Sensor™ THC Plasma Lifter

Installation Manual
808970 | Revision 0
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Sensor THC Plasma Lifter

Installation Manual

808970
Revision 0

Original instructions

May 2016

Hypertherm Inc.
Hanover, NH 03755 USA
www.hypertherm.com
Hypertherm Inc. Hypertherm Europe B.V.
Etna Road, P.O. Box 5010 Vaartveld 9, 4704 SE
Hanover, NH 03755 USA Roosendaal, Nederland
603-643-3441 Tel (Main Office) 31 165 596907 Tel
603-643-5352 Fax (All Departments) 31 165 596901 Fax
[email protected] (Main Office Email) 31 165 596908 Tel (Marketing)
800-643-9878 Tel (Technical Service) 31 (0) 165 596900 Tel (Technical Service)
[email protected] (Technical Service Email) 00 800 4973 7843 Tel (Technical Service)
800-737-2978 Tel (Customer Service) [email protected]
[email protected] (Customer Service Email) (Technical Service Email)
866-643-7711 Tel (Return Materials Authorization)
877-371-2876 Fax (Return Materials Authorization) Hypertherm (Shanghai) Trading Co., Ltd.
[email protected] (RMA email) B301, 495 ShangZhong Road
Shanghai, 200231
Hypertherm México, S.A. de C.V. PR China
Avenida Toluca No. 444, Anexo 1, 86-21-80231122 Tel
Colonia Olivar de los Padres 86-21-80231120 Fax
Delegación Álvaro Obregón 86-21-80231128 Tel (Technical Service)
México, D.F. C.P. 01780 [email protected]
52 55 5681 8109 Tel (Technical Service Email)
52 55 5683 2127 Fax
[email protected] (Technical Service Email) South America & Central America: Hypertherm Brasil Ltda.
Rua Bras Cubas, 231 – Jardim Maia
Hypertherm Plasmatechnik GmbH Guarulhos, SP – Brasil
Sophie-Scholl-Platz 5 CEP 07115-030
63452 Hanau 55 11 2409 2636 Tel
Germany [email protected] (Technical Service Email)
00 800 33 24 97 37 Tel
00 800 49 73 73 29 Fax Hypertherm Korea Branch
31 (0) 165 596900 Tel (Technical Service) #3904. APEC-ro 17. Heaundae-gu. Busan.
00 800 4973 7843 Tel (Technical Service) Korea 48060
[email protected] (Technical Service Email) 82 (0)51 747 0358 Tel
82 (0)51 701 0358 Fax
Hypertherm (Singapore) Pte Ltd. [email protected] (Marketing Email)
82 Genting Lane [email protected]
Media Centre (Technical Service Email)
Annexe Block #A01-01
Singapore 349567, Republic of Singapore Hypertherm Pty Limited
65 6841 2489 Tel GPO Box 4836
65 6841 2490 Fax Sydney NSW 2001, Australia
[email protected] (Marketing Email) 61 (0) 437 606 995 Tel
[email protected] (Technical Service Email) 61 7 3219 9010 Fax
[email protected] (Main Office Email)
Hypertherm Japan Ltd. [email protected]
Level 9, Edobori Center Building (Technical Service Email)
2-1-1 Edobori, Nishi-ku
Osaka 550-0002 Japan Hypertherm (India) Thermal Cutting Pvt. Ltd
81 6 6225 1183 Tel A-18 / B-1 Extension,
81 6 6225 1184 Fax Mohan Co-Operative Industrial Estate,
[email protected] (Main Office Email) Mathura Road, New Delhi 110044, India
[email protected] (Technical Service Email) 91-11-40521201/ 2/ 3 Tel
91-11 40521204 Fax
[email protected] (Main Office Email)
[email protected]
(Technical Service Email)

1/28/16
ENGLISH DANSK / DANISH
WARNING! Before operating any Hypertherm equipment, read the safety ADVARSEL! Inden Hypertherm udstyr tages i brug skal
instructions in your product’s manual. Failure to follow safety instructions can sikkerhedsinstruktionerne i produktets manual gennemlæses. Følges
result in personal injury or in damage to equipment. sikkerhedsvejledningen ikke kan det resultere i personskade eller beskadigelse
Copies of the manuals may accompany the product in electronic and printed af udstyret.
formats. You can also obtain copies of the manuals, in all languages available Kopier af manualerne kan ledsage produktet i elektroniske og trykte formater.
for each manual, from the “Downloads library” at www.hypertherm.com. Du kan også få kopier af manualer, på alle sprog der er til rådighed for hver
manuel, fra "Download-biblioteket" på www.hypertherm.com.
DEUTSCH / GERMAN
WARNUNG! Bevor Sie ein Hypertherm-Gerät in Betrieb nehmen, lesen Sie PORTUGUÊS / PORTUGUESE
bitte die Sicherheitsanweisungen in Ihrer Bedienungsanleitung. Das ADVERTÊNCIA! Antes de operar qualquer equipamento Hypertherm, leia as
Nichtbefolgen der Sicherheitsanweisungen kann zu Verletzungen von Personen instruções de segurança no manual do seu produto. Não seguir as instruções
oder Schäden am Gerät führen. de segurança pode resultar em lesões corporais ou danos ao equipamento.
Bedienungsanleitungen und Handbücher können dem Gerät in elektronischer Cópias dos manuais podem acompanhar os produtos nos formatos eletrônico
Form oder als Druckversion beiliegen. Sie können alle Handbücher und e impresso. Também é possível obter cópias dos manuais em todos os idiomas
Anleitungen in den jeweils verfügbaren Sprachen eines bestimmten disponíveis para cada manual na “Biblioteca de downloads” em
Handbuchs auch in der „Download-Bibliothek“ unter www.hypertherm.com www.hypertherm.com.
herunterladen.

FRANÇAIS / FRENCH 日本語 / JAPANESE

AVERTISSEMENT! Avant d’utiliser tout équipement Hypertherm, lire les 警告 ! Hypertherm 機器を操作する前に、この製品説明書にある安全情報を
consignes de sécurité dans le manuel de votre produit. Le non-respect des お読みください。安全情報に従わないと怪我や装置の損傷を招くことがあ
consignes de sécurité peut engendrer des blessures physiques ou des ります。
dommages à l’équipement. 説明書のコピーは、電子フォーマット、または印刷物として製品に同梱さ
Des copies de ces manuels peuvent accompagner le produit en format れています。各説明書は、 www.hypertherm.com の「ダンロードライブラ
électronique et papier. Vous pouvez également obtenir des copies de chaque リ」から各言語で入手できます。
manuel dans toutes les langues disponibles à partir de la « Bibliothèque de
téléchargement » sur www.hypertherm.com. 简体中文 / CHINESE (SIMPLIFIED)
警告！在操作任何海宝设备之前，请阅读产品手册中的安全操作说明。若未
ESPAÑOL / SPANISH
能遵循安全操作说明，可能会造成人员受伤或设备损坏。
¡ADVERTENCIA! Antes de operar cualquier equipo Hypertherm, leer las
随产品提供的手册可能提供电子版和印刷版两种格式。您也可从
instrucciones de seguridad del manual de su producto. No cumplir las
“Downloads library” （下载资料库）中获取每本手册所有可用语言的副本，
instrucciones de seguridad podría dar lugar a lesiones personales o daño a los
网址为 www.hypertherm.com.
equipos.
Pueden venir copias de los manuales en formato electrónico e impreso junto NORSK / NORWEGIAN
con el producto. También se pueden obtener copias de los manuales, en todos
los idiomas disponibles para cada manual, de la “Biblioteca” en ADVARSEL! Før du bruker noe Hypertherm-utstyr, må du lese
www.hypertherm.com. sikkerhetsinstruksjonene i produktets håndbok. Unnlatelse av å følge
sikkerhetsinstruksjoner kan føre til personskade eller skade på utstyr.
ITALIANO / ITALIAN Eksemplarer av håndbøkene kan medfølge produktet i elektroniske og trykte
utgaver. Du kan også få eksemplarer av håndbøkene, i alle tilgjengelige språk
AVVERTENZA! Prima di utilizzare le attrezzature Hypertherm, leggere
for hver håndbok, fra "nedlastningsbiblioteket" på www.hypertherm.com.
le istruzioni di sicurezza nel manuale del prodotto. Il mancato rispetto delle
istruzioni sulla sicurezza può causare lesioni personali o danni all’attrezzatura.
SVENSKA / SWEDISH
Il prodotto può essere accompagnato da copie elettroniche e cartacee del
manuale. È anche possibile ottenere copie del manuale, in tutte le lingue VARNING! Läs säkerhetsinstruktionerna i din produktmanual försiktigt innan
disponibili per ogni manuale, da “Archivio download” all’indirizzo du använder din någon Hypertherm-utrustning. Underlåtenhet att följa
www.hypertherm.com. dessa säkerhetsinstruktionerkan resultera i personskador eller skador
på utrustningen.
NEDERLANDS / DUTCH Kopior av manualen kan medfölja produkten i elektronisk och tryckform.
Du hittar även kopior av manualerna i alla tillgängliga språk i
WAARSCHUWING! Lees voordat u Hypertherm-apparatuur gebruikt
”nedladdningsbiblioteket” (Downloads library) på www.hypertherm.com.
de veiligheidsinstructies in de producthandleiding en in de Veiligheids- en
nalevingshandleiding (80669C). Het niet volgen van de veiligheidsinstructies
kan resulteren in persoonlijk letsel of schade aan apparatuur. 한국어 / KOREAN
De handleidingen kunnen in elektronische en gedrukte vorm met het product 경고 ! Hypertherm 장비를 사용하기 전에 제품 설명서에 나와 있는 안전
worden meegeleverd. De handleidingen, elke handleiding beschikbaar in alle 지침을 읽으십시오 . 안전 지침을 준수하지 않으면 신체 부상이나 장비
talen, zijn ook verkrijgbaar via de “Downloadbibliotheek” op 손상을 초래할 수 있습니다 .
www.hypertherm.com. 전자 형식과 인쇄된 형식으로 설명서 사본이 제품과 함께 제공될
수 있습니다 . www.hypertherm.com 의 'Downloads library( 다운로드
라이브러리 )' 에서도 모든 언어로 이용할 수 있는 설명서 사본을 얻을
수 있습니다 .
ČESKY / CZECH TÜRKÇE / TURKISH
VAROVÁNÍ! Před uvedením jakéhokoliv zařízení Hypertherm do provozu UYARI! Bir Hypertherm ekipmanını çalıştırmadan önce, ürün kullanım
si přečtěte bezpečnostní pokyny v příručce k produktu. Nedodržování kılavuzunda yer alan güvenlik talimatlarını okuyun. Güvenlik talimatlarına
bezpečnostních pokynů může mít za následek zranění osob nebo poškození uyulmaması durumunda kişisel yaralanmalar veya ekipman hasarı meydana
majetku. gelebilir.
Kopie příruček a manuálů mohou být součástí dodávky produktu, a to v Kılavuzların kopyaları, elektronik ve basılı formatta ürünle birlikte verilebilir.
elektronické i tištěné formě. Kopie příruček a manuálů ve všech jazykových Her biri tüm dillerde yayınlanan kılavuzların kopyalarını www.hypertherm.com
verzích, v nichž byly dané příručky a manuály vytvořeny, naleznete v „Knihovně adresindeki “Downloads library” (Yüklemeler kitaplığı) başlığından da elde
ke stažení“ na webových stránkách www.hypertherm.com. edebilirsiniz.

POLSKI / POLISH MAGYAR / HUNGARIAN

OSTRZEŻENIE! Przed rozpoczęciem obsługi jakiegokolwiek systemu firmy VIGYÁZAT! Mielőtt bármilyen Hypertherm berendezést üzemeltetne, olvassa
Hypertherm należy się zapoznać z instrukcjami bezpieczeństwa el a biztonsági információkat a termék kézikönyvében. A biztonági utasítások
zamieszczonymi w podręczniku produktu. Nieprzestrzeganie instrukcji betartásának elmulasztása személyi sérüléshez vagy a berendezés
bezpieczeństwa może skutkować obrażeniami ciała i uszkodzeniem sprzętu. károsodásához vezethet.
Do produktu mogą być dołączone kopie podręczników w formacie A termékhez a kézikönyv példányai elektronikus és nyomtatott formában
elektronicznym i drukowanym. Kopie podręczników, w każdym udostępnionym is mellékelve lehetnek. A kézikönyvek példányai (minden nyelven) a
języku, można również znaleźć w „Bibliotece materiałów do pobrania” pod www.hypertherm.com weboldalon a „Downloads library” (Letöltési könyvtár)
adresem www.hypertherm.com. részben is beszerezhetők.

PУССКИЙ / RUSSIAN ΕΛΛΗΝΙΚΆ / GREEK

БЕРЕГИСЬ! Перед работой с любым оборудованием Hypertherm ΠΡΟΕΙΔΟΠΟΙΗΣΗ! Πριν θέσετε σε λειτουργία οποιονδήποτε εξοπλισμό της
ознакомьтесь с инструкциями по безопасности, представленными в Hypertherm, διαβάστε τις οδηγίες ασφαλείας στο εγχειρίδιο του προϊόντος. Η
руководстве, которое поставляется вместе с продуктом. Невыполнение μη τήρηση των οδηγιών ασφαλείας μπορεί να επιφέρει σωματική βλάβη ή
инструкций по безопасности может привести к телесным повреждениям ζημιά στον εξοπλισμό.
или повреждению оборудования. Αντίγραφα των εγχειριδίων μπορεί να συνοδεύουν το προϊόν σε ηλεκτρονική
Копии руководств, которые поставляются вместе с продуктом, могут быть και έντυπη μορφή. Μπορείτε, επίσης, να λάβετε αντίγραφα των εγχειριδίων
представлены в электронном и бумажном виде. Копии руководств на всех σε όλες τις γλώσσες που διατίθενται για κάθε εγχειρίδιο από την ψηφιακή
языках, на которые переведено то или иное руководство, можно также βιβλιοθήκη λήψεων (Downloads library) στη διαδικτυακή τοποθεσία
загрузить из раздела «Библиотека документов» на веб-сайте www.hypertherm.com.
www.hypertherm.com.
繁體中文 / CHINESE (TRADITIONAL)
SUOMI / FINNISH
警告！ 操作任何 Hypertherm 設備前，請閱讀產品手冊中的安全說明。不遵
VAROITUS! Ennen minkään Hypertherm-laitteen käyttöä lue tuotteen 守安全指示可能會導致人身傷害或設備損壞。
käyttöoppaassa olevat turvallisuusohjeet. Turvallisuusohjeiden laiminlyönti
手冊複本可能以電子和印刷格式隨附產品提供。您也可以在
voi aiheuttaa henkilökohtaisen loukkaantumisen tai laitevahingon.
www.hypertherm.com 的 「下載資料庫」內獲取所有手冊的多語種複本。
Käyttöoppaiden kopiot voivat olla tuotteen mukana elektronisessa ja
tulostetussa muodossa. Voit saada käyttöoppaiden kopiot kaikilla kielillä
SLOVENŠČINA / SLOVENIAN
”latauskirjastosta” osoitteessa www.hypertherm.com.
OPOZORILO! Pred uporabo katerekoli Hyperthermove opreme preberite
БЪЛГAPCКИ / BULGARIAN varnostna navodila v priročniku vašega izdelka. Neupoštevanje navodil za
uporabo lahko povzroči telesne poškodbe ali materialno škodo.
ПРЕДУПРЕЖДЕНИЕ! Преди да работите с оборудване Hypertherm,
прочетете инструкциите за безопасност в ръководството на вашия Izdelku so lahko priloženi izvodi priročnikov v elektronski ali tiskani obliki. Izvode
продукт. Неспазването на инструкциите за безопасност би могло да priročnikov v vseh razpoložljivih jezikih si lahko prenesete tudi iz knjižnice
доведе до телесно нараняване или до повреда на оборудването. prenosov “Downloads library” na naslovu www.hypertherm.com.

Копия на ръководствата може да придружават продукта в електронен и в

SRPSKI / SERBIAN
печатен формат. Можете да получите копия на ръководствата, предлагани
на всички езици, от “Downloads library” (Библиотека за теглене) на адрес UPOZORENJE! Pre rukovanja bilo kojom Hyperthermovom opremom
www.hypertherm.com. pročitajte uputstva o bezbednosti u svom priručniku za proizvod. Oglušavanje o
praćenje uputstava o bezbednosti može da ima za posledicu ličnu povredu ili
ROMÂNĂ / ROMANIAN oštećenje opreme.

AVERTIZARE! Înainte de a utiliza un echipament Hypertherm, citiţi instrucţiunile Može se dogoditi da kopije priručnika prate proizvod u elektronskom
privind siguranţa din manualul de utilizare a produsului. Nerespectarea i štampanom formatu. Takođe možete da pronađete kopije priručnika, na svim
instrucțiunilor de siguranță pot rezulta în vătămare personală sau în avarierea jezicima koji su dostupni za svaki od priručnika, u “Biblioteci preuzimanja”
echipamentului. (“Downloads library”) na www.hypertherm.com.

Produsul poate fi însoțit de copii ale manualului în format tipărit și electronic.

SLOVENČINA / SLOVAK
De asemenea, dumneavoastră puteți obține copii ale manualelor, în toate limbile
disponibile pentru fiecare manual, din cadrul secțiunii ”Librărie de descărcare” VÝSTRAHA! Pred použitím akéhokoľvek zariadenia od spoločnosti Hypertherm
aflată pe site-ul www.hypertherm.com. si prečítajte bezpečnostné pokyny v návode na obsluhu vášho zariadenia. V
prípade nedodržania bezpečnostných pokynov môže dôjsť k ujme na zdraví
alebo poškodeniu zariadenia.
Kópia návodu, ktorá je dodávaná s produktom, môže mať elektronickú alebo
tlačenú podobu. Kópie návodov, vo všetkých dostupných jazykoch, sú k
dispozícii aj v sekcii “Downloads library” na www.hypertherm.com.
 Contents

Safety .................................................................................................................................... SC-11

Recognize safety information ........................................................................................................................... SC-11

Inspect equipment before using ..................................................................................................................... SC-11

Follow safety instructions ................................................................................................................................... SC-11

Responsibility for safety....................................................................................................................................... SC-11

A plasma arc can damage frozen pipes...................................................................................................... SC-11

Static electricity can damage printed circuit boards............................................................................ SC-11

Grounding safety ..................................................................................................................................................... SC-12

Electrical hazards .................................................................................................................................................... SC-12

Electric shock can kill ........................................................................................................................................... SC-12

Cutting can cause fire or explosion............................................................................................................... SC-13

Fire prevention ....................................................................................................................................... SC-13
Explosion prevention ............................................................................................................................ SC-13

Machine motion can cause injury ................................................................................................................... SC-13

Compressed gas equipment safety............................................................................................................... SC-14

Gas cylinders can explode if damaged ....................................................................................................... SC-14

Toxic fumes can cause injury or death........................................................................................................ SC-14

Sensor THC Plasma Lifter Installation Manual 808970 7

 Contents

A plasma arc can cause injury and burns .................................................................................................. SC-15

Arc rays can burn eyes and skin ..................................................................................................................... SC-15

Pacemaker and hearing aid operation......................................................................................................... SC-15

Noise can damage hearing ................................................................................................................................ SC-16

Dry dust collection information........................................................................................................................ SC-16

Laser radiation........................................................................................................................................................... SC-17

Additional safety information ............................................................................................................................ SC-17

Product Stewardship.......................................................................................................... SC-19

Introduction................................................................................................................................................................. SC-19

National and local safety regulations ........................................................................................................... SC-19

Certification test marks ........................................................................................................................................ SC-19

Differences in national standards................................................................................................................... SC-19

Safe installation and use of shape cutting equipment ....................................................................... SC-19

Procedures for periodic inspection and testing...................................................................................... SC-19

Qualification of test personnel ......................................................................................................................... SC-20

Residual current devices (RCDs) .................................................................................................................... SC-20

Higher-level systems............................................................................................................................................. SC-20

Environmental Stewardship.............................................................................................. SC-21

Introduction................................................................................................................................................................. SC-21

National and local environmental regulations.......................................................................................... SC-21

The RoHS directive................................................................................................................................................. SC-21

Proper disposal of Hypertherm products................................................................................................... SC-21

The WEEE Directive................................................................................................................................................ SC-21

The REACH regulation .......................................................................................................................................... SC-21

Proper handling and safe use of chemicals ............................................................................................. SC-22

Fumes emission and air quality....................................................................................................................... SC-22

8 808970 Installation Manual Sensor THC Plasma Lifter

 Contents

Electromagnetic Compatibility (EMC) ............................................................................ SC-23

Introduction................................................................................................................................................................. SC-23

Installation and use ................................................................................................................................................ SC-23

Assessment of area ............................................................................................................................................... SC-23

Methods of reducing emissions ...................................................................................................................... SC-23

Mains supply .......................................................................................................................................... SC-23

Maintenance of cutting equipment................................................................................................................. SC-23

Cutting cables............................................................................................................................................................ SC-23

Equipotential bonding .......................................................................................................................... SC-23
Earthing of the workpiece ................................................................................................................... SC-24

Screening and shielding ...................................................................................................................................... SC-24

Warranty............................................................................................................................... SC-25
Attention ....................................................................................................................................................................... SC-25

General.......................................................................................................................................................................... SC-25

Patent indemnity ...................................................................................................................................................... SC-25

Limitation of liability ............................................................................................................................................... SC-25

National and local codes ..................................................................................................................................... SC-25

Liability cap ................................................................................................................................................................. SC-26

Insurance...................................................................................................................................................................... SC-26

Transfer of rights ..................................................................................................................................................... SC-26

Waterjet product warranty coverage ............................................................................................................. SC-26

Product.................................................................................................................................................... SC-26
Parts coverage....................................................................................................................................... SC-26

1 Overview ..................................................................................................................................... 27

2 Specifications and parts ......................................................................................................... 29

Upon receipt...................................................................................................................................................................... 29
Claims............................................................................................................................................................. 29

Sensor THC Plasma Lifter Installation Manual 808970 9

 Contents

Sensor THC Plasma Lifter.......................................................................................................................................... 30

Data plate....................................................................................................................................................... 32

Lifter interface cable ..................................................................................................................................................... 33

Motors and drives........................................................................................................................................................... 33

Motor couplings ........................................................................................................................................... 35

Replacement parts......................................................................................................................................................... 36
Lifter parts...................................................................................................................................................... 36
Breakaway parts........................................................................................................................................... 38

Wiring diagram ................................................................................................................................................................. 38

3 Install .......................................................................................................................................... 41
Install the motor .............................................................................................................................................................. 41

Move the connector for the lifter interface cable (optional).................................................................... 43

Install the lifter ................................................................................................................................................................. 45

Ground the lifter .............................................................................................................................................................. 46

Install the THC drive...................................................................................................................................................... 46

Install voltage divider board/VDC3....................................................................................................................... 46

4 Connect....................................................................................................................................... 47
Connect the lifter to the THC drive ....................................................................................................................... 47

Connect the THC drive to the network ............................................................................................................... 49

Connect the VDC3 board............................................................................................................................................ 49

10 808970 Installation Manual Sensor THC Plasma Lifter

 Safety

DANGER WARNING CAUTION

RECOGNIZE SAFETY
INFORMATION American National Standards Institute (ANSI) guidelines are used for
safety signal words and symbols. The signal word DANGER or
WARNING is used with a safety symbol. DANGER identifies the most
The symbols shown in this section are used to identify potential serious hazards.
hazards. When you see a safety symbol in this manual or on your
• DANGER and WARNING safety labels are located on your machine
machine, understand the potential for personal injury, and follow the
near specific hazards.
related instructions to avoid the hazard.
• DANGER safety messages precede related instructions in the
manual that will result in serious injury or death if not followed
FOLLOW SAFETY correctly.
INSTRUCTIONS • WARNING safety messages precede related instructions in this
manual that may result in injury or death if not followed correctly.
Carefully read all safety messages in this manual and safety labels • CAUTION safety messages precede related instructions in this
on your machine. manual that may result in minor injury or damage to equipment if not
followed correctly.
• 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
INSPECT EQUIPMENT BEFORE USING
properly. Do not let anyone operate it without instruction. All cutting equipment must be inspected as required to make sure it is in
• Keep your machine in proper working condition. Unauthorized safe operating condition. When found to be incapable of reliable and
modifications to the machine may affect safety and machine safe operation, the equipment must be repaired by qualified personnel
service life. prior to its next use or withdrawn from service.

RESPONSIBILITY FOR SAFETY

The person or entity responsible for the safety of the workplace must: • Select contractors who provide trained and qualified personnel, and
• Make sure that operators and their supervisors are trained in the safe who have awareness of the risks involved, to do cutting.
use of their equipment, the safe use of the process, and emergency • Tell contractors about flammable materials or hazardous conditions
procedures. that are specific to the site, or hazardous conditions that they may not
• Make sure that all hazards and safety precautions identified herein be aware of.
are communicated to and understood by workers before the start of • Make sure that the quality and quantity of air for ventilation is such
work. that personnel exposures to hazardous contaminants are below the
• Designate approved cutting areas and establish procedures for safe allowable limits.
cutting. • Make sure that ventilation in confined spaces is sufficient to allow
• Be responsible for authorizing cutting operations in areas not adequate oxygen for life support, to prevent accumulation of
specifically designed or approved for such processes. asphixiants or flammable explosive mixtures, to prevent
• Make sure that only approved equipment, such as torches and oxygen-enriched atmospheres, and to keep airborne contaminants in
breathing atmospheres below allowable limits.
personal protective equipment, are used.

A PLASMA ARC CAN DAMAGE FROZEN PIPES

Frozen pipes may be damaged or can burst if you attempt to thaw them with a plasma torch.

STATIC ELECTRICITY CAN DAMAGE PRINTED CIRCUIT BOARDS

Use proper precautions when handling printed circuit boards:
• Store printed circuit boards in anti-static containers.
• Wear a grounded wrist strap when handling printed circuit boards.

Safety and compliance SC-11

Safety

GROUNDING SAFETY
Work lead Attach the work lead securely to the workpiece or the Input power
cutting table with good metal-to-metal contact. Do not connect it to • Make sure to connect the power cord ground wire to the ground in
the piece that will fall away when the cut is complete. the disconnect box.
Cutting table Connect the cutting table to an earth ground, in • If installation of the plasma system involves connecting the power
accordance with appropriate national and local electrical regulations. cord to the power supply, make sure to connect the power cord
ground wire properly.
• Place the power cord’s ground wire on the stud first, then place any
other ground wires on top of the power cord ground. Tighten the
retaining nut.
• Tighten all electrical connections to avoid excessive heating.

ELECTRICAL HAZARDS
• Only trained and authorized personnel may open this equipment. • If the equipment must have power when the enclosure is open for
• If the equipment is permanently connected, turn it off, and lock servicing, arc flash explosion hazards may exist. Follow all local
out/tag out power before the enclosure is opened. requirements (NFPA 70E in the USA) for safe work practices and for
personal protective equipment when servicing energized equipment.
• If power is supplied to the equipment with a cord, unplug the unit
before the enclosure is opened. • Prior to operating the equipment after moving, opening, or servicing,
• Lockable disconnects or lockable plug covers must be provided by make sure to close the enclosure and make sure that there is proper
others. earth ground continuity to the enclosure.
• Wait 5 minutes after removal of power before entering the enclosure • Always follow these instructions for disconnecting power before
inspecting or changing torch consumable parts.
to allow stored energy to discharge.

ELECTRIC SHOCK CAN KILL

Touching live electrical parts can cause a fatal shock or severe burn. • Install and ground this equipment according to the instruction
• Operating the plasma system completes an electrical circuit manual and in accordance with national and local regulations.
between the torch and the workpiece. The workpiece and anything • Inspect the input power cord frequently for damage or cracking
touching the workpiece are part of the electrical circuit. of the cover. Replace a damaged power cord immediately.
• In machine torch applications, never touch the torch body, Bare wiring can kill.
workpiece, or water in a water table when the plasma system is • Inspect and replace any worn or damaged torch leads.
operating. • Do not pick up the workpiece, including the waste cutoff, while you
cut. Leave the workpiece in place or on the workbench with the
Electric shock prevention
work lead attached during the cutting process.
All plasma systems use high voltage in the cutting process • Before checking, cleaning, or changing torch parts, disconnect the
(200 to 400 VDC are common). Take the following main power or unplug the power supply.
precautions when operating this system: • Never bypass or shortcut the safety interlocks.
• Wear insulated gloves and boots, and keep your body and clothing • Before removing any power supply or system enclosure cover,
dry. disconnect electrical input power. Wait 5 minutes after
• Do not stand, sit, or lie on – or touch – any wet surface when using disconnecting the main power to allow capacitors to discharge.
the plasma system. • Never operate the plasma system unless the power supply covers
• Insulate yourself from the work and ground using dry insulating are in place. Exposed power supply connections present a severe
mats or covers big enough to prevent any physical contact with the electrical hazard.
work or ground. If you must cut in or near a damp area, use • When making input connections, attach a proper grounding
extreme caution. conductor first.
• Provide a disconnect switch close to the power supply with • Each plasma system is designed to be used only with specific
properly sized fuses. This switch allows the operator to turn off the torches. Do not substitute other torches, which could overheat and
power supply quickly in an emergency situation. present a safety hazard.
• When using a water table, make sure that it is correctly connected
to an earth ground.

SC-12 Safety and compliance

 Safety

CUTTING CAN CAUSE FIRE OR EXPLOSION

Fire prevention WARNING

• Make sure the cutting area is safe before doing any cutting. Keep a Explosion Hazard
fire extinguisher nearby. Argon-Hydrogen and Methane
• Remove all flammables within 35 feet (10 m) of the cutting area. Hydrogen and methane are flammable gases that present an
• Quench hot metal or allow it to cool before handling or before explosion hazard. Keep flames away from cylinders and hoses that
letting it touch combustible materials. contain methane or hydrogen mixtures. Keep flames and sparks away
• Never cut containers with potentially flammable materials inside – from the torch when using methane or argon-hydrogen plasma.
they must be emptied and properly cleaned first. WARNING
• Ventilate potentially flammable atmospheres before cutting. Explosion Hazard
• When cutting with oxygen as the plasma gas, an exhaust ventilation Underwater Cutting with Fuel Gases
system is required. Containing Hydrogen
• Do not cut underwater with fuel gases containing hydrogen.
Explosion prevention • Cutting underwater with fuel gases containing hydrogen can result
• Do not use the plasma system if explosive dust or vapors may be in an explosive condition that can detonate during plasma cutting
present. operations.
• Do not cut pressurized cylinders, pipes, or any closed containers.
• Do not cut containers that have held combustible materials.

WARNING
Explosion Hazard
Hydrogen Detonation with Aluminum Cutting

When you use a plasma torch to cut aluminum alloys under water or Also, make sure that the water table, fume extraction (ventilation), and
on a water table, a chemical reaction between the water and the other parts of the cutting system have been designed with aluminum
workpiece, parts, fine particles, or molten aluminum droplets cutting in mind.
generates significantly more hydrogen gas than occurs with other
metals. This hydrogen gas may get trapped under the workpiece. If Do not cut aluminum alloys underwater or on a water table
exposed to oxygen or air, the plasma arc or a spark from any source unless you can prevent the accumulation of hydrogen gas.
can ignite this trapped hydrogen gas, causing an explosion that may
Note: With proper mitigation, most aluminum alloys can be plasma
result in death, personal injury, loss of property, or equipment damage. cut on a water table. An exception is aluminum-lithium alloys. Never
Consult with the table manufacturer and other experts prior to cutting cut aluminum-lithium alloys in the presence of water. Contact
aluminum to implement a risk assessment and mitigation plan that your aluminum supplier for additional safety information regarding
eliminates the risk of detonation by preventing hydrogen hazards associated with aluminum-lithium alloys.
accumulation.

MACHINE MOTION CAN CAUSE INJURY

When an original equipment manufacturer (OEM) makes a cutting system by combining Hypertherm equipment with other equipment, the end-use
customer and the OEM are responsible for providing protection against the hazardous moving parts of this cutting system. However, we advise the
following to prevent operator injury and equipment damage:
• Read and follow the instruction manual provided by the OEM. • Do not service or clean the machinery during operation.
• Maintain a restricted-access area larger than the maximum • If servicing is required, enable the safety interlock or disconnect
movement range of the cutting system’s moving parts. and lock out/tag out power to disable the motors and prevent
• Where there is a risk of collision, do not allow personnel or motion.
equipment near the cutting system’s moving parts. • Allow only qualified personnel to operate, maintain, and service the
• Avoid accidental contact with the CNC touchscreen or joystick. machinery.
Accidental contact can activate commands and result in
unintended motion.

Safety and compliance SC-13

Safety

COMPRESSED GAS EQUIPMENT GAS CYLINDERS CAN

SAFETY EXPLODE IF DAMAGED

• Never lubricate cylinder valves or regulators with oil or grease. Gas cylinders contain gas under high pressure. If damaged, a
• Use only correct gas cylinders, regulators, hoses, and fittings cylinder can explode.
designed for the specific application. • Handle and use compressed gas cylinders in accordance with
• Maintain all compressed gas equipment and associated parts in applicable national and local regulations.
good condition. • Never use a cylinder that is not upright and secured in place.
• Label and color-code all gas hoses to identify the type of gas in • Keep the protective cap in place over the valve except when the
each hose. Consult applicable national and local regulations. cylinder is in use or connected for use.
• Never allow electrical contact between the plasma arc and a
cylinder.
• Never expose cylinders to excessive heat, sparks, slag, or open
flame.
• Never use a hammer, wrench, or other tool to open a stuck cylinder
valve.

TOXIC FUMES CAN CAUSE INJURY OR DEATH

The plasma arc by itself is the heat source used for cutting. The air quality level in any relevant workplace depends on site-specific
Accordingly, although the plasma arc has not been identified as a variables such as:
source of toxic fumes, the material being cut can be a source of toxic • Table design (wet, dry, underwater).
fumes or gases that deplete oxygen.
• Material composition, surface finish, and composition of coatings.
The fumes produced vary depending on the metal that is cut. Metals • Volume of material removed.
that may release toxic fumes include, but are not limited to, stainless • Duration of cutting or gouging.
steel, carbon steel, zinc (galvanized), and copper. • Size, air volume, ventilation, and filtration of the workplace.
In some cases, the metal may be coated with a substance that could • Personal protective equipment.
release toxic fumes. Toxic coatings include, but are not limited to, • Number of welding and cutting systems in operation.
lead (in some paints), cadmium (in some paints and fillers), and • Other workplace processes that may produce fumes.
beryllium.
If the workplace must conform to national or local regulations, only
The gases produced by plasma cutting vary based on the material to monitoring or testing done at the site can determine whether the
be cut and the method of cutting, but may include ozone, oxides of workplace is above or below allowable levels.
nitrogen, hexavalent chromium, hydrogen, and other substances if
To reduce the risk of exposure to fumes:
such are contained in or released by the material being cut.
• Remove all coatings and solvents from the metal before cutting.
Caution should be taken to minimize exposure to fumes produced by • Use local exhaust ventilation to remove fumes from the air.
any industrial process. Depending on the chemical composition and
• Do not inhale fumes. Wear an air-supplied respirator when cutting
concentration of the fumes (as well as other factors, such as
any metal coated with, containing, or suspected to contain toxic
ventilation), there may be a risk of physical illness, such as birth
elements.
defects or cancer.
• Make sure that those using welding or cutting equipment, as well as
It is the responsibility of the equipment and site owner to test the air air-supplied respiration devices, are qualified and trained in the
quality in the cutting area and to make sure that the air quality in the proper use of such equipment.
workplace meets all local and national standards and regulations. • Never cut containers with potentially toxic materials inside. Empty
and properly clean the container first.
• Monitor or test the air quality at the site as needed.
• Consult with a local expert to implement a site plan to make sure air
quality is safe.

SC-14 Safety and compliance

 Safety

A PLASMA ARC CAN CAUSE INJURY AND BURNS

Instant-on torches The plasma arc will cut quickly through gloves and skin.
• Keep away from the torch tip.
A plasma arc ignites immediately when the torch switch is activated.
• Do not hold metal near the cutting path.
• Never point the torch toward yourself or others.

ARC RAYS CAN BURN EYES AND SKIN

Eye protection Plasma arc rays produce intense visible and invisible • Wear flame-retardant clothing to cover all exposed areas.
(ultraviolet and infrared) rays that can burn eyes and skin. • Wear cuffless trousers to prevent entry of sparks and slag.
• Use eye protection in accordance with applicable national and local
Also, remove any combustibles, such as a butane lighter or matches,
regulations.
from your pockets before cutting.
• Wear eye protection (safety glasses or goggles with side shields,
and a welding helmet) with appropriate lens shading to protect your Cutting area Prepare the cutting area to reduce reflection and
eyes from the arc’s ultraviolet and infrared rays. transmission of ultraviolet light:

Skin protection Wear protective clothing to protect against burns • Paint walls and other surfaces with dark colors to reduce reflection.
caused by ultraviolet light, sparks, and hot metal. • Use protective screens or barriers to protect others from flash
and glare.
• Wear gauntlet gloves, safety shoes, and hat.
• Warn others not to watch the arc. Use placards or signs.
Minimum protective Suggested shade
OSHA 29CFR Europe
Arc current shade number number for comfort
1910.133(a)(5) EN168:2002
(ANSI Z49.1:2012) (ANSI Z49.1:2012)
Less than 40 A 5 5 8 9
41 A to 60 A 6 6 8 9
61 A to 80 A 8 8 8 9
81 A to 125 A 8 9 8 9
126 A to 150 A 8 9 8 10
151 A to 175 A 8 9 8 11
176 A to 250 A 8 9 8 12
251 A to 300 A 8 9 8 13
301 A to 400 A 9 12 9 13
401 A to 800 A 10 14 10 N/A

PACEMAKER AND HEARING AID OPERATION

Pacemaker and hearing aid operation can be affected by magnetic To reduce magnetic field hazards:
fields from high currents. • Keep both the work lead and the torch lead to one side, away from
your body.
Pacemaker and hearing aid wearers should consult a doctor before
going near any plasma arc cutting and gouging operations. • Route the torch leads as close as possible to the work lead.
• Do not wrap or drape the torch lead or work lead around your body.
• Keep as far away from the power supply as possible.

Safety and compliance SC-15

Safety

NOISE CAN DAMAGE HEARING

Cutting with a plasma arc can exceed acceptable noise levels as Use ear protectors if the noise is disruptive or if there is a risk of
defined by local regulations in many applications. Prolonged exposure hearing damage after all other engineering and administrative
to excessive noise can damage hearing. Always wear proper ear controls have been implemented. If hearing protection is required,
protection when cutting or gouging, unless sound pressure level wear only approved personal protective equipment such as ear muffs
measurements taken at the site have verified personal hearing or ear plugs with a noise reduction rating appropriate for the
protection is not necessary per relevant international, regional, and situation. Warn others near the cutting area of possible noise
local regulations. hazards. In addition, ear protection can prevent hot splatter from
entering the ear.
Significant noise reduction can be obtained by adding simple
engineering controls to cutting tables such as barriers or curtains
positioned between the plasma arc and the workstation, and/or
locating the workstation away from the plasma arc. Implement
administrative controls in the workplace to restrict access and limit
operator exposure time, and screen off noisy areas and/or take
measures to reduce reverberation in cutting areas by putting up noise
absorbers.

DRY DUST COLLECTION INFORMATION

In some workplaces, dry dust can represent a potential explosion Note 1 – Unless a site-specific evaluation has been completed that
hazard. determines that none of the dust generated is combustible, then
NFPA standard 68 requires the use of explosion vents. Design the
The U.S. National Fire Protection Association’s NFPA standard 68, explosion vent size and type to conform to the worst-case Kst value
“Explosion Protection by Deflagration Venting,” provides requirements as described in Annex F of NFPA standard 68. NFPA standard 68
for the design, location, installation, maintenance, and use of devices does not specifically identify plasma cutting or other thermal cutting
and systems to vent combustion gases and pressures after any processes as requiring deflagration venting systems, but it does
deflagration event. Consult with the manufacturer or installer of any apply these new requirements to all dry dust collection systems.
dry dust collection system for applicable requirements before you
install a new dry dust collection system or make significant changes Note 2 – Users should consult and comply with all applicable
in the process or materials used with an existing dry dust collection national, state, and local regulations. Publications do not intend to
system. urge action that is not in compliance with all applicable regulations
and standards, and this manual may never be construed as doing so.
Consult your local “Authority Having Jurisdiction” (AHJ) to determine
whether any edition of NFPA standard 68 has been “adopted by
reference” in your local building codes.

Refer to NFPA standard 68 for definitions and explanations of

regulatory terms such as deflagration, AHJ, adopted by reference, the
Kst value, deflagration index, and other terms.

SC-16 Safety and compliance

 Safety

LASER RADIATION
Exposure to the laser beam from a laser pointer can result in serious eye injury. Avoid direct eye exposure.

On products that use a laser pointer for alignment, one of the following laser radiation labels has been applied on the product near where the laser
beam exits the enclosure. The maximum output (mV), wavelength emitted (nM), and, if appropriate, pulse duration are also provided.

Additional laser safety instructions: • Modifying the laser or product in any way can increase the risk of
• Consult with an expert on local laser regulations. Laser safety laser radiation.
training may be required. • Use of adjustments or performance of procedures other than those
• Do not allow untrained persons to operate the laser. Lasers can be specified in this manual may result in hazardous laser radiation
dangerous in the hands of untrained users. exposure.
• Do not look into the laser aperture or beam at any time. • Do not operate in explosive atmospheres, such as in the presence
of flammable liquids, gases, or dust.
• Position the laser as instructed to avoid unintentional eye contact.
• Use only laser parts and accessories that are recommended or
• Do not use the laser on reflective workpieces.
provided by the manufacturer for your model.
• Do not use optical tools to view or reflect the laser beam.
• Repairs and servicing must be performed by qualified personnel.
• Do not disassemble or remove the laser or aperture cover.
• Do not remove or deface the laser safety label.

ADDITIONAL SAFETY INFORMATION

1. ANSI Standard Z49.1, Safety in Welding and Cutting, American 6. CGA Pamphlet P-1, Safe Handling of Compressed Gases in
Welding Society, 550 LeJeune Road, P.O. Box 351020, Miami, Cylinders, Compressed Gas Association, 1235 Jefferson Davis
FL 33135 Highway, Arlington, VA 22202
2. ANSI Standard Z49.2, Fire Prevention in the Use of Cutting and 7. CSA Standard W117.2, Code for Safety in Welding and
Welding Processes, American National Standards Institute, Cutting, Canadian Standards Association Standard Sales,
1430 Broadway, New York, NY 10018 178 Rexdale Boulevard, Rexdale, Ontario M9W 1R3, Canada
3. ANSI Standard Z87.1, Safe Practices for Occupation and 8. NFPA Standard 51B, Cutting and Welding Processes, National
Educational Eye and Face Protection, American National Fire Protection Association, 1 Batterymarch Park, Quincy, MA
Standards Institute, 1430 Broadway, New York, NY 10018 02169-7471
4. AWS F4.1, Recommended Safe Practices for the Preparation 9. NFPA Standard 70, National Electrical Code, National Fire
for Welding and Cutting of Containers and Piping That Have Protection Association, 1 Batterymarch Park, Quincy, MA
Held Hazardous Substances, American Welding Society, 550 02169-7471
LeJeune Road, P.O. Box 351040, Miami, FL 33135 10. OSHA, Safety and Health Standards, 29FR 1910 U.S.
5. AWS F5.2, Recommended Safe Practices for Plasma Arc Government Printing Office, Washington, D.C. 20402
Cutting, American Welding Society, 550 LeJeune Road, 11. AWS Safety and Health Fact Sheets, American Welding
P.O. Box 351040, Miami, FL 33135 Society, 550 LeJeune Road, P.O. Box 351040, Miami, FL
33135, www.aws.org/technical/facts/

Safety and compliance SC-17

Safety

SC-18 Safety and compliance

 Product Stewardship

Introduction Differences in national standards

Hypertherm maintains a global Regulatory Management System to Nations may apply different performance, safety or other standards.
ensure that products comply with regulatory and environmental National differences in standards include, but are not limited to:
requirements. • Voltages
• Plug and cord ratings
National and local safety regulations • Language requirements

National and Local safety regulations shall take precedence over any • Electromagnetic compatibility requirements
instructions provided with the product. The product shall be imported, These differences in national or other standards may make it impossible
installed, operated and disposed of in accordance with national and local
or impractical for all certification test marks to be placed on the same
regulations applicable to the installed site.
version of a product. For example, the CSA versions of Hypertherm’s
products do not comply with European EMC requirements, and therefore
Certification test marks do not have a CE marking on the data plate.

Countries that require CE marking or have compulsory EMC regulations

Certified products are identified by one or more certification test marks
must use CE versions of Hypertherm products with the CE marking on
from accredited testing laboratories. The certification test marks are
located on or near the data plate. the data plate. These include, but are not limited to:
• Australia
Each certification test mark means that the product and its safety-critical
• New Zealand
components conform to the relevant national safety standards as
reviewed and determined by that testing laboratory. Hypertherm places • Countries in the European Union
a certification test mark on its products only after that product is • Russia
manufactured with safety-critical components that have been authorized
by the accredited testing laboratory. It is important that the product and its certification test mark be suitable
for the end-use installation site. When Hypertherm products are shipped
Once the product has left the Hypertherm factory, the certification test to one country for export to another country; the product must be
marks are invalidated if any of the following occurs: configured and certified properly for the end-use site.
• The product is modified in a manner that creates a hazard or
non-conformance with the applicable standards.
Safe installation and use of shape cutting
• Safety-critical components are replaced with unauthorized spare
parts.
equipment
• Any unauthorized assembly, or accessory that uses or generates a IEC 60974-9, titled Arc Welding Equipment – Installation and use,
hazardous voltage is added. provides guidance in the safe installation and use of shape cutting
• There is any tampering with a safety circuit or other feature that is equipment and the safe performance of cutting operations. The
designed into the product as part of the certification, or otherwise. requirements of national and local regulations shall be taken into
consideration during installation, including, but not limited to, grounding
CE marking constitutes a manufacturer’s declaration of conformity to or protective earth connections, fuses, supply disconnecting device, and
applicable European directives and standards. Only those versions of type of supply circuit. Read these instructions before installing the
Hypertherm products with a CE Marking located on or near the data equipment. The first and most important step is the safety assessment of
plate have been tested for compliance with the European Low Voltage the installation.
Directive and the European EMC Directive. EMC filters needed to
comply with the European EMC Directive are incorporated within The safety assessment must be performed by an expert, and determines
versions of the power supply with a CE Marking. what steps are necessary to create a safe environment, and what
precautions should be adopted during the actual installation and
Certificates of compliance for Hypertherm products are available from operation.
the Downloads Library on the Hypertherm web site at
https://www.hypertherm.com.
Procedures for periodic inspection and
testing
Where required by local national regulations, IEC 60974-4 specifies test
procedures for periodic inspection and after repair or maintenance, to
ensure electrical safety for plasma cutting power sources built in
conformity with IEC 60974-1. Hypertherm performs the continuity of the
protective circuit and insulation resistance tests in the factory as
non-operating tests. The tests are performed with the power and ground
connections removed.

Safety and compliance SC-19

Product Stewardship

Hypertherm also removes some protective devices that would cause Higher-level systems
false test results. Where required by local national regulations, a label
shall be attached to the equipment to indicate that it has passed the When a system integrator adds additional equipment; such as cutting
tests prescribed by IEC 60974-4. The repair report shall indicate the tables, motor drives, motion controllers or robots; to a Hypertherm
results of all tests unless an indication is made that a particular test has plasma cutting system, the combined system may be considered a
not been performed. higher-level system. A higher-level system with hazardous moving parts
may constitute industrial machinery or robotic equipment, in which case
the OEM or end-use customer may be subject to additional regulations
Qualification of test personnel and standards than those relevant to the plasma cutting system as
manufactured by Hypertherm.
Electrical safety tests for shape cutting equipment can be hazardous and
shall be carried out by an expert in the field of electrical repair, preferably It is the responsibility of the end-use customer and the OEM to perform a
someone also familiar with welding, cutting, and allied processes. The risk assessment for the higher-level system, and to provide protection
safety risks to personnel and equipment, when unqualified personnel are against hazardous moving parts. Unless the higher-level system is
performing these tests, may be much greater than the benefit of periodic certified when the OEM incorporates Hypertherm products into it, the
inspection and testing. installation also may be subject to approval by local authorities. Seek
advice from legal counsel and local regulatory experts if you are uncertain
Hypertherm recommends that only visual inspection be performed unless
the electrical safety tests are specifically required by local national about compliance.
regulations in the country where the equipment is installed. External interconnecting cables between component parts of the higher
level system must be suitable for contaminants and movement as
Residual current devices (RCDs) required by the final end use installation site. When the external
interconnecting cables are subject to oil, dust, water, or other
In Australia and some other countries, local codes may require the use of contaminants, hard usage ratings may be required.
a Residual Current Devices (RCD) when portable electrical equipment is
When external interconnecting cables are subject to continuous
used in the workplace or at construction sites to protect operators from
movement, constant flexing ratings may be required. It is the
electrical faults in the equipment. RCDs are designed to safely
responsibility of the end-use customer or the OEM to ensure the cables
disconnect the mains electrical supply when an imbalance is detected
are suitable for the application. Since there are differences in the ratings
between the supply and return current (there is a leakage current to
and costs that can be required by local regulations for higher level
earth). RCDs are available with both fixed and adjustable trip currents
systems, it is necessary to verify that any external interconnecting cables
between 6 to 40 milliamperes and a range of trip times up to
are suitable for the end-use installation site.
300 milliseconds selected for the equipment installation, application and
intended use. Where RCDs are used, the trip current and trip time on
RCDs should be selected or adjusted high enough to avoid nuisance
tripping during normal operation of the plasma cutting equipment and
low enough in the extremely unlikely event of an electrical fault in the
equipment to disconnect the supply before the leakage current under a
fault condition can pose a life threatening electrical hazard to operators.

To verify that the RCDs continue to function properly over time, both the
trip current and the trip time should be tested periodically. Portable
electrical equipment and RCDs used in commercial and industrial areas
in Australia and New Zealand are tested to the Australian standard
AS/NZS 3760. When you test the insulation of plasma cutting
equipment to AS/NZS 3760, measure the insulation resistance
according to Appendix B of the standard, at 250 VDC with the power
switch in the ON position to verify proper testing and to avoid the false
failure of the leakage current test. False failures are possible because the
metal oxide varistors (MOVs) and electromagnetic compatibility (EMC)
filters, used to reduce emissions and protect the equipment from power
surges, may conduct up to 10 milliamperes leakage current to earth
under normal conditions.

If you have any questions regarding the application or interpretation of

any IEC standards described here, you are required to consult with an
appropriate legal or other advisor familiar with the International
Electrotechnical standards, and shall not rely on Hypertherm in any
respect regarding the interpretation or application of such standards.

SC-20 Safety and compliance

 Environmental Stewardship

Introduction • In the United States, check all federal, state, and local laws.
• In the European Union, check the EU directives, national, and local
The Hypertherm Environmental Specification requires RoHS, WEEE and laws. For more information, visit www.hypertherm.com/weee.
REACH substance information to be provided by Hypertherm’s • In other countries, check national and local laws.
suppliers.
• Consult with legal or other compliance experts when appropriate.
Product environmental compliance does not address the indoor air
quality or environmental release of fumes by the end user. Any materials
that are cut by the end user are not provided by Hypertherm with the
The WEEE Directive
product. The end user is responsible for the materials being cut as well On January 27, 2003, the European Parliament and the Council of the
as for safety and air quality in the workplace. The end user must be aware European Union authorized Directive 2002/96/EC or WEEE (Waste
of the potential health risks of the fumes released from the materials Electrical and Electronic Equipment).
being cut and comply with all local regulations.
As required by the legislation, any Hypertherm product covered by the
directive and sold in the EU after August 13, 2005 is marked with the
National and local environmental WEEE symbol. This directive encourages and sets specific criteria for
regulations the collection, handling, and recycling of EEE waste. Consumer and
business-to-business wastes are treated differently (all Hypertherm
National and local environmental regulations shall take precedence over products are considered business-to-business). Disposal instructions for
any instructions contained in this manual. the CE versions of Powermax plasma systems can be found at
www.hypertherm.com/weee.
The product shall be imported, installed, operated and disposed of in
accordance with all national and local environmental regulations The URL is printed on the symbol-only warning label for each of these
applicable to the installed site. CE version Powermax series units shipped since 2006. The CSA
versions of Powermax and other products manufactured by Hypertherm
The European Environmental regulations are discussed later in are either out of scope or exempt from WEEE.
The WEEE Directive.

The REACH regulation

The RoHS directive
The REACH regulation (1907/2006), in force since June 1, 2007, has an
Hypertherm is committed to complying with all applicable laws and
impact on chemicals available to the European market. The REACH
regulations, including the European Union Restriction of Hazardous
regulation requirements for component manufacturers states that the
Substances (RoHS) Directive that restricts the use of hazardous component shall not contain more than 0.1% by weight of the
materials in electronics products. Hypertherm exceeds RoHS Directive
Substances of Very High Concern (SVHC).
compliance obligations on a global basis.
Component manufacturers and other downstream users, such as
Hypertherm continues to work toward the reduction of RoHS materials in
Hypertherm, are obligated to obtain assurances from its suppliers that all
our products, which are subject to the RoHS Directive, except where it is
chemicals used in or on Hypertherm products will have a European
widely recognized that there is no feasible alternative. Chemical Agency (ECHA) registration number. To provide chemical
Declarations of RoHS Conformity have been prepared for the current information as required by the REACH regulation, Hypertherm requires
CE versions of Powermax plasma cutting systems manufactured by suppliers to provide REACH declarations and identify any known use of
Hypertherm. There is also a “RoHS mark” on the Powermax CE versions REACH SVHC. Any use of SVHC in amounts exceeding 0.1% w/w of
below the “CE Marking” on the data plate of CE versions of Powermax the parts has been eliminated. The MSDS contains a full disclosure of all
series units shipped since 2006. Parts used in CSA versions of substances in the chemical and can be used to verify REACH SVHC
Powermax and other products manufactured by Hypertherm that are compliance.
either out of scope or exempt from RoHS are continuously being
The lubricants, sealants, coolants, adhesives, solvents, coatings and
converted to RoHS compliance in anticipation of future requirements. other preparations or mixtures used by Hypertherm in, on, for, or with its
shape cutting equipment are used in very small quantities (except the
Proper disposal of Hypertherm products coolant) and are commercially available with multiple sources that can
and will be replaced in the event of a supplier problem associated with
Hypertherm plasma cutting systems, like all electronic products, may REACH Registration or REACH Authorization (SVHCs).
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.

Safety and compliance SC-21

Environmental Stewardship

Proper handling and safe use of chemicals

Chemical Regulations in the USA, Europe, and other locations require
that Material Safety Data Sheets (MSDS) be made available for all
chemicals. The list of chemicals is provided by Hypertherm. The MSDS
are for chemicals provided with the product and other chemicals used in
or on the product. MSDS can be downloaded from the Downloads
Library on the Hypertherm web site at https://www.hypertherm.com.
On the Search screen, insert MSDS in the document title and click on
Search.

In the USA, OSHA does not require Material Safety Data Sheets for
articles such as electrodes, swirl rings, retaining caps, nozzles, shields,
deflectors and other solid parts of the torch.

Hypertherm does not manufacture or provide the materials that are cut
and has no knowledge whether the fumes released from materials that
are cut will pose a physical hazard or health risk. Please consult with your
supplier or other technical advisor if you need guidance concerning the
properties of the material you will cut using a Hypertherm product.

Fumes emission and air quality

Note: The following information on air quality is intended for general
information only and should not be used as a substitute for reviewing and
implementing applicable government regulations or legal standards in
the country where the cutting equipment will be installed and operated.

In the USA, the National Institute for Occupational Safety and Health
(NIOSH) Manual of Analytical Methods (NMAM) is a collection of
methods for sampling and analyzing contaminants in workplace air.
Methods published by others, such as OSHA, MSHA, EPA, ASTM, ISO
or commercial suppliers of sampling and analytical equipment, may have
advantages over NIOSH methods.

For example, ASTM Practice D 4185 is a standard practice for the

collection, dissolution, and determination of trace metals in workplace
atmospheres. The sensitivity, detection limit, and optimum working
concentrations for 23 metals are listed in ASTM D 4185. An industrial
hygienist should be used to determine the optimum sampling protocol,
considering analytical accuracy, cost, and optimum sample number.
Hypertherm uses a third party industrial hygienist to perform and interpret
air quality testing results taken by air sampling equipment positioned at
operator stations in Hypertherm buildings where plasma cutting tables
are installed and operated.

Where applicable, Hypertherm also uses a third party industrial hygienist

to obtain air and water permits.

If you are not fully aware and up to date on all applicable government
regulations and legal standards for the installation site, you should
consult a local expert prior to purchasing, installing, and operating the
equipment.

SC-22 Safety and compliance

 Electromagnetic Compatibility (EMC)

Introduction Methods of reducing emissions

Hypertherm’s CE-marked equipment is built in compliance with standard Mains supply
EN60974-10. The equipment should be installed and used in
accordance with the information below to achieve electromagnetic Cutting equipment must be connected to the mains supply according to
compatibility. the manufacturer’s recommendations. If interference occurs, it may be
necessary to take additional precautions such as filtering of the mains
The limits required by EN60974-10 may not be adequate to completely supply.
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 Consideration should be given to shielding the supply cable of
use other measures to further reduce interference. permanently installed cutting equipment, in metallic conduit or
equivalent. Shielding should be electrically continuous throughout its
This cutting equipment is designed for use only in an industrial length. The shielding should be connected to the cutting mains supply so
environment. that good electrical contact is maintained between the conduit and the
cutting power source enclosure.
Installation and use
Maintenance of cutting equipment
The user is responsible for installing and using the plasma equipment
according to the manufacturer’s instructions. The cutting equipment must be routinely maintained according to the
manufacturer’s recommendations. All access and service doors and
If electromagnetic disturbances are detected then it shall be the
covers should be closed and properly fastened when the cutting
responsibility of the user to resolve the situation with the technical
equipment is in operation. The cutting equipment should not be modified
assistance of the manufacturer. In some cases this remedial action may in any way, except as set forth in and in accordance with the
be as simple as earthing the cutting circuit, see Earthing of the
manufacturer’s written instructions. For example, the spark gaps of arc
workpiece. In other cases, it could involve constructing an
striking and stabilizing devices should be adjusted and maintained
electromagnetic screen enclosing the power source and the work according to the manufacturer’s recommendations.
complete with associated input filters. In all cases, electromagnetic
disturbances must be reduced to the point where they are no longer
troublesome. Cutting cables
The cutting cables should be kept as short as possible and should be
Assessment of area positioned close together, running at or close to the floor level.

Before installing the equipment, the user shall make an assessment of Equipotential bonding
potential electromagnetic problems in the surrounding area. The
following shall be taken into account: Bonding of all metallic components in the cutting installation and
adjacent to it should be considered.
a. Other supply cables, control cables, signaling and telephone
cables; above, below and adjacent to the cutting equipment. However, metallic components bonded to the workpiece will increase
b. Radio and television transmitters and receivers. the risk that the operator could receive a shock by touching these
metallic components and the electrode (nozzle for laser heads) at the
c. Computer and other control equipment. same time.
d. Safety critical equipment, for example guarding of industrial
equipment. The operator should be insulated from all such bonded metallic
components.
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 boundaries of the premises.

Safety and compliance SC-23

Electromagnetic Compatibility (EMC)

Earthing of the 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 steel work, 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 in crease
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 provided in IEC 60974-9, Arc Welding Equipment,
Part 9: 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 considered for special
applications.

SC-24 Safety and compliance

 Warranty

Attention The warranty set forth above is exclusive and is in lieu of all other
warranties, express, implied, statutory, or otherwise with respect to the
Genuine Hypertherm parts are the factory-recommended replacement Products or as to the results which may be obtained therefrom, and all
parts for your Hypertherm system. Any damage or injury caused by the implied warranties or conditions of quality or of merchantability or fitness
use of other than genuine Hypertherm parts may not be covered by the for a particular purpose or against infringement. The foregoing shall
Hypertherm warranty, and will constitute misuse of the Hypertherm constitute the sole and exclusive remedy for any breach by Hypertherm
Product. of its warranty.

You are solely responsible for the safe use of the Product. Hypertherm Distributors/OEMs may offer different or additional warranties, but
does not and cannot make any guarantee or warranty regarding the safe Distributors/OEMs are not authorized to give any additional warranty
use of the product in your environment. protection to you or make any representation to you purporting to be
binding upon Hypertherm.

General
Patent indemnity
Hypertherm Inc. warrants that its Products shall be free from defects in
materials and workmanship for the specific periods of time set forth Except only in cases of products not manufactured by Hypertherm or
herein and as follows: if Hypertherm is notified of a defect (i) with respect manufactured by a person other than Hypertherm not in strict conformity
to the plasma power supply within a period of two (2) years from the date with Hypertherm’s specifications and in cases of designs, processes,
of its delivery to you, with the exception of Powermax brand power formulae, or combinations not developed or purported to be developed
supplies, which shall be within a period of three (3) years from the date of by Hypertherm, Hypertherm will have the right to defend or settle, at its
delivery to you, and (ii) with respect to the torch and leads within a period own expense, any suit or proceeding brought against you alleging that
of one (1) year from its date of delivery to you, with the exception of the the use of the Hypertherm product, alone and not in combination with
HPRXD short torch with integrated lead, which shall be within a period of any other product not supplied by Hypertherm, infringes any patent of
six (6) months from the date of delivery to you, and with respect to torch any third party. You shall notify Hypertherm promptly upon learning of any
lifter assemblies within a period of one (1) year from its date of delivery to action or threatened action in connection with any such alleged
you, and with respect to Automation products one (1) year from its date infringement (and in any event no longer than fourteen (14) days after
of delivery to you, with the exception of the EDGE Connect CNC, learning of any action or threat of action), and Hypertherm’s obligation to
EDGE Connect T CNC, EDGE Connect TC CNC, EDGE Pro CNC, defend shall be conditioned upon Hypertherm’s sole control of, and the
EDGE Pro Ti CNC, MicroEDGE Pro CNC, and ArcGlide THC, which indemnified party’s cooperation and assistance in, the defense of the
shall be within a period of two (2) years from the date of delivery to you, claim.
and (iii) with respect to HyIntensity fiber laser components within a
period of two (2) years from the date of its delivery to you, with the
exception of laser heads and beam delivery cables, which shall be within
Limitation of liability
a period of one (1) year from its date of delivery to you. In no event shall Hypertherm be liable to any person or entity for
This warranty shall not apply to any Powermax brand power supplies that any incidental, consequential direct, indirect, punitive or
have been used with phase converters. In addition, Hypertherm does not exemplary damages (including but not limited to lost profits)
warranty systems that have been damaged as a result of poor power regardless of whether such liability is based on breach of
quality, whether from phase converters or incoming line power. This contract, tort, strict liability, breach of warranty, failure of
warranty shall not apply to any product which has been incorrectly essential purpose, or otherwise, and even if advised of the
installed, modified, or otherwise damaged. possibility of such damages. Hypertherm shall not be liable for
any losses to Distributor based on down time, lost production or
Hypertherm provides repair, replacement or adjustment of the Product as lost profits. It is the intention of the Distributor and Hypertherm
the sole and exclusive remedy, if and only if the warranty set forth herein that this provision be construed by a court as being the
properly is invoked and applies. Hypertherm, at its sole option, shall broadest limitation of liability consistent with applicable law.
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 National and local codes
packed, to Hypertherm’s place of business in Hanover, New Hampshire,
National and local codes governing plumbing and electrical installation
or to an authorized Hypertherm repair facility, all costs, insurance and
shall take precedence over any instructions contained in this manual.
freight pre paid by the customer. Hypertherm shall not be liable for any
In no event shall Hypertherm be liable for injury to persons or property
repairs, replacement, or adjustments of Products covered by this
damage by reason of any code violation or poor work practices.
warranty, except those made pursuant to this paragraph and with
Hypertherm’s prior written consent.

Safety and compliance SC-25

Warranty

Liability cap
In no event shall Hypertherm’s liability, if any, 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 (whether in court,
arbitration, regulatory proceeding or otherwise) 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.

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. Within thirty (30) days before any
such transfer occurs, you agree to notify in writing Hypertherm, which
reserves the right of approval. Should you fail timely to notify Hypertherm
and seek its approval as set forth herein, the Warranty set forth herein
shall be null and void and you will have no further recourse against
Hypertherm under the Warranty or otherwise.

Waterjet product warranty coverage

Product Parts coverage
HyPrecision pumps 27 months from the ship date, or 24 months
from the date of proven installation, or
4,000 hours, whichever occurs first

PowerDredge 15 months from the ship date or 12 months

abrasive removal from the date of proven installation,
system whichever occurs first

EcoSift abrasive 15 months from the ship date or 12 months

recycling system from the date of proven installation,
whichever occurs first

Abrasive metering 15 months from the ship date or 12 months

devices from the date of proven installation,
whichever occurs first

On/off valve air 15 months from the ship date or 12 months

actuators from the date of proven installation,
whichever occurs first

Diamond orifices 600 hours of use with the use of a thimble

filter and compliance with Hypertherm’s
water quality requirements

Consumable parts are not covered by this warranty. Consumable parts

include, but are not limited to, high-pressure water seals, check valves,
cylinders, bleed-down valves, low-pressure seals, high-pressure tubing,
low- and high-pressure water filters and abrasive collection bags. All
third-party pumps, pump accessories, hoppers, hopper accessories,
dryer boxes, dryer box accessories and plumbing accessories are
covered by the respective manufacturers’ warranties and not covered by
this warranty.

SC-26 Safety and compliance

 Overview

The Hypertherm Sensor THC Plasma Lifter accessory supplies lifter mechanics that you combine
with a motor and drive for torch height control.

The Sensor THC Plasma Lifter is compatible with the Phoenix® Sensor THC software features that
run on EDGE® Pro, MicroEDGE® Pro, EDGE Connect, EDGE Connect T, and EDGE Connect TC
computer numerical controllers (CNCs).

Sensor THC Plasma Lifter Installation Manual 808970 27

 1 Overview

28 808970 Installation Manual Sensor THC Plasma Lifter

 Specifications and parts

Upon receipt

 Make sure that you received all items on your order in good condition. Contact your
distributor if any parts are damaged or missing.
 Inspect the items for damage that may have occurred during shipment. If you find evidence
of damage, see Claims, below. All communications regarding this equipment must include
the model number and the serial number.
 Before you set up this equipment, read the safety information included with your equipment.
Failure to follow safety instructions can result in personal injury or in damage to equipment.

Claims
 Claims for damage during shipment – If your equipment was damaged during shipment, file
a claim with the carrier. You can contact Hypertherm for a copy of the bill of lading. If you
need additional assistance, call the nearest Hypertherm office listed in the front of this
manual.
 Claims for defective or missing merchandise – If any component is missing or defective,
contact your Hypertherm distributor. If you need additional assistance, call the nearest
Hypertherm office listed in the front of this manual.

Sensor THC Plasma Lifter Installation Manual 808970 29

 2 Specifications and parts

Sensor THC Plasma Lifter

The Hypertherm Sensor THC Plasma Lifter has the following specifications.

Table 1 – Specifications

Upper limit switch (Home) +24 VDC

Lower limit switch +24 VDC

Maximum Z-axis speed 15,200 mm/min (600 in/min)

(recommended maximum)

Maximum Z-axis stroke 239 mm (9.40 in.)

Lead screw pitch 5.0 mm/revolution (0.20 in/revolution)

Breakaway switch +24 VDC

Lifter capacity 11.3 kg (25.0 lb)

(recommended maximum)

Motor mount 60 mm (2.36 in.) flange with a 70 mm (2.756 in.) bolt circle diameter
Note: Hypertherm does not offer a motor for the Sensor THC Plasma
Lifter. See Figure 2 on page 34 for motor mount specifications.

 For signal and lifter interface specifications, see Table 7 on page 48.

The following Sensor THC Plasma Lifter assemblies are available from Hypertherm.

Table 2 – Assemblies

Part number Torch mounting block Magnetic breakaway

090187 Not included (lifter only) Not included (lifter only)

090188 Not included 4.5 kg (10 lb)

090189 Not included 11 kg (25 lb)

090190 35 mm (1-3/8 in.) 4.5 kg (10 lb)

090191 35 mm (1-3/8 in.) 11 kg (25 lb)

090192 44 mm (1-3/4 in.) 4.5 kg (10 lb)

090193 44 mm (1-3/4 in.) 11 kg (25 lb)

090194 51 mm (2 in.) 4.5 kg (10 lb)

090195 51 mm (2 in.) 11 kg (25 lb)

090197 57 mm (2-1/4 in.) 11 kg (25 lb)

30 808970 Installation Manual Sensor THC Plasma Lifter

 Specifications and parts 2
Figure 1 – Lifter dimensions (090195 model shown)

107.93 mm
(4.25 in.)

Laser pointer
offset

66.04 mm
78.40 mm (2.60 in.) 526.50 mm
(3.09 in.) 152.00 mm (20.73 in.)
(5.98 in.)

60.60 mm
(2.38 in.)

Optional

11.27 kg
(24.85 lb)

(without torch mounting block or

breakaway)

149.10 mm (5.87 in.) 186.70 mm (7.35 in.)

Sensor THC Plasma Lifter Installation Manual 808970 31

 2 Specifications and parts

Data plate
The data plate shows the lifter’s part number and serial number. If you contact Hypertherm Technical
Service, they ask for this information.

090###

2 ##########

1 Part number
2 Serial number (YYMM######, where YY is the year
and MM is the month of manufacture)
3 Serial number bar code

32 808970 Installation Manual Sensor THC Plasma Lifter

 Specifications and parts 2

Lifter interface cable

The lifter interface cable connects the lifter interface board and the lifter drive. See Table 7 on
page 48 for pinout information.

Table 3 – Lifter interface cables

Part number Description Quantity

223472 8 m (25 ft) 1

223473 15 m (50 ft) 1

223614 30 m (100 ft) 1

Motors and drives

Hypertherm does not offer a drive, motor, brake, or motor cables for the lifter.

 We strongly recommend a motor and brake combination.

To select a compatible motor, see Figure 2 on page 34 for the motor mount specifications. Select a
drive that is compatible with your motor.

Sensor THC Plasma Lifter Installation Manual 808970 33

 2 Specifications and parts

Figure 2 – Motor mount specifications

1 2

5 4

1 Motor mount flange: 60 mm (2.362 in.) square 4 Coupling maximum length: 45 mm (1.772 in.)
2 Screws: four M4 X 0.70 mm screws on 70 mm 5 Linear slide shaft diameter: 6 mm (0.236 in.)
(2.756 in.) bolt circle diameter
6 Linear slide shaft height: 10.6 mm (0.416 in.)
3 Coupling maximum diameter: 41 mm (1.615 in.)

34 808970 Installation Manual Sensor THC Plasma Lifter

 Specifications and parts 2

Motor couplings
Couplings join the linear slide shaft and the motor shaft. Hypertherm supplies 2 flexible couplings
(031165 and 031164). If you supply your own coupling, see Figure 2 for coupling specifications.

 For a strong connection, make sure that when you insert the linear slide
shaft and the motor shaft into the coupling, each of them reaches at least
past the coupling screws.

Figure 3 – Hypertherm couplings

25 mm (0.98 in.)

031165 031164

11 mm (0.43 in.) 14 mm (0.55 in.)

Table 4 – Hypertherm couplings

Part number Description

031165 25 mm (0.98 in.) flexible coupling with 11 mm (0.43 in.) motor shaft diameter

031164 25 mm (0.98 in.) flexible coupling with 14 mm (0.55 in.) motor shaft diameter

Coupling screws hex head size is 2.50 mm (0.098 in.), with a torque rating of 9.2 kg∙cm (8.0 in∙lb).

Sensor THC Plasma Lifter Installation Manual 808970 35

 2 Specifications and parts

Replacement parts

Lifter parts

2
1

3
3

3 5
6

36 808970 Installation Manual Sensor THC Plasma Lifter

 Specifications and parts 2
Table 5 – Replacement lifter parts

Item Kit number Description Quantity

1 428453 Laser pointer 1

2 428452 Interface board 1

3 428651 Exterior hardware: 30

• Ground hex head bolt (1) and washers (2)
• Lifter screws (18)
• Interface cable ground screw (1)
• Interface cable connector screws (4)
• Breakaway cable track and bracket screws (4)

4 428449 Side shields 2

5 428451 Slide 1

6 428450 Upper/lower limit switch 1

7 428612 Sealing strip 1

8 127505 Sealing strip hardware 1

9 428611 Grease gun 1

Sensor THC Plasma Lifter Installation Manual 808970 37

 2 Specifications and parts

Breakaway parts
1 3

2 4
6

Table 6 – Breakaway replacement parts

Item Kit number Description Quantity

1 428606 11.34 kgf (25 lbf) magnetic breakaway 1

2 104473 35.7 kgf (78.7 lbf) replacement magnet for 1

11.34 kgf (25 lbf) magnetic breakaway

2 428610 35.7 kgf (78.7 lbf) replacement magnets for 4

11.34 kgf (25 lbf) magnetic breakaway (set of 4)

3 428607 4.54 kgf (10 lbf) magnetic breakaway 1

4 104513 20 kgf (45 lbf) replacement magnet for 1

4.54 kgf (10 lbf) magnetic breakaway

4 428609 20 kgf (45 lbf) replacement magnets for 4

4.54 kgf (10 lbf) magnetic breakaway (set of 4)

5 428448 Breakaway cable and sensor 1

6 428608 Magnetic breakaway retaining tether 1

Wiring diagram

See Figure 4.

38 808970 Installation Manual Sensor THC Plasma Lifter

 Specifications and parts 2
Figure 4

223472 7.6M (25FT)

223473 15.2M (50FT)
223614 30.5M (100FT)
TO/FROM I/O

PCB LOCATED INSIDE LIFTER HOUSING

WIRE J2
PAIR CPC
CONNECT TO I/O
COLORS POSITION LIFTER DESTINATION
+24VDC POWER TO LIFTER PCB RED 1 +24VDC
OUTPUT LOW = LASER POINTER ON WHT 2 LASER POINTER MODULE J2

24VDC-5VDC
REGULATOR
COMMON WHT 3 COMMON
POSITIVE LOGIC INPUT ORG 4 BREAKAWAY SIGNAL
ZERO VDC = BREAKAWAY (COLLISION) PNP TYPE PROXIMITY SWITCH 428452
+24VDC = NORMAL INTERFACE PCB KIT
COMMON WHT 5 COMMON J3 J4
POSITIVE LOGIC INPUT BLK 6 UPPER LIMIT SIGNAL J1
1 1 1
ZERO VDC = NORMAL PNP TYPE PROXIMITY SWITCH
+24VDC = LIMIT

COMMON WHT 7 COMMON

POSITIVE LOGIC INPUT BRN 8 LOWER LIMIT SIGNAL
ZERO VDC = NORMAL PNP TYPE PROXIMITY SWITCH
+24VDC = LIMIT 1 1 1

9 NO CONNECT
DRAIN WIRE TO CHASSIS SHIELD DRAIN RING TERMINAL TO LIFTER SCREW

NOTES:

BRN +24VDC

BRN +24VDC

BRN +24VDC
BLU COMMON

BLU COMMON

BLU COMMON
BLK SIGNAL

BLK SIGNAL

BLK SIGNAL
RED +3.6 TO 5VDC
1. PINS 3, 5, AND 7 MUST CONNECT TO I/O COMMON

BLK COMMON
2. 24VDC POWER SUPPLY COMMON MUST CONNECT TO EITHER PIN 3, 5, OR 7

MODULE
LASER
UPPER
LIMIT
SWITCH
428453
LASER POINTER KIT

LOWER
LIMIT
SWITCH

428448
BREAKAWAY 428450
SWITCH KIT UPPER/LOWER LIMIT SWITCH KIT
KIT INCLUDES BRACKET

SENSOR THC LIFTER

WITHOUT MOTOR

ELEC SCHEM: S-THC LIFTER

013399 SHEET 1 OF 1 01

Sensor THC Plasma Lifter Installation Manual 808970 39

 2 Specifications and parts

40 808970 Installation Manual Sensor THC Plasma Lifter

 Install

Install the motor

 Hypertherm does not offer a motor for the lifter. For motor mount
specifications, see Figure 2 on page 34.

1. Loosen the 2 screws on the front of the lifter

interface enclosure.
2
2. Move the front panel up and off the 2 screws
and the studs on the sides of the interface
enclosure.

3. Remove the 2 screws from the motor

coupling cover.

4. Remove the motor coupling cover. 4

Sensor THC Plasma Lifter Installation Manual 808970 41

 3 Install

5. Put a coupling on the end of the motor shaft.

 Hypertherm supplies 2 couplings. See Figure 3
on page 35 for more information.
7
 If you supply your own coupling, see Figure 2 on
page 34 for coupling specifications.

6. Put the motor and coupling on the linear slide shaft. 6

 For a strong connection, make sure that when

you connect the linear slide shaft and the motor
shaft with the coupling, each of them reaches
at least past the coupling screws.

7. Rotate the motor as necessary to keep the motor

cables away from the gantry and the connector for
the lifter interface cable.
 If necessary, move the connector for the lifter
interface cable to the side of the interface
enclosure. See Move the connector for the lifter
interface cable (optional) on page 43 for more
information. 8

8. Make sure that you can access the 2 hex head screws on the coupling.

9. Use four M4 X 0.70 screws to attach the motor to the motor flange.

10. Tighten the 2 screws on the coupling to a torque of 9.2 kg∙cm (8.0 in∙lb).

11. Install the motor coupling cover.

12. Install the front panel of the interface enclosure.

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 Install 3

Move the connector for the lifter interface cable (optional)

The lifter comes with the connector for the lifter interface cable on the top of the interface enclosure.
You can move it to the side of the interface enclosure.

 The connector and the lifter interface board are one piece.

1. Remove the front panel of the interface

enclosure. For more information, see step 1
on page 41.

2. Disconnect the 3 wire harnesses from the

lifter interface board.

3. Remove the 4 screws that attach the

connector to the interface enclosure.

4. Remove the connector from the interface

enclosure.

5. Remove the cover of the connector hole on

the side of the interface enclosure.

6. Install the cover for the hole on the top of the interface enclosure.

 Make sure that the flat side of the cover is on the underside of the
interface enclosure.

5 6
Flat side

Sensor THC Plasma Lifter Installation Manual 808970 43

 3 Install

7. Install the connector in the hole on the side of the interface enclosure.

 Make sure that the connectors for the 3 wire harnesses point toward the
front of the lifter enclosure.

8. Connect the 3 wire harnesses to the lifter interface board.

9. Install the front panel of the interface enclosure.

44 808970 Installation Manual Sensor THC Plasma Lifter

 Install 3

Install the lifter

1. Remove the 4 screws on each side of the lifter slide.

 Slide the torch mounting plate up or down as necessary to access all

4 screws on each side.

2. Remove the 2 side shields.

3. Remove the 2 side panels.

3

2
1

4. Loosely tighten a minimum of four 1/4-in. or M6 socket head cap screws

to attach the lifter to the gantry.
 Attach the screws in a diagonal pattern. See the figure at right.
 Slide the torch mounting plate up or down as necessary to access all 3 1
the screw holes. If the motor is already installed on the lifter, release
the brake or remove the motor so you can move the torch mounting
plate.

5. Make sure that the lifter is high enough that the torch does not touch the
table, but low enough that the torch can touch the workpiece. The
bottom of the lifter must be within 20 mm (8 in.) of the thinnest
workpiece.

6. Use the vertical side of the lifter to level the lifter.

7. Tighten the screws in a diagonal pattern to a torque of 9.2 kg∙cm

(8.0 in∙lb).
2 4
8. Install the 2 side panels and 2 side shields.

Sensor THC Plasma Lifter Installation Manual 808970 45

 3 Install

Ground the lifter

 The lifter must be grounded correctly to do an accurate initial height

sense (IHS).

1. Remove the M6 X 12 mm hex head

bolt and 2 washers of the grounding
assembly from the bottom of the
enclosure.

2. Put a ground wire terminal on the hex

head bolt between the 2 washers.

3. Loosely tighten the hex head bolt with

the washers and terminal into the
bottom of the enclosure.

4. Make sure that the terminal is in

contact with both washers and the hex
head bolt.

5. Tighten the hex head bolt to a torque of

51.8 kg∙cm (45.0 in∙lb).

6. Connect the other end of the ground

wire to a terminal on the table ground
bus bar on the cutting machine.

7. Make sure that the ground wire is not in the path of the lifter mechanics.

Install the THC drive

Install the THC drive into the table’s drive enclosure.

Hypertherm does not offer a drive for the lifter. Select a drive that is compatible with your motor.

Install voltage divider board/VDC3

A VDC3 board (141201) supplies the necessary arc voltage feedback from the plasma power
supply to the CNC. You install the VDC3 board inside the plasma power supply.
 If you have an EDGE Connect/T/TC CNC with an HPRXD plasma power supply, see the
Field Service Bulletin HPR130XD®, HPR260XD®, and HPR400XD® EtherCAT® and
VDC3 Board Installation (809470) for instructions.

46 808970 Installation Manual Sensor THC Plasma Lifter

 Connect

Connect the lifter to the THC drive

1. Connect the motor and encoder cables from the lifter to the THC drive.

2. Connect the brake, and wire it to energize and de-energize as follows:

 Energize when the CNC enables the THC drive
 De-energize when the CNC disables the THC drive

Sensor THC Plasma Lifter Installation Manual 808970 47

 4 Connect

3. Connect the female end of the lifter interface cable to the

male connector on the lifter interface enclosure.

 In the figure at right the connector for the lifter

interface cable is on top of the enclosure. These
instructions are the same if you moved the
connector to the side of the enclosure.

4. To ground the interface cable, remove the screw and

2 washers of the cable grounding assembly from the top
of the enclosure.

5. Put the ground wire terminal on the screw between the

2 washers.

6. Loosely tighten the screw with the washers and terminal

into the top of the enclosure.

7. Make sure that the terminal is in contact with both

washers and the screw.

8. Tighten the screw to a torque of 17.3 kg∙cm (15.0 in∙lb).

9. Connect the loose wires on the other end of the lifter

interface cable to the I/O on your drive. See Table 7 for
the pinouts.

Table 7 – Pinouts for the interface cable to the drive

Pin no. Color Signal

1 Red Power +24 VDC (customer supplied)

2 White Laser pointer enable (active low)

3 White 24 VDC ground (customer supplied)

4 Orange Torch collision input (active high)

5 White Not connected

6 Black Upper limit switch input (active high)

7 White Not connected

8 Brown Lower limit switch input (active high)

9 Not connected

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 Connect 4

Connect the THC drive to the network

Connect the THC drive to the network.

Hypertherm does not offer a drive for the lifter. Select a drive that is compatible with your motor.

Connect the VDC3 board

If you have an EDGE Connect/T/TC CNC with an HPRXD plasma power supply, see the Field
Service Bulletin HPR130XD®, HPR260XD®, and HPR400XD® EtherCAT® and VDC3 Board
Installation (809470) for instructions.

Sensor THC Plasma Lifter Installation Manual 808970 49

 4 Connect

50 808970 Installation Manual Sensor THC Plasma Lifter