Hypertherm powermax1250 User manual

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5.0
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PSI
80
70
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Plasma Arc
Cutting System
Operator Manual
803950 Revision 1
powermax1250®

Operator Manual
(P/N 803950)
Revision 1 – April 2007
Hypertherm, Inc.
Hanover, NH USA
www.hypertherm.com
© Copyright 2007 Hypertherm, Inc.
All Rights Reserved
Hypertherm, Powermax, and FineCut are trademarks of Hypertherm, Inc.
and may be registered in the United States and/or other countries.
powermax1250

1/19/07
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)
Hypertherm Automation
5 Technology Drive, Suite 300
West Lebanon, NH 03784 USA
603-298-7970 Tel
603-298-7977 Fax
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.
No. 19 Kaki Bukit Road 2
K.B. Warehouse Complex
Singapore 417847, Republic of Singapore
65 6 841 2489 Tel
65 6 841 2490 Fax
65 6 841 2489 (Technical Service)
Hypertherm (Shanghai) Trading Co., Ltd.
Unit 1308-09, Careri Building
432 West Huai Hai Road
Shanghai, 200052
PR China
86-21 5258 3330/1 Tel
86-21 5258 3332 Fax
Hypertherm
Branch of Hypertherm, UK, UC
PO Box 244
Wigan, Lancashire, England WN8 7WU
00 800 3324 9737 Tel
00 800 4973 7329 Fax
00 800 4973 7843 (Technical Service)
France (Representative office)
15 Impasse des Rosiers
95610 Eragny, France
00 800 3324 9737 Tel
00 800 4973 7329 Fax
Hypertherm S.r.l.
Via Torino 2
20123 Milano, Italia
39 02 725 46 312 Tel
39 02 725 46 400 Fax
39 02 725 46 314 (Technical Service)
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 49 73 7843 Tel (Technical Ser
v
Hypertherm Japan Ltd.
801 Samty Will Building
2-40 Miyahara 1-Chome,
Yodogawa-ku, Osaka
532-0003, Japan
81 6 6170 2020 Tel
81 6 6170 2015 Fax
HYPERTHERM BRASIL LTDA.
Avenida Doutor Renato de
Andrade Maia 350
Parque Renato Maia
CEP 07114-000
Guarulhos, SP Brasil
55 11 6409 2636 Tel
55 11 6408 0462 Fax

ELECTROMAGNETIC COMPATIBILITY (EMC)
8-06
Hypertherm Plasma Systems i
EMC Introduction
Hypertherm’s CE-marked equipment is built in
compliance with standard EN60974-10. The
equipment should be installed and used in
accordance with the information below to achieve
electromagnetic compatibility.
The limits required by EN60974-10 may not be
adequate to completely eliminate interference
when the affected equipment is in close proximity
or has a high degree of sensitivity. In such cases
it may be necessary to use other measures to
further reduce interference.
This plasma equipment is designed for use only in
an industrial environment.
Installation and use
The user is responsible for installing and using
the plasma equipment according to the
manufacturer’s instructions. If electromagnetic
disturbances are detected then it shall be the
responsibility of the user to resolve the situation
with the technical assistance of the manufacturer.
In some cases this remedial action may be as
simple as earthing the cutting circuit, see
Earthing of Workpiece. In other cases it could
involve constructing an electromagnetic screen
enclosing the power source and the work
complete with associated input filters. In all cases
electromagnetic disturbances must be reduced to
the point where they are no longer troublesome.
Assessment of area
Before installing the equipment the user shall
make an assessment of potential electromagnetic
problems in the surrounding area. The following
shall be taken into account:
a. Other supply cables, control cables, signalling
and telephone cables; above, below and
adjacent to the cutting equipment.
b. Radio and television transmitters and
receivers.
c. Computer and other control equipment.
d. Safety critical equipment, for example guarding
of industrial equipment.
e. Health of the people around, for example the
use of pacemakers and hearing aids.
f. Equipment used for calibration or
measurement.
g. Immunity of other equipment in the
environment. User shall ensure that other
equipment being used in the environment is
compatible. This may require additional
protection measures.
h. Time of day that cutting or other activities are
to be carried out.
The size of the surrounding area to be considered
will depend on the structure of the building and
other activities that are taking place. The
surrounding area may extend beyond the bound-
aries of the premises.
Methods of reducing emissions
Mains supply
Cutting equipment must be connected to the
mains supply according to the manufacturer’s
recommendations. If interference occurs, it may
be necessary to take additional precautions such
as filtering of the mains supply. Consideration
should be given to shielding the supply cable of
permanently installed cutting equipment, in
metallic conduit or equivalent. Shielding should
be electrically continuous throughout its length.
The shielding should be connected to the cutting
mains supply so that good electrical contact is
maintained between the conduit and the cutting
power source enclosure.
Maintenance of cutting equipment
The cutting equipment must be routinely
maintained according to the manufacturer’s
recommendations. All access and service doors
and covers should be closed and properly
fastened when the cutting equipment is in
operation. The cutting equipment should not be
modified in any way except for those changes and
adjustments covered in the manufacturer’s

ELECTROMAGNETIC COMPATIBILITY (EMC)
8-06
ii Hypertherm Plasma Systems
instructions. In particular, the spark gaps of arc
striking and stabilizing devices should be adjusted
and maintained according to the manufacturer’s
recommendations.
Cutting cables
The cutting cables should be kept as short as
possible and should be positioned close together,
running at or close to the floor level.
Equipotential bonding
Bonding of all metallic components in the cutting
installation and adjacent to it should be
considered. However, metallic components
bonded to the workpiece will increase the risk that
the operator could receive a shock by touching
these metallic components and the electrode at
the same time. The operator should be insulated
from all such bonded metallic components.
Earthing of workpiece
Where the workpiece is not bonded to earth for
electrical safety, nor connected to earth because
of its size and position, for example, ship’s hull or
building steelwork, a connection bonding the
workpiece to earth may reduce emissions in
some, but not all instances. Care should be
taken to prevent the earthing of the workpiece
increasing the risk of injury to users, or damage to
other electrical equipment. Where necessary, the
connection of the workpiece to earth should be
made by a direct connection to the workpiece, but
in some countries where direct connection is not
permitted, the bonding should be achieved by
suitable capacitances selected according to
national regulations.
Note: the cutting circuit may or may not be
earthed for safety reasons. Changing the earthing
arrangements should only be authorized by a
person who is competent to assess whether the
changes will increase the risk of injury, for
example, by allowing parallel cutting current return
paths which may damage the earth circuits of
other equipment. Further guidance is given in
IEC/ TS 62081Arc Welding Equipment Installation
and Use.
Screening and shielding
Selective screening and shielding of other cables
and equipment in the surrounding area may
alleviate problems of interference. Screening of
the entire plasma cutting installation may be con-
sidered for special applications.

WARRANTY
Hypertherm Plasma Systems iii
8-06
Warning
Genuine Hypertherm parts are the factory-
recommended replacement parts for your
Hypertherm system. Any damage caused by the
use of other than genuine Hypertherm parts may
not be covered by the Hypertherm warranty.
Warning
You are responsible for the safe use of the
Product. Hypertherm does not and cannot make
any guarantee or warranty regarding the safe use
of the Product in your environment.
General
Hypertherm, Inc. warrants that its Products shall
be free from defects in materials and
workmanship, if Hypertherm is notified of a defect
(i) with respect to the power supply within a period
of two (2) years from the date of its delivery to
you, with the exception of Powermax Series
power supplies, which shall be within a period of
three (3) years from the date of delivery to you,
and (ii) with respect to the torch and leads within a
period of one (1) year from its date of delivery to
you. This warranty shall not apply to any Product
which has been incorrectly installed, modified, or
otherwise damaged. Hypertherm, at its sole
option, shall repair, replace, or adjust, free of
charge, any defective Products covered by
this warranty which shall be returned with
Hypertherm’s prior authorization (which shall not
be unreasonably withheld), properly packed, to
Hypertherm’s place of business in Hanover,
New Hampshire, or to an authorized Hypertherm
repair facility, all costs, insurance and freight
prepaid. Hypertherm shall not be liable for any
repairs, replacement, or adjustments of Products
covered by this warranty, except those made
pursuant to this paragraph or with Hypertherm’s
prior written consent. The warranty above is
exclusive and is in lieu of all other warranties,
express, implied, statutory, or otherwise with
respect to the Products or as to the results
which may be obtained therefrom, and all
implied warranties or conditions of quality or
of merchantability or fitness for a particular
purpose or against infringement. The
foregoing shall constitute the sole and
exclusive remedy for any breach by
Hypertherm of its warranty. Distributors/OEMs
may offer different or additional warranties, but
Distributors/OEMs are not authorized to give any
additional warranty protection to you or make any
representation to you purporting to be binding
upon Hypertherm.
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 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 significantly modified in a manner
that creates a hazard or non-conformance.
• 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.
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.

WARRANTY
8-06
iv Hypertherm Plasma Systems
EMC filters needed to comply with the European
EMC Directive are incorporated within versions of
the power supply with a CE Marking.
Patent indemnity
Except only in cases of products not
manufactured by Hypertherm or manufactured by
a person other than Hypertherm not in strict
conformity with Hypertherm’s specifications and in
cases of designs, processes, formulae, or
combinations not developed or purported to be
developed by Hypertherm, Hypertherm will
defend or settle, at its own expense, any suit or
proceeding brought against you alleging that the
use of the Hypertherm product, alone and not in
combination with any other product not supplied
by Hypertherm, infringes any patent of any third
party. You shall notify Hypertherm promptly upon
learning of any action or threatened action in
connection with any such alleged infringement,
and Hypertherm’s obligation to indemnify shall be
conditioned upon Hypertherm’s sole control of,
and the indemnified party’s cooperation and
assistance in, the defense of the claim.
Limitation of liability
In no event shall Hypertherm be liable to any
person or entity for any incidental,
consequential, indirect, or punitive damages
(including but not limited to lost profits)
regardless of whether such liability is based
on breach of contract, tort, strict liability,
breach of warranties, failure of essential
purpose or otherwise and even if advised of
the possibility of such damages.
Liability cap
In no event shall Hypertherm’s liability,
whether such liability is based on breach of
contract, tort, strict liability, breach of
warranties, failure of essential purpose or
otherwise, for any claim action suit or
proceeding arising out of or relating to the use
of the Products exceed in the aggregate the
amount paid for the Products that gave rise to
such claim.
Insurance
At all times you will have and maintain insurance
in such quantities and types, and with coverage
sufficient and appropriate to defend and to hold
Hypertherm harmless in the event of any cause of
action arising from the use of the Products.
National and Local codes
National and Local codes governing plumbing and
electrical installation shall take precedent over any
instructions contained in this manual. In no event
shall Hypertherm be liable for injury to persons or
property damage by reason of any code violation
or poor work practices.
Transfer of rights
You may transfer any remaining rights you may
have hereunder only in connection with the sale of
all or substantially all of your assets or capital
stock to a successor in interest who agrees to be
bound by all of the terms and conditions of this
Warranty.
Proper disposal of Hypertherm
products
Hypertherm plasma cutting systems, like all
electronic products, may contain materials or
components, such as printed circuit boards, that
cannot be discarded with ordinary waste. It is your
responsibility to dispose of any Hypertherm product
or component part in an environmentally
acceptable manner according to national and local
codes.
• In the United States, check all federal, state, and
local laws.
• In the European Union, check the EU directives,
national, and local laws.
• In other countries, check national and local laws.
Register your product on-line at:
www.hypertherm.com/warranty.htm

TABLE OF CONTENTS
1
powermax1250 Operator Manual v
Electromagnetic Compatibility ......................................................................................................i
Warranty......................................................................................................................................iii
Section 1 Safety
Recognize safety information...................................................................................................1-2
Follow safety instructions .........................................................................................................1-2
Cutting can cause fire or explosion ..........................................................................................1-2
Electric shock can kill ...............................................................................................................1-3
Static electricity can damage circuit boards .............................................................................1-3
Toxic fumes can cause injury or death .....................................................................................1-4
A plasma arc can cause injury and burns.................................................................................1-5
Arc rays can burn eyes and skin ..............................................................................................1-5
Grounding safety......................................................................................................................1-6
Compressed gas equipment safety..........................................................................................1-6
Gas cylinders can explode if damaged ....................................................................................1-6
Noise can damage hearing ......................................................................................................1-7
Pacemaker and hearing aid operation .....................................................................................1-7
A plasma arc can damage frozen pipes ...................................................................................1-7
Additional safety information ....................................................................................................1-7
Warning label............................................................................................................................1-8
Section 1a Sécurité
Identifier les consignes de sécurité ........................................................................................1a-2
Suivre les instructions de sécurité..........................................................................................1a-2
Danger Avertissement Précaution........................................................................................1a-2
Le coupage peut provoquer un incendie ou une explosion....................................................1a-2
Les chocs électriques peuvent être fatals ..............................................................................1a-3
L’électricité statique peut endommager les cartes de circuits imprimés.................................1a-3
Le vapeurs toxiques peuvent provoquer des blessures ou la mort........................................1a-4
L’arc plasma peut provoquer des blessures ou des brûlures.................................................1a-5
Les rayons de l’arc peuvent brûler les yeux et la peau ..........................................................1a-5
Mise à la masse et à la terre ..................................................................................................1a-6
Sécurité des bouteilles de gaz comprimé...............................................................................1a-6
Les bouteilles de gaz comprimé peuvent exploser en cas de dommages.............................1a-6
Le bruit peut provoquer des problèmes auditifs .....................................................................1a-7
Pacemakers et prothèses auditives .......................................................................................1a-7
Un arc plasma peut endommager les tuyaux gelés ...............................................................1a-7
Étiquette de sécurité...............................................................................................................1a-8
Section 1b Seguridad
Reconocimiento de información de seguridad .......................................................................1b-2
Siga las instrucciones de seguridad.......................................................................................1b-2
Los cortes pueden provocar incendios o explosiones............................................................1b-2
El choque eléctrico puede provocar la muerte.......................................................................1b-3
Electricidad estática puede dañar tablillas de circuito............................................................1b-3
Humos tóxicos pueden causar lesiones o muerte..................................................................1b-4
El arco de plasma puede causar lesiones y quemaduras......................................................1b-5
Los rayos del arco pueden producir quemaduras en los ojos y en la piel..............................1b-5

TABLE OF CONTENTS
1
vi powermax1250 Operator Manual
Seguridad de toma a tierra.....................................................................................................1b-6
Seguridad de los equipos de gas comprimido .......................................................................1b-6
Los cilindros de gas pueden explotar si están dañados.........................................................1b-6
El ruido puede deteriorar la audición......................................................................................1b-7
Operación de marcapasos y de audífonos.............................................................................1b-7
Un arco plasma puede dañar tubos congelados....................................................................1b-7
Etiquetas de advertencia........................................................................................................1b-8
Section 2 Specifications
Power supply ...........................................................................................................................2-2
Dimensions and weight....................................................................................................2-3
T80 Torches .............................................................................................................................2-4
Dimensions......................................................................................................................2-5
Symbols and markings.............................................................................................................2-6
S mark ............................................................................................................................2-6
CE mark...........................................................................................................................2-6
IEC symbols used............................................................................................................2-6
Section 3 Setup
Upon receipt.............................................................................................................................3-2
Claims ......................................................................................................................................3-2
Contents of box ........................................................................................................................3-2
Locating the power supply........................................................................................................3-3
Lifting the power supply............................................................................................................3-3
Power connection.....................................................................................................................3-4
Three-phase power cord – plug installation .............................................................................3-4
Single-phase power cord..........................................................................................................3-5
Power cord installation.....................................................................................................3-5
Plug installation................................................................................................................3-5
Grounding ................................................................................................................................3-6
Extension cords........................................................................................................................3-6
Torch installation.......................................................................................................................3-7
Plasma gas supply ..................................................................................................................3-9
Additional gas filtration.....................................................................................................3-9
Gas supply installation ...........................................................................................................3-10
T80M torch alignment.............................................................................................................3-10
ON/OFF pendant connection.........................................................................................3-11
Machine interface connection ........................................................................................3-11
Arc voltage.....................................................................................................................3-12
Changing XFER (start machine motion) from dry contact closure to voltage signal......3-14
Driving an industrial isolated input module....................................................................3-15
Driving a relay coil with an external power source........................................................3-16
Driving an industrial isolated input module with an external power source ...................3-17

TABLE OF CONTENTS
1
powermax1250 Operator Manual vii
Section 4 Operation
Controls and indicators.............................................................................................................4-2
Indicator LEDs.................................................................................................................4-2
T80 consumable configurations ...............................................................................................4-3
Shielded...........................................................................................................................4-3
FineCut............................................................................................................................4-3
Gouging...........................................................................................................................4-4
T80M consumable configurations ............................................................................................4-4
Shielded...........................................................................................................................4-4
FineCut............................................................................................................................4-5
Ohmic sensing retaining cap ...........................................................................................4-5
Unshielded.......................................................................................................................4-5
Install the torch consumables...................................................................................................4-7
Set the mode switch.................................................................................................................4-8
Set the power switch to ON......................................................................................................4-8
Check the indicator lights .........................................................................................................4-8
Adjust the gas pressure and current setting.............................................................................4-9
Hand torch operation..............................................................................................................4-10
Safety trigger operation .................................................................................................4-10
Attach the work clamp....................................................................................................4-11
Starting a cut from the edge of the workpiece ...............................................................4-11
Hand torch cutting technique.........................................................................................4-12
Piercing..........................................................................................................................4-13
Gouging.........................................................................................................................4-14
Cut charts...............................................................................................................................4-15
80 amp mechanized shielded consumables..................................................................4-15
60 amp mechanized shielded consumables..................................................................4-16
40 amp mechanized shielded consumables..................................................................4-17
FineCut consumables....................................................................................................4-18
40 amp mechanized unshielded consumables..............................................................4-19
Section 5 Maintenance and Parts
Routine maintenance ...............................................................................................................5-2
Inspect the consumables..........................................................................................................5-3
Controls and indicators.............................................................................................................5-4
Indicator LEDs.................................................................................................................5-4
Basic troubleshooting...............................................................................................................5-5
System circuit diagram.............................................................................................................5-8
Technical questions..................................................................................................................5-9
Parts.........................................................................................................................................5-9
Torch parts.......................................................................................................................5-9
Power supply parts........................................................................................................5-10
Accessories ...................................................................................................................5-10

TABLE OF CONTENTS
0
viii powermax1250 Operator Manual

Hypertherm Plasma Systems 1-1
8-06
Section 1
SAFETY
In this section:
Recognize safety information...................................................................................................1-2
Follow safety instructions .........................................................................................................1-2
Cutting can cause fire or explosion ..........................................................................................1-2
Electric shock can kill ...............................................................................................................1-3
Static electricity can damage circuit boards .............................................................................1-3
Toxic fumes can cause injury or death .....................................................................................1-4
A plasma arc can cause injury and burns.................................................................................1-5
Arc rays can burn eyes and skin ..............................................................................................1-5
Grounding safety......................................................................................................................1-6
Compressed gas equipment safety..........................................................................................1-6
Gas cylinders can explode if damaged ....................................................................................1-6
Noise can damage hearing ......................................................................................................1-7
Pacemaker and hearing aid operation .....................................................................................1-7
A plasma arc can damage frozen pipes ...................................................................................1-7
Additional safety information ....................................................................................................1-7
Warning labels..........................................................................................................................1-8

1-2 Hypertherm Plasma Systems
11-98
SAFETY
RECOGNIZE SAFETY INFORMATION
The symbols shown in this section are
used to identify potential hazards. When you see a
safety symbol in this manual or on your machine,
understand the potential for personal injury, and
follow the related instructions to avoid the hazard.
FOLLOW SAFETY INSTRUCTIONS
Read carefully all safety messages in
this manual and safety labels on your
machine.
• Keep the safety labels on your machine in good
condition. Replace missing or damaged labels
immediately.
• Learn how to operate the machine and how to
use the controls properly. Do not let anyone
operate it without instruction.
• Keep your machine in proper working condition.
Unauthorized modifications to the machine may
affect safety and machine service life.
DANGER WARNING CAUTION
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.
• 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
damage to equipment if not followed correctly.
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.
CUTTING CAN CAUSE FIRE OR EXPLOSION
WARNING
Explosion Hazard
Argon-Hydrogen and Methane
Hydrogen and methane are flammable gases that
present an explosion hazard. Keep flames away
from cylinders and hoses that contain methane or
hydrogen mixtures. Keep flames and sparks away
from the torch when using methane or argon-
hydrogen plasma.
WARNING
Hydrogen Detonation with
Aluminum Cutting
• When cutting aluminum underwater, or with the
water touching the underside of the aluminum,
free hydrogen gas may collect under the
workpiece and detonate during plasma cutting
operations.
• Install an aeration manifold on the floor of the
water table to eliminate the possibility of hydrogen
detonation. Refer to the Appendix section of this
manual for aeration manifold details.

Hypertherm Plasma Systems 1-3
8-06
SAFETY
Touching live electrical parts can cause a fatal
shock or severe burn.
• Operating the plasma system completes an
electrical circuit between the torch and the
workpiece. The workpiece and anything touching
the workpiece are part of the electrical circuit.
• Never touch the torch body, workpiece or the
water in a water table when the plasma system is
operating.
Electric Shock Prevention
All Hypertherm plasma systems use high
voltage in the cutting process (200 to 400 VDC
are common). Take the following precautions
when operating this system:
• Wear insulated gloves and boots, and keep your
body and clothing dry.
• Do not stand, sit or lie on – or touch – any wet
surface when using the plasma system.
• Insulate yourself from work and ground using dry
insulating mats or covers big enough to prevent
any physical contact with the work or ground. If
you must work in or near a damp area, use
extreme caution.
• Provide a disconnect switch close to the power
supply with properly sized fuses. This switch
allows the operator to turn off the power supply
quickly in an emergency situation.
• When using a water table, be sure that it is
correctly connected to earth ground.
ELECTRIC SHOCK CAN KILL
• 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.
Use proper precautions when handling printed
circuit boards.
STATIC ELECTRICITY CAN DAMAGE CIRCUIT BOARDS
• Store PC boards in anti-static containers.
• Wear a grounded wrist strap when handling
PC boards.

1-4 Hypertherm Plasma Systems
8-06
SAFETY
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:
TOXIC FUMES CAN CAUSE INJURY OR DEATH
• 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.

Hypertherm Plasma Systems 1-5
5-02
SAFETY
Instant-On Torches
Plasma arc comes on immediately when the
torch switch is activated.
A PLASMAARC CAN CAUSE INJURY AND BURNS
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.
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 or 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.
Lens Shade
Arc Current AWS (USA) ISO 4850
Up to 100 A No. 8 No. 11
100-200 A No. 10 No. 11-12
200-400 A No. 12 No. 13
Over 400 A No. 14 No. 14
ARC RAYS CAN BURN EYES AND SKIN
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.

1-6 Hypertherm Plasma Systems
11-98
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 or local codes.
GAS CYLINDERS CAN
EXPLODE IF DAMAGED
COMPRESSED GAS EQUIPMENT SAFETY
Gas cylinders contain gas under high pressure.
If damaged, a cylinder can explode.
• Handle and use compressed gas cylinders in
accordance with applicable national or 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.
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 or
local electrical codes.
GROUNDING SAFETY
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.

Hypertherm Plasma Systems 1-7
8-01
SAFETY
Prolonged exposure to noise from cutting or
gouging can damage hearing.
• Use approved ear protection when using
plasma system.
• Warn others nearby about the noise hazard.
Frozen pipes may be damaged or can burst if
you attempt to thaw them with a plasma torch.
NOISE CAN DAMAGE HEARING
A PLASMAARC
CAN DAMAGE
FROZEN PIPES
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.
PACEMAKER AND
HEARING AID OPERATION
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, 470 Atlantic Avenue,
Boston, MA 02210
9. NFPA Standard 70–1978, National Electrical Code, National
Fire Protection Association, 470 Atlantic Avenue, Boston, MA
02210
10. OSHA, Safety and Health Standards, 29FR 1910
U.S. Government Printing Office, Washington, D.C. 20402

1-8 Hypertherm Plasma Systems
SAFETY
WARNING LABEL
This warning label is affixed to some power supplies. It is
important that the operator and maintenance technician
understand the intent of these warning symbols as
described. The numbered text corresponds to the numbered
boxes on the label.
1. Cutting sparks can cause
explosion or fire.
1.1 Keep flammables away from
cutting.
1.2 Keep a fire extinguisher nearby,
and have a watchperson ready to
use it.
1.3 Do not cut on any closed
containers.
2. The plasma arc can cause injury
and burns.
2.1 Turn off power before
disassembling torch.
2.2 Do not hold the material near
cutting path.
2.3 Wear complete body protection.
3. Electric shock from torch or wiring
can kill. Protect yourself from
electric shock.
3.1 Wear insulating gloves. Do not
wear wet or damaged gloves.
3.2 Insulate yourself from work and
ground.
3.3 Disconnect input plug or power
before working on machine.
4. Breathing cutting fumes can be
hazardous to your health.
4.1 Keep your head out of the fumes.
4.2 Use forced ventilation or local
exhaust to remove the fumes.
4.3 Use ventilating fan to remove the
fumes.
5. Arc rays can burn eyes and injure
skin.
5.1 Wear hat and safety glasses. Use
ear protection and button shirt
collar. Use welding helmet with
correct shade of filter. Wear
complete body protection.
6. Become trained and read the
instructions before working on the
machine or cutting.
7. Do not remove or paint over
(cover) warning labels.
110391 Rev A

8-06
Hypertherm Systèmes plasma 1a-1
Section 1a
SÉCURITÉ
Dans cette section :
Identifier les consignes de sécurité ........................................................................................1a-2
Suivre les instructions de sécurité..........................................................................................1a-2
Le coupage peut provoquer un incendie ou une explosion....................................................1a-2
Les chocs électriques peuvent être fatals ..............................................................................1a-3
L’électricité statique peut endommager les cartes de circuits imprimés.................................1a-3
Les vapeurs toxiques peuvent provoquer des blessures ou la mort ......................................1a-4
L’arc plasma peut provoquer des blessures ou des brûlures.................................................1a-5
Les rayons de l’arc peuvent brûler les yeux et la peau ..........................................................1a-5
Mise à la masse et à la terre ..................................................................................................1a-6
Sécurité des bouteilles de gaz comprimé...............................................................................1a-6
Les bouteilles de gaz comprimé peuvent exploser en cas de dommages.............................1a-6
Le bruit peut provoquer des problèmes auditifs .....................................................................1a-7
Pacemakers et prothèses auditives .......................................................................................1a-7
Un arc plasma peut endommager les tuyaux gelés ...............................................................1a-7
Étiquettes de sécurité.............................................................................................................1a-8