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SERIES

G3

_

+

405 0

5060

AC

7080

V

BAR

60

PSI

AMPS

30

40

100

80

60

Plasma ArcCutting & Gouging System

Operator Manual804480 Revision 4

powermax1650


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Operator Manual

(P/N 804480)

Revision 4 November 2013

Hypertherm, Inc.Hanover, NH USA

www.hypertherm.com

Copyright 2013 Hypertherm, Inc.

All Rights Reserved

Hypertherm and powermax are trademarks of Hypertherm, Inc.

and may be registered in the United States and/or other countries.


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7/1/09

Hypertherm, Inc.

Etna Road, P.O. Box 5010Hanover, NH 03755 USA603-643-3441 Tel (Main Office)603-643-5352 Fax (All Departments)[email protected] (Main Office Email)800-643-9878 Tel (Technical Service)

[email protected] (Technical Service Email)800-737-2978 Tel (Customer Service)[email protected] (Customer Service Email)

Hypertherm Automation

5 Technology Drive, Suite 300West Lebanon, NH 03784 USA603-298-7970 Tel603-298-7977 Fax

Hypertherm Plasmatechnik GmbH

Technologiepark HanauRodenbacher Chaussee 6D-63457 Hanau-Wolfgang, Deutschland49 6181 58 2100 Tel49 6181 58 2134 Fax

49 6181 58 2123 (Technical Service)

Hypertherm (S) Pte Ltd.

82 Genting LaneMedia CentreAnnexe Block #A01-01Singapore 349567, Republic of Singapore65 6841 2489 Tel65 6841 2490 Fax65 6841 2489 (Technical Service)

Hypertherm (Shanghai) Trading Co., Ltd.

Unit A, 5th Floor, Careri Building432 West Huai Hai Road

Shanghai, 200052PR China86-21 5258 3330/1 Tel86-21 5258 3332 Fax

Hypertherm Europe B.V.

Vaartveld 94704 SERoosendaal, Nederland31 165 596907 Tel31 165 596901 Fax31 165 596908 Tel (Marketing)

31 165 596900 Tel (Technical Service)

00 800 4973 7843 Tel (Technical Service)

Hypertherm Japan Ltd.

801 Samty Will Building2-40 Miyahara 1-Chome,Yodogawa-ku, Osaka532-0003, Japan81 6 6170 2020 Tel

81 6 6170 2015 Fax

Hypertherm Brasil Ltda.

Avenida Doutor Renato deAndrade Maia 350

Parque Renato MaiaCEP 07114-000Guarulhos, SP Brasil55 11 2409 2636 Tel55 11 2408 0462 Fax

Hypertherm Mxico, S.A. de C.V.

Avenida Toluca No. 444, Anexo 1,Colonia Olivar de los PadresDelegacin lvaro ObregnMxico, D.F. C.P. 0178052 55 5681 8109 Tel52 55 5683 2127 Fax


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ELECTROMAGNETIC COMPATIBILITY (EMC)

4-08

Hypertherm i

EMC Introduction

Hypertherms CE-marked equipment is built incompliance with standard EN60974-10. Theequipment should be installed and used in

accordance with the information below toachieve electromagnetic compatibility.

The limits required by EN60974-10 may notbe adequate to completely eliminate interfer-ence when the affected equipment is in closeproximity or has a high degree of sensitivity.In such cases it may be necessary to use othermeasures to further reduce interference.

This cutting equipment is designed for use

only in an industrial environment.

Installation and use

The user is responsible for installing andusing the plasma equipment according to themanufacturers instructions. If electromagneticdisturbances are detected then it shall be theresponsibility of the user to resolve thesituation with the technical assistance of themanufacturer. In some cases this remedialaction may be as simple as earthing thecutting circuit, see Earthing of Workpiece.In other cas es it could involve constructing anelectromagnetic screen enclosing the powersource and the work complete with associatedinput filters. In all cases electromagneticdisturbances must be reduced to the pointwhere they are no longer troublesome.

Assessment of area

Before installing the equipment the user shallmake an assessment of potential electro-magnetic problems in the surrounding area.The following shall be taken into account:

a. Other supply cables, control cables,signalling and telephone cables; above,below and adjacent to the cutting equipment.

b. Radio and television transmitters andreceivers.

c. Computer and other control equipment.

d. Safety critical equipment, for example

guarding of industrial equipment.e. Health of the people around, for example the

use of pacemakers and hearing aids.

f. Equipment used for calibration ormeasurement.

g. Immunity of other equipment in theenvironment. User shall ensure that otherequipment being used in the environment iscompatible. This may require additionalprotection measures.

h. Time of day that cutting or other activitiesare to be carried out.

The size of the surrounding area to be con-sidered will depend on the structure of thebuilding and other activities that are takingplace. The surrounding area may extendbeyond the boundaries of the premises.

Methods of reducingemissions

Mains supply

Cutting equipment must be connected to themains supply according to the manufacturersrecommendations. If interference occurs, it maybe necessary to take additional precautionssuch as filtering of the mains supply.Consideration should be given to shielding the

supply cable of permanently installed cuttingequipment, in metallic conduit or equivalent.Shielding should be electrically continuousthroughout its length. The shielding shouldbe connected to the cutting mains supply sothat good electrical contact is maintainedbetween the conduit and the cutting powersource enclosure.


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ELECTROMAGNETIC COMPATIBILITY (EMC)

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ii Hypertherm

Maintenance of cutting equipment

The cutting equipment must be routinelymaintained according to the manufacturersrecommendations. All access and service doorsand covers should be closed and properlyfastened when the cutting equipment is inoperation. The cutting equipment should not bemodified in any way except for those chang esand adjustments covered in the manufacturersinstructions. In particular, the spark gaps of arcstriking and stabilizing devices should beadjusted and maintained according to themanufacturers recommendations.

Cutting cables

The cutting cables should be kept as shortas possible and should be positioned closetogether, running at or close to the floor level.

Equipotential bonding

Bonding of all metallic components in thecutting installation and adjacent to it should beconsidered. However, metallic componentsbonded to the workpiece will increase the risk

that the operator could receive a shock bytouching these metallic components and theelectrode (nozzle for laser heads) at the sametime. The operator should be insulated from allsuch bonded metallic components.

Earthing of workpiece

Where the workpiece is not bonded to earthfor electrical safety, nor connected to earthbecause of its size and position, for example,ships hull or building steelwork, a connectionbonding the workpiece to earth may reduceemissions in some, but not all instances.Care should be taken to prevent the earthingof the workpiece increasing the risk of injury tousers, or damage to other electrical equipment.Where necessary, the connection of the

workpiece to earth should be made by a directconnection to the workpiece, but in somecountries where direct connection is notpermitted, the bonding should be achieved bysuitable capacitances selected according to

national regulations.

Note: the cutting circuit may or may not beearthed for safety reasons. Changing theearthing arrangements should only beauthorized by a person who is competent toassess whether the changes will increase therisk of injury, for example, by allowing parallelcutting current return paths which may damagethe earth circuits of other equipment. Furtherguidance is given in IEC/ TS 62081 ArcWelding Equipment Installation and Use.

Screening and shielding

Selective screening and shielding of othercables and equipment in the surrounding areamay alleviate problems of interference.Screening of the entire plasma cuttinginstallation may be considered for specialapplications.


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WARRANTY

Hypertherm iii

4-08

AttentionGenuine Hypertherm parts are the factory-recommended replacement parts for yourHypertherm system. Any damage caused by theuse of other than genuine Hypertherm parts may

not be covered by the Hypertherm warranty.

You are responsible for the safe use of theProduct. Hypertherm does not and cannot makeany guarantee or warranty regarding the safeuse of the Product in your environment.

GeneralHypertherm, Inc. warrants that its Products shallbe free from defects in materials and workman-

ship, if Hypertherm is notified of a defect (i) withrespect to the power supply within a period oftwo (2) years from the date of its delivery to you,with the exception of Powermax brand powersupplies, which shall be within a period of three(3) years from the date of delivery to you, and(ii) with respect to the torch and leads within aperiod of one (1) year from its date of delivery toyou, and with respect to torch lifter assemblieswithin a period of one (1) year from its date ofdelivery to you, and with respect to laser heads

within a period of one (1) year from its date ofdelivery to you. This warranty shall not apply toany Powermax brand power supplies that havebeen used with phase converters. In addition,Hypertherm does not warranty systems thathave been damaged as a result of poor powerquality, whether from phase converters orincoming line power. This warranty shall notapply to any Product which has been incorrectlyinstalled, modified, or otherwise damaged.

Hypertherm, at its sole option, shall repair,replace, or adjust, free of charge, any defectiveProducts covered by this warranty which shallbe returned with Hypertherms priorauthorization (which shall not be unreasonablywithheld), properly packed, to Hyperthermsplace of business in Hanover, New Hampshire,or to an authorized Hypertherm repair facility, all

costs, insurance and freight prepaid.Hypertherm shall not be liable for any repairs,replacement, or adjustments of Productscovered by this warranty, except those madepursuant to this paragraph or with Hypertherms

prior written consent. The warranty above isexclusive and is in lieu of all other

warranties, express, implied, statutory, or

otherwise with respect to the Products or

as to the results which may be obtained

therefrom, and all implied warranties or

conditions of quality or of merchantability

or fitness for a particular purpose or

against infringement. The foregoing shall

constitute the sole and exclusive remedy

for any breach by Hypertherm of its

warranty. Distributors/OEMs may offer differentor additional warranties, but Distributors/OEMsare not authorized to give any additionalwarranty protection to you or make anyrepresentation to you purporting to be bindingupon Hypertherm.

Certification test marksCertified products are identified by one or morecertification test marks from accredited testinglaboratories. The certification test marks arelocated on or near the data plate. Eachcertification test mark means that the productand its safety-critical components conform tothe relevant national safety standards asreviewed by that testing laboratory. Hyperthermplaces a certification test mark on its productsonly after that product is manufactured withsafety-critical components that have beenauthorized by the accredited testing laboratory.

Once the product has left the Hyperthermfactory, the certification test marks areinvalidated if any of the following occurs:

The product is significantly modifiedin a manner that creates a hazard ornon-conformance.

Safety-critical components are replaced withunauthorized spare parts.


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iv Hypertherm

Any unauthorized assembly or accessory thatuses or generates a hazardous voltage isadded.

There is any tampering with a safety circuit orother feature that is designed into the product

as part of the certification.CE marking constitutes a manufacturersdeclaration of conformity to applicable Europeandirectives and standards. Only those versions ofHypertherm products with a CE Marking locatedon or near the data plate have been tested forcompliance with the European Low VoltageDirective and the European EMC Directive.EMC filters needed to comply with the EuropeanEMC Directive are incorporated within versionsof the power supply with a CE Marking.

Differences in National Standards

Differences in standards include, but are notlimited to:

Voltages

Plug and cord ratings

Language requirements

Electromagnetic compatibility requirements

These differences in national standards maymake it impossible or impractical for allcertification test marks to be placed on thesame version of a product. For example, theCSA versions of Hypertherms products do notcomply with European EMC requirements andthey do not have a CE marking on the dataplate.

Countries that require CE marking or havecompulsory EMC regulations must use CEversions of Hypertherm products with the CE

marking on the data plate. These include:

Australia

New Zealand

Countries in the European Union

Russia

It is important that the product and itscertification test mark be suitable for the end-use installation site. When Hyperthermproducts are shipped to one country for exportto another country, the product must be

configured and certified properly for the end-use site.

Higher-level systemsWhen a system integrator adds additionalequipment; such as cutting tables, motor drives,motion controllers or robots; to a Hyperthermplasma cutting system, the combined systemmay be considered a higher-level system. Ahigher-level system with hazardous moving partsmay constitute industrial machinery or robotic

equipment, in which case the OEM or end-usecustomer may be subject to additionalregulations and standards than those relevant tothe plasma cutting system as manufactured byHypertherm.

It is the responsibility of the end-use customerand the OEM to perform a risk assessment forthe higher-level system and to provideprotection against hazardous moving parts.Unless the higher-level system is certified when

the OEM incorporates Hypertherm productsinto it, the installation also may be subject toapproval by local authorities. Seek advice fromlegal counsel and local regulatory experts ifuncertain about compliance.

External interconnecting cables betweencomponent parts of the higher level systemmust be suitable for contaminants andmovement as required by the final end-useinstallation site. When the external inter-

connecting cables are subject to oil, dust, orwater contaminants, hard usage ratings may berequired. When external interconnecting cablesare subject to continuous movement, constantflexing ratings may be required. It is theresponsibility of the end-use customer or theOEM to ensure the cables are suitable for theapplication. Since there are differences in the


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WARRANTY

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Hypertherm v

ratings and costs that can be required bylocal regulations for higher-level systems,it is necessary to verify that any externalinterconnecting cables are suitable for theend-use installation site.

Patent indemnityExcept only in cases of products notmanufactured by Hypertherm or manufacturedby a person other than Hypertherm not in strictconformity with Hypertherms specifications andin cases of designs, processes, formulae, orcombinations not developed or purported to bedeveloped by Hypertherm, Hypertherm willdefend or settle, at its own expense, any suit orproceeding brought against you alleging that the

use of the Hypertherm product, alone and not incombination with any other product not suppliedby Hypertherm, infringes any patent of any thirdparty. You shall notify Hypertherm promptly uponlearning of any action or threatened action inconnection with any such alleged infringement,and Hypertherms obligation to indemnify shallbe conditioned upon Hypertherms sole controlof, and the indemnified partys cooperation andassistance in, the defense of the claim.

Limitation of liabilityIn no event shall Hypertherm be liable to

any person or entity for any incidental,

consequential, indirect, or punitive damages

(including but not limited to lost profits)

regardless of whether such liability is based

on breach of contract, tort, strict liability,

breach of warranties, failure of essential

purpose or otherwise and even if advised

of the possibility of such damages.

Liability capIn no event shall Hypertherms liability,

whether such liability is based on breach

of contract, tort, strict liability, breach of

warranties, failure of essential purpose or

otherwise, for any claim action suit or

proceeding arising out of or relating to the

use of the Products exceed in the aggregate

the amount paid for the Products that gave

rise to such claim.

Insurance

At all times you will have and maintain insurancein such quantities and types, and with coveragesufficient and appropriate to defend and to holdHypertherm harmless in the event of any causeof action arising from the use of the Products.

National and Local codesNational and Local codes governing plumbingand electrical installation shall take precedentover any instructions contained in this manual.In no event shall Hypertherm be liable for injury

to persons or property damage by reason ofany code violation or poor work practices.

Transfer of rightsYou may transfer any remaining rights you mayhave hereunder only in connection with the saleof all or substantially all of your assets or capitalstock to a successor in interest who agrees tobe bound by all of the terms and conditions ofthis Warranty.

Proper disposal ofHypertherm products

Hypertherm plasma cutting systems, like allelectronic products, may contain materials orcomponents, such as printed circuit boards, thatcannot be discarded with ordinary waste. It isyour responsibility to dispose of any Hyperthermproduct or component part in an environmentallyacceptable manner according to national andlocal codes.

In the United States, check all federal, state,and local laws.

In the European Union, check the EUdirectives, national, and local laws. For moreinformation, visit www.hypertherm.com/weee.

In other countries, check national and locallaws.


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WARRANTY

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TABLE OF CONTENTS

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powermax1650Operator Manual vii

Electromagnetic compatibility................................................................................................................................iWarranty....................................................................................................................................................................iii

Section 1 Safety

Recognize safety information ...........................................................................................................................1-2

Follow safety instructions..................................................................................................................................1-2Cutting can cause fire or explosion ................................................................................................................1-2Electric shock can kill.........................................................................................................................................1-3Static electricity can damage circuit boards ................................................................................................1-3Toxic fumes can cause injury or death............................................................................................................1-4A plasma arc can cause injury and burns......................................................................................................1-5Arc rays can burn eyes and skin......................................................................................................................1-5Grounding safety.................................................................................................................................................1-6Compressed gas equipment safety................................................................................................................1-6Gas cylinders can explode if damaged..........................................................................................................1-6Noise can damage hearing ...............................................................................................................................1-7

Pacemaker and hearing aid operation............................................................................................................1-7A plasma arc can damage frozen pipes.........................................................................................................1-7Additional safety information ............................................................................................................................1-8Warning labels.....................................................................................................................................................1-9Dust collection information.............................................................................................................................1-11

Section 1a Scurit

Identifier les consignes de scurit..............................................................................................................1a-2Suivre les instructions de scurit................................................................................................................1a-2Le coupage peut provoquer un incendie ou une explosion....................................................................1a-2Les chocs lectriques peuvent tre fatals ..................................................................................................1a-3Llectricit statique peut endommager les cartes de circuits imprims.............................................1a-3Les vapeurs toxiques peuvent provoquer des blessures ou la mort.....................................................1a-4Larc plasma peut provoquer des blessures ou des brlures.................................................................1a-5Les rayons de larc peuvent brler les yeux et la peau.............................................................................1a-5Mise la masse et la terre...........................................................................................................................1a-6Scurit des bouteilles de gaz comprim...................................................................................................1a-6Les bouteilles de gaz comprim peuvent exploser en cas de dommages..........................................1a-6Le bruit peut provoquer des problmes auditifs........................................................................................1a-7Pacemakers et prothses auditives ..............................................................................................................1a-7Un arc plasma peut endommager les tuyaux gels...................................................................................1a-7

Symboles et marquage....................................................................................................................................1a-8tiquette de scurit........................................................................................................................................1a-9Information sur le dpoussirage ...............................................................................................................1a-11

Section 1b Seguridad

Reconocimiento de informacin de seguridad..........................................................................................1b-2Siga las instrucciones de seguridad............................................................................................................1b-2Los cortes pueden provocar incendios o explosiones ............................................................................1b-2


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viii powermax1650Operator Manual

El choque elctrico puede provocar la muerte..........................................................................................1b-3Electricidad esttica puede daar tablillas de circuito ............ ............. ............ ............. ............. ............ .1b-3Humos txicos pueden causar lesiones o muerte....................................................................................1b-4

El arco de plasma puede causar lesiones y quemaduras.......................................................................1b-5Los rayos del arco pueden producir quemaduras en los ojos y en la piel ........... ............ ............. ......1b-5

Seguridad de toma a tierra.............................................................................................................................1b-6Seguridad de los equipos de gas comprimido..........................................................................................1b-6Los cilindros de gas pueden explotar si estn daados ............ ............ ............. ............ ............. ...........1b-6

El ruido puede deteriorar la audicin ............ ............ ............. ............. ............ ............. ............. ............ .......1b-7Operacin de marcapasos y de audfonos.................................................................................................1b-7

Un arco plasma puede daar tubos congelados ........... ............. ............ ............. ............ ............ .............1b-7Smbolos y marcas ............. ............ ............. ............. ............ ............. ............. ............ ............. ............. ............1b-8Etiquetas de advertencia ............ ............. ............. ............ ............. ............. ............ ............. ............. ............. .1b-9

Informacin sobre la coleccin de polvo seco........................................................................................1b-11

Section 2 Specifications

Power supply ......................................................................................................................................................2-2Duty cycle...................................................................................................................................................2-3

Dimensions and weight...........................................................................................................................2-3T100 torches ......................................................................................................................................................2-4

Torch dimensions......................................................................................................................................2-5

Symbols and markings.......................................................................................................................................2-6S mark........................................................................................................................................................2-6

CE mark......................................................................................................................................................2-6IEC symbols used ....................................................................................................................................2-6

Section 3 Setup

Upon receipt.........................................................................................................................................................3-2

Claims....................................................................................................................................................................3-Contents of box ............ ............ ............. ............. ............ ............. ............. ............ ............. ............. ............. ........3-2Lifting the power supply ........... ............. ............. ............ ............. ............. ............ ............. ............. ............. ......3-3

Locating power supply.......................................................................................................................................3-4Power connection............ ............. ............ ............. ............. ............ ............. ............. ............. ............ ............. ....3-4

Engine drives.............................................................................................................................................3-5Grounding ............................................................................................................................................................3-6Power cords ........... ............. ............ ............. ............. ............ ............. ............. ............ .............. ............ ............. ..3-6

Three-phase power cord plug installation..................................................................................................3-7

Power cord installation ............. ............. ............ ............. ............. ............ ............. ............. ............. .........3-7Plug installation ............. ............. ............ ............. ............. ............ ............. ............. ............. ............. .........3-7

Torch installation..................................................................................................................................................3-8Plasma gas supply ..........................................................................................................................................3-10

Additional gas filtration ............ ............ ............. ............. ............ ............. ............ ............. ............. ........3-10Gas supply installation ............ ............ ............. ............. ............ ............. ............. ............ .............. ............ ......3-11T100M-2 torch alignment...............................................................................................................................3-11


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powermax1650Operator Manual ix

ON/OFF pendant connection .......................................................................................................................3-12Machine interface connection.............................................................................................................3-12Arc voltage...............................................................................................................................................3-13Changing XFER (start machine motion) from dry contact closure to voltage signal .............3-15

Section 4 OperationControls and indicators .....................................................................................................................................4-2Indicator LEDs...........................................................................................................................................4-2

Install the consumables.....................................................................................................................................4-3T100 consumable configurations....................................................................................................................4-4

Shielded......................................................................................................................................................4-4Unshielded .................................................................................................................................................4-4FineCut........................................................................................................................................................4-4Gouging......................................................................................................................................................4-5

T100M-2 consumable configurations ............................................................................................................4-5Shielded......................................................................................................................................................4-5

FineCut........................................................................................................................................................4-6Ohmic sensing retaining cap.................................................................................................................4-6Unshielded .................................................................................................................................................4-6

Set the mode switch...........................................................................................................................................4-7Turn ON the power .............................................................................................................................................4-7Check the indicator lights..................................................................................................................................4-7Adjust the gas pressure and current setting ................................................................................................4-8Hand torch operation .........................................................................................................................................4-9

Safety trigger operation ..........................................................................................................................4-9Attach the work clamp..........................................................................................................................4-10

Start a cut from the edge of the workpiece .....................................................................................4-10Hand torch cutting technique..............................................................................................................4-11Piercing ....................................................................................................................................................4-12Gouging ...................................................................................................................................................4-13

Cut charts...........................................................................................................................................................4-14

Section 5 Maintenance and parts

Routine maintenance..........................................................................................................................................5-2Inspect the consumables........................................................................................................................5-3Filter element replacement.....................................................................................................................5-4

Controls and indicators .....................................................................................................................................5-5

Basic troubleshooting........................................................................................................................................5-6System circuit diagram ......................................................................................................................................5-9Technical questions..........................................................................................................................................5-10Parts.....................................................................................................................................................................5-10

Torch parts...............................................................................................................................................5-10Power supply parts ................................................................................................................................5-11Accessories.............................................................................................................................................5-11


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Hypertherm 1-1

11/08

Section 1

SAFETY

In this section:

Recognize safety information ...........................................................................................................................1-2

Follow safety instructions..................................................................................................................................1-2Cutting can cause fire or explosion ................................................................................................................1-2

Electric shock can kill.........................................................................................................................................1-3

Static electricity can damage circuit boards ................................................................................................1-3

Toxic fumes can cause injury or death............................................................................................................1-4

A plasma arc can cause injury and burns......................................................................................................1-5

Arc rays can burn eyes and skin......................................................................................................................1-5

Grounding safety.................................................................................................................................................1-6

Compressed gas equipment safety................................................................................................................1-6

Gas cylinders can explode if damaged..........................................................................................................1-6Noise can damage hearing ...............................................................................................................................1-7

Pacemaker and hearing aid operation............................................................................................................1-7

A plasma arc can damage frozen pipes.........................................................................................................1-7

Additional safety information.............................................................................................................................1-7

Symbols and markings.......................................................................................................................................1-8

Warning labels .....................................................................................................................................................1-9

Dry dust collection information......................................................................................................................1-11


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1-2 Hypertherm

11/08

SAFETY

RECOGNIZE SAFETY INFORMATION

The symbols shown in this section are used toidentify potential hazards. When you see a

safety symbol in this manual or on your machine,understand the potential for personal injury, and follow

the related instructions to avoid the hazard.FOLLOW SAFETYINSTRUCTIONSRead carefully all safety messages in this

manual and safety labels on your machine. Keep the safety labels on your machine in good

condition. Replace missing or damaged labelsimmediately.

Learn how to operate the machine and how to usethe controls properly. Do not let anyone operate itwithout instruction.

Keep your machine in proper working condition.Unauthorized modifications to the machine mayaffect safety and machine service life.

DANGER WARNING CAUTION

Hypertherm uses American National StandardsInstitute guidelines for safety signal words andsymbols. A signal word DANGER or WARNING isused with a safety symbol. DANGER identifies themost serious hazards. DANGER and WARNING safety labels are

located on your machine near specific hazards. DANGER safety messages precede related

instructions in the manual that will result in seriousinjury or death if not followed correctly.

WARNING safety messages precede relatedinstructions in this manual that may result in injuryor death if not followed correctly.

CAUTION safety messages precede relatedinstructions in this manual that may result in

minor injury or damage to equipment if notfollowed correctly.

Fire Prevention Be sure the area is safe before doing any cutting.

Keep a fire extinguisher nearby.

Remove all flammables within 35 feet (10 m) ofthe cutting area.

Quench hot metal or allow it to cool beforehandling or before letting it touch combustiblematerials.

Never cut containers with potentially flammablematerials inside they must be emptied andproperly cleaned first.

Ventilate potentially flammable atmospheresbefore cutting.

When cutting with oxygen as the plasma gas,

an exhaust ventilation system is required.Explosion Prevention Do not use the plasma system if explosive dust

or vapors may be present. Do not cut pressurized cylinders, pipes, or any

closed container. Do not cut containers that have held combustible

materials.

CUTTING CAN CAUSE FIRE OR EXPLOSION

WARNINGExplosion Hazard

Argon-Hydrogen and Methane

Hydrogen and methane are flammable gases thatpresent an explosion hazard. Keep flames away fromcylinders and hoses that contain methane or hydrogenmixtures. Keep flames and sparks away from the torchwhen using methane or argon-hydrogen plasma.

WARNINGHydrogen Detonation with

Aluminum Cutting When cutting aluminum underwater, or with the

water touching the underside of the aluminum,free hydrogen gas may collect under the workpieceand detonate during plasma cutting operations.

Install an aeration manifold on the floor of the watertable to eliminate the possibility of hydrogendetonation. Refer to the Appendix section of thismanual for aeration manifold details.


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Hypertherm 1-3

SAFETY

11/08

Touching live electrical parts can cause a fatal shockor severe burn.

Operating the plasma system completes anelectrical circuit between the torch and theworkpiece. The workpiece and anything touchingthe workpiece are part of the electrical circuit.

Never touch the torch body, workpiece or thewater in a water table when the plasma systemis operating.

Electric Shock Prevention

All Hypertherm plasma systems use high

voltage in the cutting process (200 to 400 VDC

are common). Take the following precautions

when operating this system:

Wear insulated gloves and boots, and keep yourbody and clothing dry.

Do not stand, sit or lie on or touch any wetsurface when using the plasma system.

Insulate yourself from work and ground using dryinsulating mats or covers big enough to preventany physical contact with the work or ground.If you must work in or near a damp area, use

extreme caution. Provide a disconnect switch close to the power

supply with properly sized fuses. This switch allowsthe operator to turn off the power supply quickly inan emergency situation.

When using a water table, be sure that it iscorrectly connected to earth ground.

ELECTRIC SHOCK CAN KILL

Install and ground this equipment according to theinstruction manual and in accordance with national

and local codes. Inspect the input power cord frequently for damageor cracking of the cover. Replace a damagedpower cord immediately. Bare wiring can kill.

Inspect and replace any worn or damaged torchleads.

Do not pick up the workpiece, including the wastecutoff, while you cut. Leave the workpiece in placeor on the workbench with the work cable attachedduring the cutting process.

Before checking, cleaning or changing torch parts,disconnect the main power or unplug the powersupply.

Never bypass or shortcut the safety interlocks. Before removing any power supply or system

enclosure cover, disconnect electrical input power.Wait 5 minutes after disconnecting the main powerto allow capacitors to discharge.

Never operate the plasma system unless the powersupply covers are in place. Exposed power supplyconnections present a severe electrical hazard.

When making input connections, attach propergrounding conductor first. Each Hypertherm plasma system is designed to be

used only with specific Hypertherm torches. Do notsubstitute other torches which could overheat andpresent a safety hazard.

Use proper precautions when handling printedcircuit boards.

STATIC ELECTRICITY CAN DAMAGE CIRCUIT BOARDS

Store PC boards in anti-static containers.

Wear a grounded wrist strap when handlingPC boards.


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1-4 Hypertherm

SAFETY

11/08

The plasma arc by itself is the heat source used forcutting. Accordingly, although the plasma arc has

not been identified as a source of toxic fumes, thematerial being cut can be a source of toxic fumesor gases that deplete oxygen.

Fumes produced vary depending on the metal thatis cut. Metals that may release toxic fumes include,but are not limited to, stainless steel, carbon steel,zinc (galvanized), and copper.

In some cases, the metal may be coated with asubstance that could release toxic fumes. Toxic

coatings include, but are not limited to, lead (insome paints), cadmium (in some paints and fillers),and beryllium.

Gases produced by plasma cutting vary based onthe material to be cut and the method of cutting,but may include ozone, oxides of nitrogen,hexavalent chromium, hydrogen, and othersubstances if such are contained in or releasedby the material being cut.

Caution should be taken to minimize exposure

to fumes produced by any industrial process.Depending upon the chemical composition andconcentration of the fumes (as well as other factors,such as ventilation), there may be a risk of physicalillness, such as birth defects or cancer.

It is the responsibility of the equipment and siteowner to test the air quality in the area where theequipment is used and to ensure that the air qualityin the workplace meets all local and nationalstandards and regulations.

The air quality level in any relevant workplacedepends on site-specific variables such as:

Table design (wet, dry, underwater).

Material composition, surface finish, andcomposition of coatings.

Volume of material removed.

TOXIC FUMES CAN CAUSE INJURY OR DEATH

Duration of cutting or gouging.

Size, air volume, ventilation and filtration of thework area.

Personal protective equipment.

Number of welding and cutting systemsin operation.

Other site processes that may produce fumes.

If the workplace must conform to national or localregulations, only monitoring or testing done at thesite can determine whether the site is above or

below allowable levels.To reduce the risk of exposure to fumes:

Remove all coatings and solvents from the metalbefore cutting.

Use local exhaust ventilation to remove fumesfrom the air.

Do not inhale fumes. Wear an air-suppliedrespirator when cutting any metal coated with,containing, or suspected to contain toxic

elements. Assure that those using welding or cutting

equipment, as well as air-supplied respirationdevices, are qualified and trained in the properuse of such equipment.

Never cut containers with potentially toxicmaterials inside. Empty and properly clean thecontainer first.

Monitor or test the air quality at the site asneeded.

Consult with a local expert to implement a siteplan to ensure safe air quality.


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Hypertherm 1-5

SAFETY

11/08

Instant-On Torches

Plasma arc comes on immediately when the torchswitch is activated.

A PLASMA ARC CAN CAUSE INJURY AND BURNS

The plasma arc will cut quickly through gloves

and skin. Keep away from the torch tip. Do not hold metal near the cutting path. Never point the torch toward yourself or others.

Eye Protection Plasma arc rays produce intense visible and invisible (ultraviolet and infrared) rays that can

burn eyes and skin. Use eye protection in accordance with applicable national or local codes. Wear eye protection (safety glasses or goggles with side shields, and a welding helmet) with appropriate

lens shading to protect your eyes from the arcs ultraviolet and infrared rays.Skin Protection Wear protective clothing to protect against burns caused by ultraviolet light, sparks andhot metal. Gauntlet gloves, safety shoes and hat. Flame-retardant clothing to cover all exposed areas. Cuffless trousers to prevent entry of sparks and slag. Remove any combustibles, such as a butane lighter or matches, from your pockets before cutting.

Cutting Area Prepare the cutting area to reduce reflection and transmission of ultraviolet light: Paint walls and other surfaces with dark colors to reduce reflection. Use protective screens or barriers to protect others from flash and glare. Warn others not to watch the arc. Use placards or signs.

ARC RAYS CAN BURN EYES AND SKIN

Arc current

(amps)

Minimum protective

shade number

(ANSI Z49.1:2005)

Suggested shade

number for comfort

(ANSI Z49.1:2005)

OSHA 29CFR

1910.133(a)(5)

Europe

EN168:2002

Less than 40 A 5 5 8 9

41 to 60 A 6 6 8 9

61 to 80 A 8 8 8 9

81 to 125 A 8 9 8 9126 to 150 A 8 9 8 10

151 to 175 A 8 9 8 11

176 to 250 A 8 9 8 12

251 to 300 A 8 9 8 13

301 to 400 A 9 12 9 13

401 to 800 A 10 14 10


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1-6 Hypertherm

SAFETY

11/08

Never lubricate cylinder valves or regulators withoil or grease.

Use only correct gas cylinders, regulators, hosesand fittings designed for the specific application.

Maintain all compressed gas equipment andassociated parts in good condition.

Label and color-code all gas hoses to identifythe type of gas in each hose. Consult applicablenational or local codes.

GAS CYLINDERS CAN

EXPLODE IF DAMAGED

COMPRESSED GAS EQUIPMENT

SAFETY

Gas cylinders contain gas under high pressure.

If damaged, a cylinder can explode. Handle and use compressed gas cylinders in

accordance with applicable national or localcodes.

Never use a cylinder that is not upright andsecured in place.

Keep the protective cap in place over valveexcept when the cylinder is in use or connectedfor use.

Never allow electrical contact between theplasma arc and a cylinder.

Never expose cylinders to excessive heat, sparks,slag or open flame.

Never use a hammer, wrench or other tool toopen a stuck cylinder valve.

Work Cable Attach the work cable securely to theworkpiece or the work table with good metal-to-metalcontact. Do not connect it to the piece that will fallaway when the cut is complete.

Work Table Connect the work table to an earthground, in accordance with appropriate national orlocal electrical codes.

Input Power

Be sure to connect the power cord ground wireto the ground in the disconnect box.

If installation of the plasma system involvesconnecting the power cord to the power supply,be sure to connect the power cord ground wireproperly.

Place the power cord's ground wire on the studfirst, then place any other ground wires on topof the power cord ground. Fasten the retainingnut tightly.

Tighten all electrical connections to avoidexcessive heating.

GROUNDING SAFETY


21/106


22/106

1-8 Hypertherm

SAFETY

11/08

SYMBOLS AND MARKINGS

Your Hypertherm product may have one or more of the following markings on or near the data plate. Due todifferences and conflicts in national regulations, not all marks are applied to every version of a product.

S mark symbol

The S mark symbol indicates that the power supply and torch are suitable for operations carried outin environments with increased hazard of electrical shock per IEC 60974-1.

CSA mark

Hypertherm products with a CSA mark meet the United States and Canadian regulations forproduct safety. The products were evaluated, tested, and certified by CSA-International. Alternativelythe product may have a mark by one of the other Nationally Recognized Testing Laboratories (NRTL)accredited in both the United States and Canada, such as Underwriters Laboratories, Incorporated(UL) or TV.

CE markingThe CE marking signifies the manufacturers declaration of conformity to applicable Europeandirectives and standards. Only those versions of Hypertherm products with a CE marking located onor near the data plate have been tested for compliance with the European Low Voltage Directive andthe European Electromagnetic Compatibility (EMC) Directive. EMC filters needed to comply with theEuropean EMC Directive are incorporated within versions of the product with a CE marking.

GOST-R mark

CE versions of Hypertherm products that include a GOST-R mark of conformity meet the productsafety and EMC requirements for export to the Russian Federation.

c-Tick mark

CE versions of Hypertherm products with a c-Tick mark comply with the EMC regulations requiredfor sale in Australia and New Zealand.

CCC mark

The China Compulsory Certification (CCC) mark indicates that the product has been tested andfound compliant with product safety regulations required for sale in China.


23/106

Hypertherm 1-9

SAFETY

11/08

WARNING LABEL

This warning label is affixed to some power supplies. It is important that the operatorand maintenance technician understand the intent of these warning symbols asdescribed. The numbered text corresponds to the numbered boxes on the label.

1. Cutting sparks can cause explosion or fire.

1.1 Do not cut near flammables.

1.2 Have a fire extinguisher nearby and ready to use.

1.3 Do not use a drum or other closed container asa cutting table.

2. Plasma arc can injure and burn; point the nozzleaway from yourself. Arc starts instantly whentriggered.

2.1 Turn off power before disassembling torch.

2.2 Do not grip the workpiece near the cutting path.

2.3 Wear complete body protection.

3. Hazardous voltage. Risk of electric shock orburn.

3.1 Wear insulating gloves. Replace gloves whenwet or damaged.

3.2 Protect from shock by insulating yourself fromwork and ground.

3.3 Disconnect power before servicing. Do nottouch live parts.

4. Plasma fumes can be hazardous.

4.1 Do not inhale fumes.

4.2 Use forced ventilation or local exhaust to removethe fumes.

4.3 Do not operate in closed spaces. Remove fumeswith ventilation.

5. Arc rays can burn eyes and injure skin.

5.1 Wear correct and appropriate protectiveequipment to protect head, eyes, ears, hands,and body. Button shirt collar. Protect ears fromnoise. Use welding helmet with the correctshade of filter.

6. Become trained. Only qualified personnel shouldoperate this equipment. Use torches specified inthe manual. Keep non-qualified personnel andchildren away.

7. Do not remove, destroy, or cover this label.Replace if it is missing, damaged, or worn.

Read and follow these instructions, employersafetypractices, and material safety data sheets. RefertoANS Z49.1, Safety inWelding, Cuttingand AlliedProcessesfromAmericanWeldingSociety(http://www.aws.org) and OSHA Safety and HealthStandards, 29 CFR 1910 (http://www.osha.gov).

WARNING

1. Cutting sparks cancause explosionorfire.1.1 Do not cut nearflammables.1.2 Have a fire extinguishernearby and ready to use.1.3 Do not use a drumorotherclosed containeras a cuttingtable.

2. Plasma arc caninjure and burn; point the nozzle away

fromyourself. Arc starts instantly whentriggered.2.1 Turnoff powerbefore disassemblingtorch.2.2 Do not grip the workpiece nearthe cuttingpath.2.3 Wearcomplete body protection.

3. Hazardous voltage. Risk of electric shock orburn.3.1 Wearinsulatinggloves. Replace gloves whenwet ordamaged.3.2 Protect fromshock by insulatingyourself fromwork and ground.3.3 Disconnect powerbefore servicing. Do not touch live parts.

4. Plasma fumes canbe hazardous.4.1 Do not inhale fumes.4.2 Use forced ventilationorlocal exhaust to remove the fumes.4.3 Do not operate inclosed spaces. Remove fumes with ventilation.

6.Become trained.Only qualified personnel should operate this equipment. Use torches specified inthe manual. Keep non-qualified

personnel and childrenaway.

5. Arc rays canburneyes and injure skin.5.1 Wearcorrect and appropriate protective equipment to protect

head, eyes, ears, hands, and body. Buttonshirt collar. Protect earsfromnoise. Use weldinghelmet with the correct shade of filter.

7.Do not remove, destroy, orcoverthis label.Replace if it is missing, damaged, orworn (PN 110584 Rev C).

Plasma cuttingcanbe injurious to operatorand personsinthe work area. Consult manual before operating. Failureto follow all these safety instructions canresult indeath.

AVERTISSEMENTLe coupage plasma peut tre prjudiciable pourloprateuret les personnes qui setrouvent surles lieux de travail. Consulterle manuel avant de faire fonctionner. Lenonrespect des ces instructions de scurit peut entranerla mort.

1. Les tincelles de coupage peuvent provoquerune explosion

ouunincendie.1.1 Ne pas couperprs des matires inflammables.1.2 Unextincteurdoit tre proximit et prt tre utilis.1.3 Ne pas utiliserunft ou unautre contenant ferm comme table de coupage.

2. Larc plasma peut blesseret brler; loignerla buse de soi.

Il sallume instantanment quand onlamorce;2.1 Couperlalimentationavant de dmonterla torche.2.2 Ne pas saisirla pice couperde la trajectoire de coupage.2.3 Se protgerentirement le corps.

3. Tensiondangereuse. Risque de choc lectrique oude brlure.3.1 Porterdes gants isolants. Remplacerles gants quand ils sont humides ou

endommags.3.2 Se protgercontre les chocs ensisolant de la pice et de la te rre.3.3 Couperlalimentationavant lentretien. Ne pas toucherles pices sous tension.

4. Les fumes plasma peuvent tre dangereuses.4.1 Ne pas inhalerles fumes4.2 Utiliserune ventilationforce ou unextracteurlocal pourdissiperles fumes.4.3 Ne pas couperdans des espaces clos. Chasserles fumes parventilation.

5. Les rayons darc peuvent brlerles yeux et blesserla peau.5.1 Porterunbonquipement de protectionpourse protgerla tte, les yeux, les

oreilles, les mains et le corps. Boutonnerle col de la chemise. Protgerles oreillescontre le bruit. Utiliserunmasque de soudeuravec unfiltre de nuance approprie.

6. Suivre une formation.Seul le personnel qualifi a le droit de fairefonctionnercet quipement. Utiliserexclusivement les torches indiques dans lemanual. Le personnel nonqualifi et les enfants doivent se tenir lcart.

7. Ne pas enlever, dtruire ni couvrircette tiquette.La remplacersi elle est absente, endommage ou use (PN 110584 Rev C).


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1-10 Hypertherm

SAFETY

11/08

WARNING LABELThis warning label is affixed to some power supplies. It isimportant that the operator and maintenance technicianunderstand the intent of these warning symbols as described.The numbered text corresponds to the numbered boxes on

the label.

1. Cutting sparks can cause explosionor fire.

1.1 Do not cut near flammables.

1.2 Have a fire extinguisher nearby andready to use.

1.3 Do not use a drum or other closedcontainer as a cutting table.

2. Plasma arc can injure and burn;point the nozzle away from yourself.Arc starts instantly when triggered.

2.1 Turn off power before disassemblingtorch.

2.2 Do not grip the workpiece near thecutting path.

2.3 Wear complete body protection.

3. Hazardous voltage. Risk of electric

shock or burn.3.1 Wear insulating gloves. Replace

gloves when wet or damaged.

3.2 Protect from shock by insulatingyourself from work and ground.

3.3 Disconnect power before servicing.Do not touch live parts.

4. Plasma fumes can be hazardous.

4.1 Do not inhale fumes.

4.2 Use forced ventilation or local

exhaust to remove the fumes.4.3 Do not operate in closed spaces.

Remove fumes with ventilation.

5. Arc rays can burn eyes and injureskin.

5.1 Wear correct and appropriateprotective equipment to protecthead, eyes, ears, hands, and body.Button shirt collar. Protect ears fromnoise. Use welding helmet with thecorrect shade of filter.

6. Become trained. Only qualifiedpersonnel should operate thisequipment. Use torches specified inthe manual. Keep non-qualifiedpersonnel and children away.

7. Do not remove, destroy, or coverthis label. Replace if it is missing,damaged, or worn.

www.hypertherm.com/weee110647 Rev. A


25/106

Hypertherm 1-11

11/08

SAFETY

DRY DUST COLLECTION INFORMATION

At some sites, dry dust can represent a potential explosion hazard.

The U.S. National Fire Protection Associations 2007 edition of NFPA standard 68, Explosion Protection by

Deflagration Venting, provides requirements for the design, location, installation, maintenance, and use of

devices and systems to vent combustion gases and pressures after any deflagration event. Consult with themanufacturer or installer of any dry dust collection system for applicable requirements before you install a new

dry dust collection system or make significant changes in the process or materials used with an existing dry

dust collection system.

Consult your local Authority Having Jurisdiction (AHJ) to determine whether any edition of NFPA 68 has

been adopted by reference in your local building codes.

Refer to NFPA68 for definitions and explanations of regulatory terms such as deflagration, AHJ, adopted by

reference, the Kst value, deflagration index, and other terms.

Note 1 Hypertherms interpretation of these new requirements is that unless a site-specific evaluation has

been completed to determine that all dust generated is not combustible, the 2007 edition of NFPA 68

requires the use of explosion vents designed to the worst-case Kst value (see annex F) that could be

generated from dust so that the explosion vent size and type can be designed. NFPA 68 does not specifically

identify plasma cutting or other thermal cutting processes as requiring deflagration venting systems, but it

does apply these new requirements to all dry dust collection systems.

Note 2 Users of Hypertherm manuals should consult and comply with all applicable federal, state, and local

laws and regulations. Hypertherm does not, by the publication of any Hypertherm manual, intend to urge

action that is not in compliance with all applicable regulations and standards, and this manual may never be

construed as doing so.


26/106

1-12 Hypertherm

11/08

SAFETY


27/10611/08

Hypertherm 1a-1

Section 1a

SCURIT

Dans cette section :

Identifier les consignes de scurit..............................................................................................................1a-2

Suivre les instructions de scurit................................................................................................................1a-2Le coupage peut provoquer un incendie ou une explosion....................................................................1a-2Les chocs lectriques peuvent tre fatals ..................................................................................................1a-3Llectricit statique peut endommager les cartes de circuits imprims.............................................1a-3Les vapeurs toxiques peuvent provoquer des blessures ou la mort.....................................................1a-4Larc plasma peut provoquer des blessures ou des brlures.................................................................1a-5Les rayons de larc peuvent brler les yeux et la peau.............................................................................1a-5Mise la masse et la terre...........................................................................................................................1a-6Scurit des bouteilles de gaz comprim...................................................................................................1a-6

Les bouteilles de gaz comprim peuvent exploser en cas de dommages..........................................1a-6Le bruit peut provoquer des problmes auditifs........................................................................................1a-7Pacemakers et prothses auditives ..............................................................................................................1a-7Un arc plasma peut endommager les tuyaux gels...................................................................................1a-7Symboles et marquage....................................................................................................................................1a-8tiquettes de scurit......................................................................................................................................1a-9Information sur le dpoussirage ...............................................................................................................1a-11


28/10611/08

1a-2 Hypertherm

SCURIT

IDENTIFIER LES CONSIGNESDE SCURITLes symboles indiqus dans cette section sont utiliss

pour identifier les risques ventuels. Si vous trouvez un symbolede scurit, que ce soit dans ce manuel ou sur lquipement,soyez conscient des risques de blessures et suivez lesinstructions correspondantes afin dviter ces risques.

SUIVRE LES INSTRUCTIONSDE SCURITLire attentivement toutes les consignes de scurit

dans le prsent manuel et sur les tiquettes de scurit setrouvant sur la machine. Les tiquettes de scurit doivent rester lisibles. Remplacer

immdiatement les tiquettes manquantes ou abmes. Apprendre faire fonctionner la machine et utiliser

correctement les commandes. Ne laisser personne utiliserla machine sans connatre son fonctionnement.

Garder la machine en bon tat. Des modifications nonautorises sur la machine peuvent engendrer des problmesde scurit et raccourcir la dure dutilisation de lquipement.

DANGER AVERTISSEMENT ATTENTION

Hypertherm adopte les lignes directrices de lAmericanNational Standards Institute relativement aux termes, auxsymboles et la signalisation de scurit. Les signauxDANGER ou AVERTISSEMENT sont utiliss avec un symbolede scurit, DANGER correspondant aux risques les plussrieux. Les tiquettes de scurit DANGER et AVERTISSEMENT

sont situes sur la machine pour signaler certains dangersspcifiques.

Les messages de scurit DANGER prcdent lesdirectives associes dans le manuel qui, si elles ne sont passuivies scrupuleusement, entranent des blessures gravesvoire mortelles.

Les messages dAVERTISSEMENT prcdent lesinstructions dutilisation expliques dans ce manuel etsignalent les risques de blessures ou de mort au cas o cesinstructions ne seraient pas suivies correctement.

Les messages de scurit ATTENTION prcdent lesdirectives associes dans le manuel qui, si elles ne sont passuivies scrupuleusement, peuvent entraner des blessuressecondaires ou endommager lquipement.

Prvention des incendies

Avant de commencer, sassurer que la zone de coupagene prsente aucun danger. Conserver un extincteur proximit.

loigner toute matire inflammable une distancedau moins 10 m du poste de coupage.

Tremper le mtal chaud ou le laisser refroidir avantde le manipuler ou avant de le mettre en contact avecdes matriaux combustibles.

Ne jamais couper des rcipients pouvant contenirdes matires inflammables avant de les avoir vidset nettoys correctement.

Arer toute atmosphre potentiellement inflammableavant dutiliser un systme plasma.

Lors de lutilisation doxygne comme gaz plasma, unsystme de ventilation par aspiration est ncessaire.

Prvention des explosions

Ne pas couper en prsence de poussire ou de vapeurs. Ne pas couper de bouteilles, de tuyaux ou autres

rcipients ferms et pressuriss. Ne pas couper de rcipients contenant des matires

combustibles.

LE COUPAGE PEUT PROVOQUERUN INCENDIE OU UNE EXPLOSION

AVERTISSEMENT

Risque dexplosionargon-hydrogne et mthane

Lhydrogne et le mthane sont des gaz inflammableset potentiellement explosifs. Conserver lcart de touteflamme les bouteilles et tuyaux contenant des mlanges base dhydrogne ou de mthane. Maintenir touteflamme et tincelle lcart de la torche lors de lutilisationdun plasma dargon-hydrogne ou de mthane.

AVERTISSEMENT

Dtonation de lhydrogne lors ducoupage de laluminium

Lors du coupage de laluminium sous leau, ou si leautouche la partie infrieure de la pice daluminium, delhydrogne libre peut saccumuler sous la pice couperet dtonner lors du coupage plasma.

Installer un collecteur daration au fond de la table eauafin dliminer les risques de dtonation de lhydrogne.Se rfrer lannexe du manuel pour plus derenseignements sur les collecteurs daration.


29/106


30/10611/08

1a-4 Hypertherm

SCURIT

Larc plasma est lui-mme la source de chaleur utilisepour le coupage. Par consquent, bien que larc plasmanait pas t reconnu comme une source de vapeurstoxiques, le matriau coup peut tre une source devapeurs ou de gaz toxiques qui puisent loxygne.

Les vapeurs produites varient selon le mtal coup.Les mtaux qui peuvent dgager des vapeurs toxiquescomprennent, entre autres, lacier inoxydable, lacier aucarbone, le zinc (galvanis) et le cuivre.

Dans certains cas, le mtal peut tre revtu dune

substance susceptible de dgager des vapeurs toxiques.Les revtements toxiques comprennent entre autres,le plomb (dans certaines peintures), le cadmium (danscertaines peintures et enduits) et le bryllium.

Les gaz produits par le coupage plasma varient selonle matriau couper et la mthode de coupage, maisils peuvent comprendre lozone, les oxydes dazote,le chrome hexavalent, lhydrogne et autres substancesprsentes dans le matriau coup ou en manent.

On doit prendre les prcautions qui simposent pourrduire au minimum lexposition aux vapeurs produites partout processus industriel. Selon la composition chimiqueet la concentration des vapeurs (ainsi que dautresfacteurs comme la ventilation), il peut y avoir un risque demaladie physique, comme des malformations ou le cancer.

Il incombe au propritaire du matriel et du site de vrifierla qualit de lair dans le secteur o lon utilise le matrielet de sassurer que la qualit de lair sur les lieux de travailrpond aux normes et rglementation locales et nationales.

LES VAPEURS TOXIQUES PEUVENT PROVOQUERDES BLESSURES OU LA MORT

Le niveau de qualit de lair dans tout lieu de travaildpend des variables propres au site comme :

Type de table (humide, sche, sous leau). Composition du matriau, fini de la surface

et composition des revtements. Volume de matriau enlev. Dure du coupage ou du gougeage. Dimensions, volume dair, ventilation et filtration

de la zone de travail. quipement de protection individuelle. Nombre de systmes de soudage et de coupage

en fonctionnement. Autres procds du site qui peuvent produire

des vapeurs.

Si les lieux de travail doivent tre conformes auxrglements nationaux ou locaux, seuls les contrles ou lesessais effectus au site peuvent dterminer si celui-ci sesitue au-dessus ou au-dessous des niveaux admissibles.

Pour rduire le risque dexposition aux vapeurs :

liminer tout revtement et solvant du mtal avantle coupage.

Utiliser la ventilation dextraction locale pour liminerles vapeurs de lair.

Ne pas inhaler les vapeurs. Porter un respirateur adduction dair quand on coupe des mtaux revtusdlments toxiques ou qui en contiennent ou sontsusceptibles den contenir.

Sassurer que les personnes qui utilisent un matrielde soudage ou de coupage ainsi que les dispositifs derespiration par adduction dair sont qualifis et ont reula formation sur la bonne utilisation dun tel matriel.

Ne jamais couper les contenants dans lesquels il peuty avoir des matriaux toxiques. En premier lieu, vider etnettoyer correctement le contenant.

Contrler ou prouver la qualit de lair au site selonles besoins.

Consulter un expert local pour mettre en uvre un plandu site afin dassurer une qualit de lair sre.


31/10611/08

Torches allumage instantan

Larc plasma sallume immdiatement aprs que la torchesoit mise en marche.

LARC PLASMA PEUT PROVOQUER DES BLESSURES OU DES BRLURES

Larc plasma coupe facilement les gants et la peau.

Rester loign de lextrmit de la torche. Ne pas tenir de mtal prs de la trajectoire de coupe. Ne jamais pointer la torche vers soi ou dautres

personnes.

Protection des yeux Les rayons de larc plasma produisent de puissants rayons visibles ou invisibles (ultraviolets et

infrarouges) qui peuvent brler les yeux et la peau. Utiliser des lunettes de scurit conformment aux codes locaux ou nationaux en vigueur. Porter des lunettes de protection (lunettes ou masque muni dcrans latraux et encore masque de soudure) avec des

verres teints appropris pour protger les yeux des rayons ultraviolets et infrarouges de larc.

Protection de la peau Porter des vtements de scurit pour se protger contre les brlures que peuvent causer lesrayons ultraviolets, les tincelles et le mtal brlant : Gants crispin, chaussures et casque de scurit. Vtements ignifuges couvrant toutes les parties exposes du corps. Pantalon sans revers pour viter que des tincelles ou des scories puissent sy loger. Avant le coupage, retirer de ses poches tout objet combustible comme les briquets au butane ou les allumettes.

Zone de coupage Prparer la zone de coupage afin de rduire la rverbration et la transmission de la lumireultraviolette : Peindre les murs et autres surfaces de couleur sombre pour rduire la rflexion de la lumire. Utiliser des crans et autres dispositifs de protection afin de protger les autres personnes de la lumire et de

la rverbration. Prvenir les autres personnes de ne pas regarder larc. Utiliser des affiches ou des panneaux.

LES RAYONS DE LARC PEUVENT BRLER LES YEUX ET LA PEAU

Hypertherm 1a-5

SCURIT

Courant de larc(A)

Indice de protectionminimum

(ANSI Z49.1:2005)

Indice de protectionsuggr pour assurer

le confort(ANSI Z49.1:2005)

OSHA 29CFR1910.133(a)(5)

EuropeEN168:2002

Moins de 40 A 5 5 8 941 60 A 6 6 8 961 80 A 8 8 8 9

81 125 A 8 9 8 9126 150 A 8 9 8 10151 175 A 8 9 8 11176 250 A 8 9 8 12251 300 A 8 9 8 13301 400 A 9 12 9 13401 800 A 10 14 10


32/10611/08

1a-6 Hypertherm

SCURIT

Ne jamais lubrifier les robinets des bouteilles ou lesrgulateurs avec de lhuile ou de la graisse.

Utiliser uniquement les bouteilles, rgulateurs, tuyaux

et accessoires appropris et conus pour chaqueapplication spcifique.

Entretenir lquipement et les pices dquipement gaz comprim afin de les garder en bon tat.

tiqueter et coder avec des couleurs tous les tuyauxde gaz afin didentifier le type de gaz contenu danschaque tuyau. Se rfrer aux codes locaux ou nationauxen vigueur.

LES BOUTEILLES DEGAZ COMPRIMPEUVENT EXPLOSEREN CAS DE DOMMAGES

SCURIT DES BOUTEILLESDE GAZ COMPRIM

Les bouteilles de gaz contiennent du gaz hautepression. Si une bouteille est endommage, elle peutexploser.

Manipuler et utiliser les bouteilles de gaz comprimconformment aux codes locaux ou nationaux.

Ne jamais utiliser une bouteille qui nest pas place la verticale et bien assujettie.

Le capuchon de protection doit tre plac sur le robinetsauf si la bouteille est en cours dutilisation ouconnecte pour utilisation.

viter tout prix le contact lectrique entre larc plasma

et une bouteille. Ne jamais exposer des bouteilles une chaleur

excessive, aux tincelles, aux scories ou aux flammesnues.

Ne jamais utiliser des marteaux, des cls ou dautresoutils pour dbloquer le robinet des bouteilles.

Cble de retour Bien fixer le cble de retour (ou demasse) la pice couper ou la table de travail de faon

assurer un bon contact mtal-mtal. Ne pas fixer le cblede retour la partie de la pice qui doit se dtacher.

Table de travail Raccorder la table de travail la terre,conformment aux codes de scurit locaux ou nationauxappropris.

Alimentation

Sassurer que le fil de terre du cordon dalimentation estconnect la terre dans le coffret du sectionneur.

Sil est ncessaire de brancher le cordon dalimentation la source de courant lors de linstallation du systme,sassurer que le fil de terre est correctement branch.

Placer tout dabord le fil de terre du cordondalimentation sur le plot de mise la terre puis placerles autres fils de terre par-dessus. Bien serrer lcroude retenue.

Sassurer que toutes les connexions sont bien serrespour viter la surchauffe.

MISE LA MASSE ET LA TERRE


33/10611/08

Une exposition prolonge au bruit du coupage ou du

gougeage peut provoquer des problmes auditifs. Utiliser un casque de protection homologu lors de

lutilisation du systme plasma.

Prvenir les personnes aux alentours des risquesencourus en cas dexposition au bruit.

Les tuyaux gels peuvent tre endommags ou clatersi l'on essaie de les dgeler avec une torche plasma.

LE BRUIT PEUT PROVOQUERDES PROBLMES AUDITIFS

UN ARC PLASMA PEUTENDOMMAGER LESTUYAUX GELS

Les champs magntiques produits par les courants haute tension peuvent affecter le fonctionnementdes prothses auditives et des pacemakers.

Les personnes portant ce type dappareil doiventconsulter un mdecin avant de sapprocher dun lieuo seffectue le coupage ou le gougeage plasma.

Pour rduire les risques associs aux champsmagntiques :

Garder loin de soi et du mme ct du corps le cblede retour et le faisceau de la torche.

Faire passer le faisceau de la torche le plus prs

possible du cble de retour. Ne pas senrouler le faisceau de la torche ou le cble

de retour autour du corps.

Se tenir le plus loin possible de la source de courant.

PACEMAKERS ETPROTHSES AUDITIVES

Hypertherm 1a-7

SCURIT


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35/10611/08

Hypertherm 1a-9

SCURIT

TIQUETTE DE SCURITCette tiquette est affiche sur la source de courant. Il est important que lutilisateur etle technicien de maintenance comprennent la signification des symboles de scurit.Les numros de la liste correspondent aux numros des images.

1. Les tincelles de coupage peuvent provoquer uneexplosion ou un incendie.

1.1 Ne pas couper prs des matires inflammables.

1.2 Un extincteur doit se trouver sur les lieux et prt tre utilis.

1.3 Ne pas utiliser un ft ou un autre contenant fermcomme table de coupe.

2. Larc plasma peut blesser et brler ; ne jamais pointerla buse vers soi. Larc samorce instantanment quandon appuie sur la gchette.

2.1 Couper lalimentation avant de dmonter la torche.

2.2 Ne pas saisir la pice prs de la trajectoire de coupage.

2.3 Se protger entirement le corps.

3. Tension dangereuse. Risque de choc lectriqueou de brlure.

3.1 Porter des gants isolants. Remplacer les gants silssont humides ou endommags.

3.2 Se protger contre les chocs en sisolant de la piceet de la terre.

3.3 Couper lalimentation avant dentretenir. Ne pastoucher les pices sous tension.

4. Les fumes du plasma peuvent tre dangereuses.

4.1 Ne pas inhaler les fumes.

4.2 Utiliser une ventilation force ou par aspiration

la source pour liminer les fumes.4.3 Ne pas utiliser dans des espaces clos. Chasser

les fumes avec la ventilation.

5. Les rayons darc peuvent brler les yeux et blesserla peau.

5.1 Porter un bon quipement de protection pour seprotger la tte, les yeux, les oreilles, les mains et lecorps. Boutonner le col de la chemise. Se protger lesoreilles contre le bruit. Utiliser le masque de soudageavec le filtre ayant le bon indice de protection.

6. Sentraner. Seul le personnel qualifi doit fairefonctionner cet quipement. Utiliser les torchesprescrites dans le manuel. Tenir le personnel nonqualifi et les enfants lcart.

7. Ne pas enlever, dtruire ou couvrir cette tiquette.La remplacer si elle est manquante, endommageou use.

Read and follow these instructions, employersafety

practices, and material safety data sheets. RefertoANS Z49.1, Safety inWelding, Cuttingand AlliedProcessesfromAmericanWeldingSociety(http://www.aws.org) and OSHA Safety and HealthStandards, 29 CFR 1910 (http://www.osha.gov).

WARNING

1. Cutting sparks cancause explosionorfire.1.1 Do not cut nearflammables.1.2 Have a fire extinguishernearby and ready to use.1.3 Do not use a drumorotherclosed containeras a cuttingtable.

2. Plasma arc caninjure and burn; point the nozzle awayfromyourself. Arc starts instantly whentriggered.

2.1 Turnoff powerbefore disassemblingtorch.2.2 Do not grip the workpiece nearthe cuttingpath.2.3 Wearcomplete body protection.

3. Hazardous voltage. Risk of electric shock orburn.3.1 Wearinsulatinggloves. Replace gloves whenwet ordamaged.3.2 Protect fromshock by insulatingyourself fromwork and ground.3.3 Disconnect powerbefore servicing. Do not touch live parts.

4. Plasma fumes canbe hazardous.4.1 Do not inhale fumes.4.2 Use forced ventilationorlocal exhaust to remove the fumes.

4.3 Do not operate inclosed spaces. Remove fumes with ventilation.

6.Become trained.Only qualified personnel should operate this equipment. Use torches specified inthe manual. Keep non-qualified

personnel and childrenaway.

5. Arc rays canburneyes and injure skin.5.1 Wearcorrect and appropriate protective equipment to protect

head, eyes, ears, hands, and body. Buttonshirt collar. Protect earsfromnoise. Use weldinghelmet with the correct shade of filter.

7.Do not remove, destroy, orcoverthis label.Replace if it is missing, damaged, orworn (PN 110584 Rev C).

Plasma cuttingcanbe injurious to operatorand personsinthe work area. Consult manual before operating. Failureto follow all these safety instructions canresult indeath.

AVERTISSEMENTLe coupage plasma peut tre prjudiciable pourloprateuret les personnes qui setrouvent surles lieux de travail. Consulterle manuel avant de faire fonctionner. Lenonrespect des ces instructions de scurit peut entranerla mort.

1. Les tincelles de coupage peuvent provoquerune explosionouunincendie.

1.1 Ne pas couperprs des matires inflammables.1.2 Unextincteurdoit tre proximit et prt tre utilis.1.3 Ne pas utiliserunft ou unautre contenant ferm comme table de coupage.

2. Larc plasma peut blesseret brler; loignerla buse de soi.Il sallume instantanment quand onlamorce;

2.1 Couperlalimentationavant de dmonterla torche.2.2 Ne pas saisirla pice couperde la trajectoire de coupage.2.3 Se protgerentirement le corps.

3. Tensiondangereuse. Risque de choc lectrique oude brlure.3.1 Porterdes gants isolants. Remplacerles gants quand ils sont humides ou

endommags.3.2 Se protgercontre les chocs ensisolant de la pice et de la terre.3.3 Couperlalimentationavant lentretien. Ne pas toucherles pices sous tension.

4. Les fumes plasma peuvent tre dangereuses.4.1 Ne pas inhalerles fumes4.2 Utiliserune ventilationforce ou unextracteurlocal pourdissiperles fumes.

4.3 Ne pas couperdans des espaces clos. Chasserles fumes parventilation.

5. Les rayons darc peuvent brlerles yeux et blesserla peau.5.1 Porterunbonquipement de protectionpourse protgerla tte, les yeux, les

oreilles, les mains et le corps. Boutonnerle col de la chemise. Protgerles oreillescontre le bruit. Utiliserunmasque de soudeuravec unfiltre de nuance approprie.

6. Suivre une formation.Seul le personnel qualifi a le droit de fairefonctionnercet quipement. Utiliserexclusivement les torches indiques dans lemanual. Le personnel nonqualifi et les enfants doivent se tenir lcart.

7. Ne pas enlever, dtruire ni couvrircette tiquette.La remplacersi elle est absente, endommage ou use (PN 110584 Rev C).


36/10611/08

1a-10 Hypertherm

SCURIT

TIQUETTE DE SCURITCette tiquette est affiche sur la source de courant. Il est important quelutilisateur et le technicien de maintenance comprennent la significationdes symboles de scurit. Les numros de la liste correspondent auxnumros des images.

1. Les tincelles de coupage peuventprovoquer une explosion ou un incendie.

1.1 Ne pas couper prs des matiresinflammables.

1.2 Un extincteur doit se trouver sur les lieuxet prt tre utilis.

1.3 Ne pas utiliser un ft ou un autre contenantferm comme table de coupe.2. Larc plasma peut blesser et brler ;

ne jamais pointer la buse vers soi. Larcsamorce instantanment quand on appuiesur la gchette.

2.1 Couper lalimentation avant de dmonterla torche.

2.2 Ne pas saisir la pice prs de la trajectoirede coupage.

2.3 Se protger entirement le corps.3. Tension dangereuse. Risque de choc

lectrique ou de brlure.3.1 Porter des gants isolants. Remplacer les

gants sils sont humides ou endommags.3.2 Se protger contre les chocs en sisolant

de la pice et de la terre.3.3 Couper lalimentation avant dentretenir.

Ne pas toucher les pices sous tension.4. Les fumes du plasma peuvent tre

dangereuses.4.1 Ne pas inhaler les fumes.4.2 Utiliser une ventilation force ou par

aspiration la source pour liminer lesfumes.

4.3 Ne pas utiliser dans des espaces clos.Chasser les fumes avec la ventilation.

5. Le

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