – 228862 ......................................................................................................................................173
Machine torches ..............................................................................................................................................................................174
Straight torch ............................................................................................................................................................................174
Quick-disconnect torch ..........................................................................................................................................................174
Leads and cables ............................................................................................................................................................................175
Machine torch leads ................................................................................................................................................................175
CNC cables ..............................................................................................................................................................................175
Work leads ................................................................................................................................................................................175
Work clamp ...............................................................................................................................................................................175
Hand torch leads .....................................................................................................................................................................175
Inline valve kit ....................................................................................................................................................................................175
Hand torch heat shield – 127389 .............................................................................................................................................175
90 degree hand torch .....................................................................................................................................................................176
65 degree hand torch .....................................................................................................................................................................177
Consumable parts kits ....................................................................................................................................................................178
Mechanized torch consumable kit – 428013 ...................................................................................................................178
Hand torch consumable kit – 428014 ...............................................................................................................................179
Supply gas hoses ............................................................................................................................................................................180
Oxygen .......................................................................................................................................................................................180
Nitrogen .....................................................................................................................................................................................180
Air ................................................................................................................................................................................................180
Recommended spare parts ...........................................................................................................................................................181
Wiring Diagrams .................................................................................................................................183
Wiring diagram symbols ................................................................................................................................................................184

8MAXPRO200 Instruction Manual 807700 Revision 1
Contents
Material Safety Data Sheet (MSDS) — Torch Coolant 30% PG Mixture .............................197
1 - Identification of the substance/mixture and of the company undertaking ................................................................... 197
2 - Hazards identification ...............................................................................................................................................................198
3 - Composition/information on ingredients .............................................................................................................................198
4 - First aid measures ..................................................................................................................................................................... 198
5 - Fire-fighting measures ............................................................................................................................................................. 198
6 - Accidental release measures ................................................................................................................................................. 199
7 - Handling and storage ............................................................................................................................................................... 199
8 - Exposure controls/personal protection ................................................................................................................................ 199
9 - Physical and chemical properties .......................................................................................................................................... 200
10 - Stability and reactivity ............................................................................................................................................................ 200
11 - Toxicological information ...................................................................................................................................................... 201
12 - Ecological information ...........................................................................................................................................................201
13 - Disposal considerations ........................................................................................................................................................201
14 - Transport information ............................................................................................................................................................. 202
15 - Ecological information ...........................................................................................................................................................202
16 - Other information .................................................................................................................................................................... 202

MAXPRO200 Instruction Manual 807700 Revision 1 9
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.

10 MAXPRO200 Instruction Manual 807700 Revision 1
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.

MAXPRO200 Instruction Manual 807700 Revision 1 11
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
Explosion Hazard
Underwater Cutting with Fuel Gases
• 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
Hydrogen Detonation with
Aluminum Cutting
• 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.

12 MAXPRO200 Instruction Manual 807700 Revision 1
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.

MAXPRO200 Instruction Manual 807700 Revision 1 13
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.

14 MAXPRO200 Instruction Manual 807700 Revision 1
Safety
COMPRESSED GAS EQUIPMENT
SAFETY
• Never lubricate cylinder valves or regulators with oil
or grease.
• Use only correct gas cylinders, regulators, hoses and
fittings designed for the specific application.
• Maintain all compressed gas equipment and
associated parts in good condition.
• Label and color-code all gas hoses to identify the
type of gas in each hose. Consult applicable national
and local codes.
GAS CYLINDERS CAN
EXPLODE IF DAMAGED
Gas cylinders contain gas under high pressure.
If damaged, a cylinder can explode.
• Handle and use compressed gas cylinders in
accordance with applicable national and local codes.
• Never use a cylinder that is not upright and secured
in place.
• Keep the protective cap in place over valve except
when the cylinder is in use or connected for use.
• Never allow electrical contact between the plasma
arc and a cylinder.
• Never expose cylinders to excessive heat, sparks,
slag or open flame.
• Never use a hammer, wrench or other tool to open a
stuck cylinder valve.
A PLASMA ARC CAN CAUSE INJURY AND BURNS
Instant-on torches
Plasma arc comes on immediately when the torch
switch is activated.
The plasma arc will cut quickly through gloves and skin.
• Keep away from the torch tip.
• Do not hold metal near the cutting path.
• Never point the torch toward yourself or others.

MAXPRO200 Instruction Manual 807700 Revision 1 15
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 5 5 8 9
41 to 60 A 6 6 8 9
61 to 80 A 8 8 8 9
81 to 125 A 8 9 8 9
126 to 150 A 8 9 8 10
151 to 175 A 8 9 8 11
176 to 250 A 8 9 8 12
251 to 300 A 8 9 8 13
301 to 400 A 9 12 9 13
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.

16 MAXPRO200 Instruction Manual 807700 Revision 1
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.