Hypertherm HPR260 User Manual

HyPerformance

Plasma HPR260

Auto gas

Instruction manual 805000 – Revision 5

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HyPerformance Plasma

HPR260 Auto Gas

Instruction Manual

(P/N 805000)

Revision 5 – April, 2008

Hypertherm, HyPerformance, HyDefinition, LongLife and CommandTHC are trademarks of Hypertherm, Inc.

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

Hypertherm, Inc.

Hanover, NH USA

www.hypertherm.com

1/19/07

Hypertherm, Inc.

Etna Road, P.O. Box 5010 Hanover, NH 03755 USA 603-643-3441 Tel (Main Office) 603-643-5352 Fax (All Departments) info@hypertherm.com (Main Office Email)

800-643-9878 Tel (Technical Service)

technical.service@hypertherm.com (Technical Service Email) 800-737-2978 Tel (Customer Service) customer.service@hypertherm.com (Customer Service Email)

Hypertherm Automation

5 Technology Drive, Suite 300 West Lebanon, NH 03784 USA 603-298-7970 Tel 603-298-7977 Fax

Hypertherm Plasmatechnik GmbH

Technologiepark Hanau Rodenbacher Chaussee 6 D-63457 Hanau-Wolfgang, Deutschland 49 6181 58 2100 Tel 49 6181 58 2134 Fax

49 6181 58 2123 (Technical Service)

Hypertherm (S) Pte Ltd.

No. 19 Kaki Bukit Road 2 K.B. Warehouse Complex Singapore 417847, Republic of Singapore 65 6 841 2489 Tel 65 6 841 2490 Fax

65 6 841 2489 (Technical Service)

Hypertherm (Shanghai) Trading Co., Ltd.

Unit 1308-09, Careri Building 432 West Huai Hai Road Shanghai, 200052 PR China 86-21 5258 3330/1 Tel 86-21 5258 3332 Fax

Hypertherm

Branch of Hypertherm, UK, UC PO Box 244 Wigan, Lancashire, England WN8 7WU 00 800 3324 9737 Tel 00 800 4973 7329 Fax

00 800 4973 7843 (Technical Service)

France (Representative office)

15 Impasse des Rosiers 95610 Eragny, France 00 800 3324 9737 Tel 00 800 4973 7329 Fax

Hypertherm S.r.l.

Via Torino 2 20123 Milano, Italia 39 02 725 46 312 Tel 39 02 725 46 400 Fax

39 02 725 46 314 (Technical Service)

Hypertherm Europe B.V.

Vaartveld 9 4704 SE Roosendaal, Nederland 31 165 596907 Tel 31 165 596901 Fax 31 165 596908 Tel (Marketing)

31 165 596900 Tel (Technical Service) 00 800 49 73 7843 Tel (Technical Service)

Hypertherm Japan Ltd.

801 Samty Will Building 2-40 Miyahara 1-Chome, Yodogawa-ku, Osaka 532-0003, Japan 81 6 6170 2020 Tel 81 6 6170 2015 Fax

HYPERTHERM BRASIL LTDA.

Avenida Doutor Renato de

Andrade Maia 350 Parque Renato Maia CEP 07114-000 Guarulhos, SP Brasil 55 11 6409 2636 Tel 55 11 6408 0462 Fax

ELECTROMAGNETIC COMPATIBILITY (EMC)

Hypertherm i

6-07

EMC Introduction

Hypertherm’s CE-marked equipment is built in compliance with standard EN60974-10. The equipment should be installed and used in accordance with the information below to achieve electromagnetic compatibility.

The limits required by EN60974-10 may not be adequate to completely eliminate interference when the affected equipment is in close proximity or has a high degree of sensitivity. In such cases it may be necessary to use other measures to further reduce interference.

This cutting equipment is designed for use only in an industrial environment.

Installation and use

The user is responsible for installing and using the plasma equipment according to the manufacturer’s instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user to resolve the situation with the technical assistance of the manufacturer. In some cases this remedial action may be as simple as earthing the cutting circuit, see Earthing of Workpiece. In other cases it could involve constructing an electromagnetic screen enclosing the power source and the work complete with associated input filters. In all cases electromagnetic disturbances must be reduced to the point where they are no longer troublesome.

Assessment of area

Before installing the equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area. The following shall be taken into account:

a. Other supply cables, control cables, signalling and

telephone cables; above, below and adjacent to the

cutting equipment. b. Radio and television transmitters and receivers. c. Computer and other control equipment. d. Safety critical equipment, for example guarding of

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

pacemakers and hearing aids. f. Equipment used for calibration or measurement. g. Immunity of other equipment in the environment. User

shall ensure that other equipment being used in the

environment is compatible. This may require additional

protection measures.

h. Time of day that cutting or other activities are to be

carried out.

The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.

Methods of reducing emissions

Mains supply

Cutting equipment must be connected to the mains supply according to the manufacturer’s recommendations. If interference occurs, it may be necessary to take additional precautions such as filtering of the mains supply. Consideration should be given to shielding the supply cable of permanently installed cutting equipment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The shielding should be connected to the cutting mains supply so that good electrical contact is maintained between the conduit and the cutting power source enclosure.

Maintenance of cutting equipment

The cutting equipment must be routinely maintained according to the manufacturer’s recommendations. All access and service doors and covers should be closed and properly fastened when the cutting equipment is in operation. The cutting equipment should not be modified in any way except for those changes and adjustments covered in the manufacturer’s instructions. In particular, the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer’s recommendations.

Cutting cables

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

Equipotential bonding

Bonding of all metallic components in the cutting installation and adjacent to it should be considered. However, metallic components bonded to the workpiece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode (nozzle for laser heads) at the same time. The operator should be insulated from all such bonded metallic components.

ELECTROMAGNETIC COMPATIBILITY (EMC)

ii Hypertherm

8-06

Earthing of workpiece

Where the workpiece is not bonded to earth for electrical safety, nor connected to earth because of its size and position, for example, ship’s hull or building steelwork, a connection bonding the workpiece to earth may reduce emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connection of the workpiece to earth should be made by a direct connection to the workpiece, but in some countries where direct connection is not permitted, the bonding should be achieved by suitable capacitances selected according to national regulations.

Note: the cutting circuit may or may not be earthed for safety reasons. Changing the earthing arrangements should only be authorized by a person who is competent to assess whether the changes will increase the risk of injury, for example, by allowing parallel cutting current return paths which may damage the earth circuits of other equipment. Further guidance is given in IEC/TS 62081 Arc Welding Equipment Installation and Use.

Screening and shielding

Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference. Screening of the entire plasma cutting installation may be considered for special applications.

WARRANTY

Hypertherm iii

6-07

Attention

Genuine Hypertherm parts are the factory-recommended replacement parts for your Hypertherm system. Any damage caused by the use of other than genuine Hypertherm parts may not be covered by the Hypertherm warranty.

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

General

Hypertherm, Inc. warrants that its Products shall be free from defects in materials and workmanship, if Hypertherm is notified of a defect (i) with respect to the power supply within a period of two (2) years from the date of its delivery to you, with the exception of Powermax Series power supplies, which shall be within a period of three (3) years from the date of delivery to you, and (ii) with respect to the torch and leads within a period of one (1) year from its date of delivery to you, and with respect to torch lifter assemblies within a period of one (1) year from its date of delivery to you, and with respect to laser heads within a period of one (1) year from its date of delivery to you. This warranty shall not apply to any Product which has been incorrectly installed, modified, or otherwise damaged. Hypertherm, at its sole option, shall repair, replace, or adjust, free of charge, any defective Products covered by this warranty which shall be returned with Hypertherm’s prior authorization (which shall not be unreasonably withheld), properly packed, to Hypertherm’s place of business in Hanover, New Hampshire, or to an authorized Hypertherm repair facility, all costs, insurance and freight prepaid. Hypertherm shall not be liable for any repairs, replacement, or adjustments of Products covered by this warranty, except those made pursuant to this paragraph or with Hypertherm’s prior written consent. The warranty

above is exclusive and is in lieu of all other warranties, express, implied, statutory, or otherwise with respect to the Products or as to the results which may be obtained therefrom, and all implied warranties or conditions of quality or of merchantability or fitness for a particular purpose or against infringement. The foregoing shall constitute the sole and exclusive remedy for any breach by Hypertherm of its warranty. Distributors/OEMs may

offer different or additional warranties, but Distributors/ OEMs are not authorized to give any additional warranty protection to you or make any representation to you purporting to be binding upon Hypertherm.

Certification test marks

Certified products are identified by one or more certification test marks from accredited testing laboratories. The certification test marks are located on or near the data plate. Each certification test mark means that the product and its safety-critical components conform to the relevant national safety standards as reviewed by that testing laboratory. Hypertherm places a certification test mark on its products only after that product is manufactured with safety-critical components that have been authorized by the accredited testing laboratory.

Once the product has left the Hypertherm factory, the certification test marks are invalidated if any of the following occurs:

• The product is significantly modified in a manner that creates a hazard or non-conformance.

• Safety-critical components are replaced with unauthorized spare parts.

• Any unauthorized assembly or accessory that uses or generates a hazardous voltage is added.

• There is any tampering with a safety circuit or other feature that is designed into the product as part of the certification.

CE marking constitutes a manufacturer’s declaration of conformity to applicable European directives and standards. Only those versions of Hypertherm products with a CE Marking located on or near the data plate have been tested for compliance with the European Low Voltage Directive and the European EMC Directive. EMC filters needed to comply with the European EMC Directive are incorporated within versions of the power supply with a CE Marking.

Patent indemnity

Except only in cases of products not manufactured by Hypertherm or manufactured by a person other than Hypertherm not in strict conformity with Hypertherm’s specifications and in cases of designs, processes, formulae, or combinations not developed or purported to be developed by Hypertherm, Hypertherm will defend or settle, at its own expense, any suit or proceeding brought against you alleging that the use of the Hypertherm product, alone and not in combination with any other product not supplied by Hypertherm, infringes any patent of any third party. You shall notify Hypertherm promptly upon learning of any action or threatened action in connection with any such alleged infringement, and Hypertherm’s

WARRANTY

iv Hypertherm

6-07

obligation to indemnify shall be conditioned upon Hypertherm’s sole control of, and the indemnified party’s cooperation and assistance in, the defense of the claim.

Limitation of liability

In no event shall Hypertherm be liable to any person or entity for any incidental, consequential, indirect, or punitive damages (including but not limited to lost profits) regardless of whether such liability is based on breach of contract, tort, strict liability, breach of warranties, failure of essential purpose or otherwise and even if advised of the possibility of such damages.

Liability cap

In no event shall Hypertherm’s liability, whether such liability is based on breach of contract, tort, strict liability, breach of warranties, failure of essential purpose or otherwise, for any claim action suit or proceeding arising out of or relating to the use of the Products exceed in the aggregate the amount paid for the Products that gave rise to such claim.

Insurance

At all times you will have and maintain insurance in such quantities and types, and with coverage sufficient and appropriate to defend and to hold Hypertherm harmless in the event of any cause of action arising from the use of the Products.

National and Local codes

National and Local codes governing plumbing and electrical installation shall take precedent over any instructions contained in this manual. In no event shall Hypertherm be liable for injury to persons or property damage by reason of any code violation or poor work practices.

Transfer of rights

You may transfer any remaining rights you may have hereunder only in connection with the sale of all or substantially all of your assets or capital stock to a successor in interest who agrees to be bound by all of the terms and conditions of this Warranty.

Proper disposal of Hypertherm products

Hypertherm plasma cutting systems, like all electronic products, may contain materials or components, such as printed circuit boards, that cannot be discarded with ordinary waste. It is your responsibility to dispose of any Hypertherm product or component part in an environmentally acceptable manner according to national and local codes.

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

• In the European Union, check the EU directives, national, and local laws. For more information, visit www.hypertherm.com/weee.

• In other countries, check national and local laws.

HPR260 Auto Gas Instruction Manual v

Electromagnetic Compatibility (EMC) ...................................................................................................................................i

Warranty........................................................................................................................................................................................ii

Section 1 SAFETY ..............................................................................................................................................................1-1

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

Follow safety instructions .........................................................................................................................................................................1-2

Cutting can cause fire or explosion........................................................................................................................................................1-2

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

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

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

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

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

Grounding safety........................................................................................................................................................................................1-5

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

Gas cylinders can explode if damaged.................................................................................................................................................1-6

Noise can damage hearing ......................................................................................................................................................................1-6

Pacemaker and hearing aid operation...................................................................................................................................................1-6

A plasma arc can damage frozen pipes................................................................................................................................................1-6

Additional safety information....................................................................................................................................................................1-6

Warning labels.............................................................................................................................................................................................1-7

Section 1a SÉCURITÉ ......................................................................................................................................................1a-1

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

Suivre les instructions de sécurité .......................................................................................................................................................1a-2

Le coupage peut provoquer un incendie ou une explosion ...........................................................................................................1a-2

Les chocs électriques peuvent être fatals..........................................................................................................................................1a-3

L’électricité statique peut endommager les cartes de circuits imprimés ....................................................................................1a-3

Les vapeurs toxiques peuvent provoquer des blessures ou la mort ............................................................................................1a-4

L’arc plasma peut provoquer des blessures ou des brûlures ........................................................................................................1a-5

Les rayons de l’arc peuvent brûler les yeux et la peau....................................................................................................................1a-5

Mise à la masse et à la terre..................................................................................................................................................................1a-5

Sécurité des bouteilles de gaz comprimé ..........................................................................................................................................1a-6

Les bouteilles de gaz comprimé peuvent exploser en cas de dommages .................................................................................1a-6

Le bruit peut provoquer des problèmes auditifs...............................................................................................................................1a-6

Pacemakers et prothèses auditives .....................................................................................................................................................1a-6

Un arc plasma peut endommager les tuyaux gelés..........................................................................................................................1a-6

Étiquettes de sécurité..............................................................................................................................................................................1a-7

Section 1b SEGURIDAD .................................................................................................................................................1b-1

Reconocimiento de información de seguridad .................................................................................................................................1b-2

Siga las instrucciones de seguridad ...................................................................................................................................................1b-2

Los cortes pueden provocar incendios o explosiones....................................................................................................................1b-2

El choque eléctrico puede provocar la muerte.................................................................................................................................1b-3

Electricidad estática puede dañar tablillas de circuito....................................................................................................................1b-3

Humos tóxicos pueden causar lesiones o muerte ...........................................................................................................................1b-4

El arco de plasma puede causar lesiones y quemaduras ..............................................................................................................1b-5

Los rayos del arco pueden producir quemaduras en los ojos y en la piel .................................................................................1b-5

Seguridad de toma a tierra....................................................................................................................................................................1b-5

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vi HPR260 Auto Gas Instruction Manual

Seguridad de los equipos de gas comprimido.................................................................................................................................1b-6

Los cilindros de gas pueden explotar si están dañados.................................................................................................................1b-6

El ruido puede deteriorar la audición ..................................................................................................................................................1b-6

Operación de marcapasos y de audífonos........................................................................................................................................1b-6

Un arco plasma puede dañar tubos congelados .............................................................................................................................1b-6

Etiquetas de advertencia........................................................................................................................................................................1b-7

Section 2 SPECIFICATIONS .............................................................................................................................................2-1

System description ....................................................................................................................................................................................2-3

General...............................................................................................................................................................................................2-3

Power supply ...................................................................................................................................................................................2-3

Ignition console ................................................................................................................................................................................2-3

Selection console ............................................................................................................................................................................2-3

Metering console .............................................................................................................................................................................2-3

Torch ...................................................................................................................................................................................................2-3

Specifications..............................................................................................................................................................................................2-4

System gas requirements ..............................................................................................................................................................2-4

Power supply ....................................................................................................................................................................................2-5

Ignition console – 078172.............................................................................................................................................................2-6

Selection console – 078185 ........................................................................................................................................................2-8

Metering console – 078184 .........................................................................................................................................................2-9

Torch – 128818.............................................................................................................................................................................2-10

Section 3 INSTALLATION...................................................................................................................................................3-1

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

Claims ...........................................................................................................................................................................................................3-3

Installation requirements...........................................................................................................................................................................3-3

Noise levels..................................................................................................................................................................................................3-3

Placement of system components .........................................................................................................................................................3-3

Torque specifications ......................................................................................................................................................................3-3

Installation requirements...........................................................................................................................................................................3-4

System components........................................................................................................................................................................3-5

Cables and hoses............................................................................................................................................................................3-5

Supply gas hoses ............................................................................................................................................................................3-5

Customer supplied power cable..................................................................................................................................................3-5

Recommended grounding and shielding practices............................................................................................................................3-6

Introduction..................................................................................................................................................................................................3-6

Types of grounding ..........................................................................................................................................................................3-6

Steps to take.....................................................................................................................................................................................3-7

Grounding diagram.......................................................................................................................................................................3-10

Placement of the power supply..................................................................................................................................................3-11

Install the ignition console...........................................................................................................................................................3-12

Placement of the selection console..........................................................................................................................................3-14

Install the metering console ........................................................................................................................................................3-15

Power supply to ignition console leads..............................................................................................................................................3-16

Pilot arc lead...................................................................................................................................................................................3-16

Negative lead..................................................................................................................................................................................3-16

TABLE OF CONTENTS

HPR260 Auto Gas Instruction Manual vii

Ignition console power cable......................................................................................................................................................3-18

Ignition console coolant hoses...................................................................................................................................................3-19

Power supply to selection console cables.........................................................................................................................................3-20

Control cable..................................................................................................................................................................................3-20

Power cable....................................................................................................................................................................................3-20

Selection console to metering console connections ......................................................................................................................3-22

Cable and gas hose assembly ...................................................................................................................................................3-22

Power supply to CNC interface cable................................................................................................................................................3-24

Optional multi-system CNC interface cable ...........................................................................................................................3-24

Notes to CNC interface cable run list ......................................................................................................................................3-25

Examples of output circuits.........................................................................................................................................................3-26

Examples of input circuits............................................................................................................................................................3-27

Remote ON/OFF switch........................................................................................................................................................................3-28

Torch lead assembly................................................................................................................................................................................3-29

Work lead ..................................................................................................................................................................................................3-30

Torch connections....................................................................................................................................................................................3-31

Connect the torch to the torch lead assembly.......................................................................................................................3-31

Connect the torch to the quick-disconnect.............................................................................................................................3-34

Torch mounting and alignment..............................................................................................................................................................3-35

Mounting the torch........................................................................................................................................................................3-35

Torch alignment..............................................................................................................................................................................3-35

Torch lifter requirement...........................................................................................................................................................................3-35

Power requirements................................................................................................................................................................................3-36

General............................................................................................................................................................................................3-36

Line disconnect switch ................................................................................................................................................................3-36

Power cable....................................................................................................................................................................................3-36

Connect the power..................................................................................................................................................................................3-37

Torch coolant requirements...................................................................................................................................................................3-38

Standard installation.....................................................................................................................................................................3-38

Coolant for cold operating temperatures.................................................................................................................................3-39

Coolant for hot operating temperatures...................................................................................................................................3-40

Water purity requirements.....................................................................................................................................................................3-40

Fill the power supply with coolant........................................................................................................................................................3-41

Gas requirements ....................................................................................................................................................................................3-42

Setting the supply regulators......................................................................................................................................................3-42

Gas regulators..........................................................................................................................................................................................3-43

Supply gas plumbing ..............................................................................................................................................................................3-44

Connect the supply gases ..........................................................................................................................................................3-44

Supply gas hoses ....................................................................................................................................................................................3-45

Section 4 OPERATION........................................................................................................................................................4-1

Daily start-up................................................................................................................................................................................................4-2

Check torch.......................................................................................................................................................................................4-2

Power indicators.........................................................................................................................................................................................4-3

Power supply ...................................................................................................................................................................................4-3

Selection console ...........................................................................................................................................................................4-3

TABLE OF CONTENTS

viii HPR260 Auto Gas Instruction Manual

Metering console .............................................................................................................................................................................4-3

CNC controller requirements ..................................................................................................................................................................4-4

CNC screen examples ..............................................................................................................................................................................4-5

Main (control) screen......................................................................................................................................................................4-5

Diagnostic screen............................................................................................................................................................................4-6

Test screen.........................................................................................................................................................................................4-7

Cut chart screen...............................................................................................................................................................................4-8

Consumable selection...............................................................................................................................................................................4-9

Mild steel............................................................................................................................................................................................4-9

Stainless steel................................................................................................................................................................................4-10

Aluminum.........................................................................................................................................................................................4-10

Install consumables.................................................................................................................................................................................4-11

Cut charts..................................................................................................................................................................................................4-12

Bevel cutting...................................................................................................................................................................................4-12

Marking ............................................................................................................................................................................................4-12

Consumables for mirror-image cutting.....................................................................................................................................4-12

Estimated kerf width compensation..........................................................................................................................................4-13

Changing consumable parts .................................................................................................................................................................4-42

Remove consumables..................................................................................................................................................................4-42

Inspect consumables....................................................................................................................................................................4-43

Inspect torch...................................................................................................................................................................................4-44

Inspect electrode pit depth.........................................................................................................................................................4-45

Replace torch water tube.......................................................................................................................................................................4-46

Common cutting faults............................................................................................................................................................................4-47

How to optimize cut quality...................................................................................................................................................................4-48

Tips for table and torch................................................................................................................................................................4-48

Plasma set-up tips.........................................................................................................................................................................4-48

Maximize the life of consumable parts......................................................................................................................................4-48

Additional factors of cut quality..................................................................................................................................................4-49

Additional improvements .............................................................................................................................................................4-50

Section 5 MAINTENANCE .................................................................................................................................................5-1

Routine maintenance.................................................................................................................................................................................5-3

Control and signal cables ..............................................................................................................................................................5-4

Sequence of operation..............................................................................................................................................................................5-5

Gas system purge cycle ...........................................................................................................................................................................5-6

Gas system valve usage ...........................................................................................................................................................................5-6

Marking process...............................................................................................................................................................................5-8

PCB block diagram....................................................................................................................................................................................5-9

Error codes................................................................................................................................................................................................5-10

Error code troubleshooting – 1 of 10.......................................................................................................................................5-11

Error code troubleshooting – 2 of 10.......................................................................................................................................5-12

Error code troubleshooting – 3 of 10.......................................................................................................................................5-13

Error code troubleshooting – 4 of 10.......................................................................................................................................5-14

Error code troubleshooting – 5 of 10.......................................................................................................................................5-15

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HPR260 Auto Gas Instruction Manual ix

Error code troubleshooting – 6 of 10.......................................................................................................................................5-16

Error code troubleshooting – 7 of 10.......................................................................................................................................5-17

Error code troubleshooting – 8 of 10.......................................................................................................................................5-18

Error code troubleshooting – 9 of 10.......................................................................................................................................5-19

Error code troubleshooting – 10 of 10 ....................................................................................................................................5-20

Power supply states................................................................................................................................................................................5-21

Plasma system operation with pump time-out ..................................................................................................................................5-22

CNC operation with pump time-out ....................................................................................................................................................5-23

Initial checks..............................................................................................................................................................................................5-24

Power measurement ...............................................................................................................................................................................5-25

Power supply coolant system servicing..............................................................................................................................................5-26

Draining the coolant system. ......................................................................................................................................................5-26

Coolant system filter................................................................................................................................................................................5-27

Filter replacement..........................................................................................................................................................................5-27

Coolant flow troubleshooting chart .....................................................................................................................................................5-28

Coolant flow tests....................................................................................................................................................................................5-29

Before testing.................................................................................................................................................................................5-29

Using the Hypertherm flow meter (128933) ..........................................................................................................................5-29

Manual pump operation...............................................................................................................................................................5-30

Test 1 – return line......................................................................................................................................................................5-31

Test 2 – supply line at ignition console .................................................................................................................................5-31

Test 3 – change the torch.........................................................................................................................................................5-32

Test 4 – supply line to the torch receptacle .........................................................................................................................5-32

Test 5 – return line from the torch receptacle......................................................................................................................5-32

Test 6 – bucket test at the pump ............................................................................................................................................5-33

Test 7 – bypass the check valve .............................................................................................................................................5-33

Pump and motor troubleshooting..............................................................................................................................................5-34

Testing the flow switch.................................................................................................................................................................5-35

Gas leak tests...........................................................................................................................................................................................5-36

Power supply control board PCB3 .....................................................................................................................................................5-38

Power supply power distribution board PCB2.................................................................................................................................5-39

Start circuit PCB1 ...................................................................................................................................................................................5-40

Operation ........................................................................................................................................................................................5-40

Start circuit functional schematic ..............................................................................................................................................5-40

Start circuit troubleshooting .......................................................................................................................................................5-40

Pilot arc current levels..................................................................................................................................................................5-42

Selection console control board PCB2 .............................................................................................................................................5-43

Selection console power distribution board PCB1.........................................................................................................................5-44

Selection console AC valve-driver board PCB3 ..............................................................................................................................5-45

Metering console control board PCB2 ..............................................................................................................................................5-46

Metering console power distribution board PCB1 ..........................................................................................................................5-47

Chopper tests...........................................................................................................................................................................................5-48

Phase-loss detection test ......................................................................................................................................................................5-50

Torch lead test ..........................................................................................................................................................................................5-51

Preventive maintenance..........................................................................................................................................................................5-52

TABLE OF CONTENTS

x HPR260 Auto Gas Instruction Manual

Section 6 PARTS LIST ........................................................................................................................................................6-1

Power supply...............................................................................................................................................................................................6-2

Ignition console ..........................................................................................................................................................................................6-7

Selection console – 1 of 2.......................................................................................................................................................................6-8

Selection console – 2 of 2.......................................................................................................................................................................6-9

Metering console........................................................................................................................................................................................6-9

HyPerformance torch..............................................................................................................................................................................6-10

Torch assembly ..............................................................................................................................................................................6-10

Torch leads......................................................................................................................................................................................6-10

Consumable parts kit – 228027..........................................................................................................................................................6-11

Consumables for mirror-image cutting ...............................................................................................................................................6-12

Recommended spare parts...................................................................................................................................................................6-13

Section 7 WIRING DIAGRAMS........................................................................................................................................7-1

Wiring Diagrams.........................................................................................................................................................................................7-5

Appendix A BENZOTRIAZOLE / PROPYLENE GLYCOL SAFETY DATA ...............................................................a-1

Section 1 Chemical Product and Company Identification..............................................................................................................a-2

Section 2 Composition / Information on Ingredients.......................................................................................................................a-2

Section 3 Hazards Identification...........................................................................................................................................................a-2

Section 4 First Aid Measures................................................................................................................................................................a-3

Section 5 Fire Fighting Measures.........................................................................................................................................................a-3

Section 6 Accidental Release Measures............................................................................................................................................a-3

Section 7 Handling and Storage..........................................................................................................................................................a-3

Section 8 Exposure Controls / Personal Protection ........................................................................................................................a-4

Section 9 Physical and Chemical Properties ....................................................................................................................................a-4

Section 10 Stability and Reactivity.........................................................................................................................................................a-4

Section 11 Toxicological Information .....................................................................................................................................................a-4

Section 12 Ecological Information..........................................................................................................................................................a-5

Section 13 Disposal Considerations .....................................................................................................................................................a-5

Section 14 Transport Information ...........................................................................................................................................................a-5

Section 15 Regulatory Information.........................................................................................................................................................a-5

Section 16 Other Information..................................................................................................................................................................a-5

Freezing point of Propylene Glycol solution.........................................................................................................................................a-6

Appendix B CNC INTERFACE PROTOCOL ...................................................................................................................b-1

Interface hardware......................................................................................................................................................................................b-2

Signal list......................................................................................................................................................................................................b-2

Signals................................................................................................................................................................................................b-2

Hardware ...........................................................................................................................................................................................b-3

Multi-drop wiring...............................................................................................................................................................................b-4

Multi-drop addressing.....................................................................................................................................................................b-5

Serial commands........................................................................................................................................................................................b-5

Format.................................................................................................................................................................................................b-5

Framing...............................................................................................................................................................................................b-5

Commands ........................................................................................................................................................................................b-5

TABLE OF CONTENTS

HPR260 Auto Gas Instruction Manual xi

Command tables..............................................................................................................................................................................b-6

Error responses..............................................................................................................................................................................b-19

Calculating checksums................................................................................................................................................................b-19

Status codes.............................................................................................................................................................................................b-22

Gas type codes........................................................................................................................................................................................b-22

CNC requirements ..................................................................................................................................................................................b-23

Auto gas console...........................................................................................................................................................................b-23

Serial interface guidelines......................................................................................................................................................................b-24

Application notes .....................................................................................................................................................................................b-24

Appendix C CUT CHARTS FOR PREVIOUS SYSTEM REVISIONS........................................................................c-1

Appendix D BEVEL CUTTING ...........................................................................................................................................d-1

Bevel torch dimensions.............................................................................................................................................................................d-2

Bevel cutting definitions............................................................................................................................................................................d-3

Connect the torch lead assembly to the quick-disconnect assembly...............................................................................d-12

Parts list......................................................................................................................................................................................................d-14

Consumables..................................................................................................................................................................................d-14

Part selection..................................................................................................................................................................................d-15

Hypertherm Plasma Systems 1-1

8-06

Section 1

SAFETY

In this section:

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

Follow safety instructions..........................................................................................................................................1-2

Cutting can cause fire or explosion...........................................................................................................................1-2

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

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

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

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

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

Grounding safety ......................................................................................................................................................1-5

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

Gas cylinders can explode if damaged.....................................................................................................................1-6

Noise can damage hearing.......................................................................................................................................1-6

Pacemaker and hearing aid operation......................................................................................................................1-6

A plasma arc can damage frozen pipes....................................................................................................................1-6

Additional safety information.....................................................................................................................................1-6

Warning labels..........................................................................................................................................................1-7

1-2 Hypertherm Plasma Systems

11-98

SAFETY

RECOGNIZE SAFETY INFORMATION

The symbols shown in this section are used to identify potential hazards. When you see a safety symbol in this manual or on your machine, understand the potential for personal injury, and follow the related instructions to avoid the hazard.

FOLLOW SAFETY INSTRUCTIONS

Read carefully all safety messages in this manual and safety labels on your machine.

• Keep the safety labels on your machine in good

condition. Replace missing or damaged labels immediately.

• Learn how to operate the machine and how to use

the controls properly. Do not let anyone operate it without instruction.

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

DANGER WARNING CAUTION

A signal word DANGER or WARNING is used with a safety symbol. DANGER identifies the most serious hazards.

• DANGER and WARNING safety labels are located on your machine near specific hazards.

• WARNING safety messages precede related instructions in this manual that may result in injury or death if not followed correctly.

• CAUTION safety messages precede related instructions in this manual that may result in damage to equipment if not followed correctly.

Fire prevention

• Be sure the area is safe before doing any cutting. Keep a fire extinguisher nearby.

• Remove all flammables within 35 feet (10 m) of the cutting area.

• Quench hot metal or allow it to cool before handling or before letting it touch combustible materials.

• Never cut containers with potentially flammable materials inside – they must be emptied and properly cleaned first.

• Ventilate potentially flammable atmospheres before cutting.

• When cutting with oxygen as the plasma gas, an exhaust ventilation system is required.

Explosion prevention

• Do not use the plasma system if explosive dust or vapors may be present.

• Do not cut pressurized cylinders, pipes, or any closed container.

• Do not cut containers that have held combustible materials.

CUTTING CAN CAUSE FIRE OR EXPLOSION

WARNING

Explosion Hazard

Argon-Hydrogen and Methane

Hydrogen and methane are flammable gases that present an explosion hazard. Keep flames away from cylinders and hoses that contain methane or hydrogen mixtures. Keep flames and sparks away from the torch when using methane or argon-hydrogen plasma.

WARNING

Hydrogen Detonation

with Aluminum Cutting

• When cutting aluminum underwater, or with the water touching the underside of the aluminum, free hydrogen gas may collect under the workpiece and detonate during plasma cutting operations.

• Install an aeration manifold on the floor of the water table to eliminate the possibility of hydrogen detonation. Refer to the Appendix section of this manual for aeration manifold details.

Hypertherm Plasma Systems 1-3

8-06

SAFETY

Touching live electrical parts can cause a fatal shock or severe burn.

• Operating the plasma system completes an electrical circuit between the torch and the workpiece. The workpiece and anything touching the workpiece are part of the electrical circuit.

• Never touch the torch body, workpiece or the water in a water table when the plasma system is operating.

Electric shock prevention All Hypertherm plasma systems use high voltage

in the cutting process (200 to 400 VDC are common). Take the following precautions when operating this system:

• Wear insulated gloves and boots, and keep your body and clothing dry.

• Do not stand, sit or lie on – or touch – any wet surface when using the plasma system.

• Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground. If you must work in or near a damp area, use extreme caution.

• Provide a disconnect switch close to the power supply with properly sized fuses. This switch allows the operator to turn off the power supply quickly in an emergency situation.

• When using a water table, be sure that it is correctly connected to earth ground.

ELECTRIC SHOCK CAN KILL

• Install and ground this equipment according to the instruction manual and in accordance with national and local codes.

• Inspect the input power cord frequently for damage or cracking of the cover. Replace a damaged power cord immediately. Bare wiring can kill.

• Inspect and replace any worn or damaged torch leads.

• Do not pick up the workpiece, including the waste cutoff, while you cut. Leave the workpiece in place or on the workbench with the work cable attached during the cutting process.

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

• Never bypass or shortcut the safety interlocks.

• Before removing any power supply or system enclosure cover, disconnect electrical input power. Wait 5 minutes after disconnecting the main power to allow capacitors to discharge.

• Never operate the plasma system unless the power supply covers are in place. Exposed power supply connections present a severe electrical hazard.

• When making input connections, attach proper grounding conductor first.

• Each Hypertherm plasma system is designed to be used only with specific Hypertherm torches. Do not substitute other torches which could overheat and present a safety hazard.

Use proper precautions when handling printed circuit boards.

STATIC ELECTRICITYCAN DAMAGE CIRCUIT BOARDS

• Store PC boards in anti-static containers.

• Wear a grounded wrist strap when handling PC boards.

1-4 Hypertherm Plasma Systems

8-06

SAFETY

The plasma arc by itself is the heat source used for cutting. Accordingly, although the plasma arc has not been identified as a source of toxic fumes, the material being cut can be a source of toxic fumes or gases that deplete oxygen.

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

In some cases, the metal may be coated with a substance that could release toxic fumes. Toxic coatings include, but are not limited to, lead (in some paints), cadmium (in some paints and fillers), and beryllium.

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

Caution should be taken to minimize exposure to fumes produced by any industrial process. Depending upon the chemical composition and concentration of the fumes (as well as other factors, such as ventilation), there may be a risk of physical illness, such as birth defects or cancer.

It is the responsibility of the equipment and site owner to test the air quality in the area where the equipment is used and to ensure that the air quality in the workplace meets all local and national standards and regulations.

TOXIC FUMES CAN CAUSE INJURYOR DEATH

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

• Table design (wet, dry, underwater).

• Material composition, surface finish, and composition of coatings.

• Volume of material removed.

• Duration of cutting or gouging.

• Size, air volume, ventilation and filtration of the work area.

• Personal protective equipment.

• Number of welding and cutting systems in operation.

• Other site processes that may produce fumes.

If the workplace must conform to national or local regulations, only monitoring or testing done at the site can determine whether the site is above or below allowable levels.

To reduce the risk of exposure to fumes:

• Remove all coatings and solvents from the metal before cutting.

• Use local exhaust ventilation to remove fumes from the air.

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

• Assure that those using welding or cutting equipment, as well as air-supplied respiration devices, are qualified and trained in the proper use of such equipment.

• Never cut containers with potentially toxic materials inside. Empty and properly clean the container first.

• Monitor or test the air quality at the site as needed.

• Consult with a local expert to implement a site plan to ensure safe air quality.

Hypertherm Plasma Systems 1-5

5-02

SAFETY

Instant-on torches

Plasma arc comes on immediately when the torch switch is activated.

A PLASMAARC CAN CAUSE INJURYAND BURNS

The plasma arc will cut quickly through gloves and skin.

• Keep away from the torch tip.

• Do not hold metal near the cutting path.

• Never point the torch toward yourself or others.

Eye protection Plasma arc rays produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin.

• Use eye protection in accordance with applicable national or local codes.

• Wear eye protection (safety glasses or goggles with side shields, and a welding helmet) with appropriate lens shading to protect your eyes from the arc’s ultraviolet and infrared rays.

Lens shade

Arc current AWS (USA) ISO 4850

Up to 100 A No. 8 No. 11 100-200 A No. 10 No. 11-12 200-400 A No. 12 No. 13 Over 400 A No. 14 No. 14

ARC RAYS CAN BURN EYES AND SKIN

Skin protection Wear protective clothing to protect

against burns caused by ultraviolet light, sparks and hot metal.

• Gauntlet gloves, safety shoes and hat.

• Flame-retardant clothing to cover all exposed areas.

• Cuffless trousers to prevent entry of sparks and slag.

• Remove any combustibles, such as a butane lighter or matches, from your pockets before cutting.

Cutting area Prepare the cutting area to reduce reflection and transmission of ultraviolet light:

• Paint walls and other surfaces with dark colors to reduce reflection.

• Use protective screens or barriers to protect others from flash and glare.

• Warn others not to watch the arc. Use placards or signs.

Work cable Attach the work cable securely to the workpiece or the work table with good metal-to-metal contact. Do not connect it to the piece that will fall away when the cut is complete.

Work table Connect the work table to an earth ground, in accordance with appropriate national or local electrical codes.

GROUNDING SAFETY

Input power

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

• If installation of the plasma system involves connecting the power cord to the power supply, be sure to connect the power cord ground wire properly.

• Place the power cord's ground wire on the stud first, then place any other ground wires on top of the power cord ground. Fasten the retaining nut tightly.

• Tighten all electrical connections to avoid excessive heating.

1-6 Hypertherm Plasma Systems

11-98

SAFETY

• Never lubricate cylinder valves or regulators with oil or grease.

• Use only correct gas cylinders, regulators, hoses and fittings designed for the specific application.

• Maintain all compressed gas equipment and associated parts in good condition.

• Label and color-code all gas hoses to identify the type of gas in each hose. Consult applicable national or local codes.

GAS CYLINDERS CAN EXPLODE IF DAMAGED

COMPRESSED GAS EQUIPMENT SAFETY

Gas cylinders contain gas under high pressure. If damaged, a cylinder can explode.

• Handle and use compressed gas cylinders in accordance with applicable national or local codes.

• Never use a cylinder that is not upright and secured in place.

• Keep the protective cap in place over valve except when the cylinder is in use or connected for use.

• Never allow electrical contact between the plasma arc and a cylinder.

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

• Never use a hammer, wrench or other tool to open a stuck cylinder valve.

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

NOISE CAN DAMAGE HEARING

A PLASMAARC CAN DAMAGE FROZEN PIPES

Pacemaker and hearing aid operation can be affected by magnetic fields from high currents. Pacemaker and hearing aid wearers should consult a doctor before going near any plasma arc cutting and gouging operations.

To reduce magnetic field hazards:

• Keep both the work cable and the torch lead to one side, away from your body.

• Route the torch leads as close as possible to the work cable.

• Do not wrap or drape the torch lead or work cable around your body.

• Keep as far away from the power supply as possible.

PACEMAKER AND HEARING AID OPERATION

ADDITIONAL SAFETY INFORMATION

1. ANSI Standard Z49.1,

Safety in Welding and Cutting,

American Welding Society, 550 LeJeune Road P.O. Box 351020, Miami, FL 33135

2. ANSI Standard Z49.2,

Fire Prevention in the Use of Cutting and

Welding Processes,

American National Standards Institute

1430 Broadway, New York, NY 10018

3. ANSI Standard Z87.1,

Safe Practices for Occupation and

Educational Eye and Face Protection,

American National

Standards Institute, 1430 Broadway, New York, NY 10018

4. AWS F4.1,

Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances,

American Welding Society

550 LeJeune Road, P.O. Box 351040, Miami, FL 33135

5. AWS F5.2,

Recommended Safe Practices for Plasma Arc

Cutting,

American Welding Society

550 LeJeune Road, P.O. Box 351040, Miami, FL 33135

6. CGAPamphlet P-1,

Safe Handling of Compressed Gases in

Cylinders,

Compressed Gas Association

1235 Jefferson Davis Highway, Arlington, VA22202

7. CSAStandard W117.2,

Code for Safety in Welding and Cutting,

Canadian Standards Association Standard Sales 178 Rexdale Boulevard, Rexdale, Ontario M9W 1R3, Canada

8. NFPA Standard 51B,

Cutting and Welding Processes,

National Fire Protection Association 470 Atlantic Avenue, Boston, MA 02210

9. NFPA Standard 70–1978,

National Electrical Code,

National Fire

Protection Association, 470 Atlantic Avenue, Boston, MA 02210

10. OSHA,

Safety and Health Standards,

29FR 1910

U.S. Government Printing Office, Washington, D.C. 20402

Prolonged exposure to noise from cutting or gouging can damage hearing.

• Use approved ear protection when using plasma system.

• Warn others nearby about the noise hazard.

Hypertherm Plasma Systems 1-7

8-99

SAFETY

WARNING LABEL

This warning label is affixed to some power supplies. It is important that the operator and maintenance technician understand the intent of these warning symbols as described.

1-8 Hypertherm Plasma Systems

8-99

SAFETY

WARNING LABEL

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

1. Cutting sparks can cause explosion or fire.

1.1 Keep flammables away from cutting.

1.2 Keep a fire extinguisher nearby, and have a watchperson ready to use it.

1.3 Do not cut on any closed containers.

2. The plasma arc can cause injury and burns.

2.1 Turn off power before disassembling torch.

2.2 Do not hold the material near cutting path.

2.3 Wear complete body protection.

3. Electric shock from torch or wiring can kill. Protect yourself from electric shock.

3.1 Wear insulating gloves. Do not wear wet or damaged gloves.

3.2 Insulate yourself from work and ground.

3.3 Disconnect input plug or power before working on machine.

4. Breathing cutting fumes can be hazardous to your health.

4.1 Keep your head out of the fumes.

4.2 Use forced ventilation or local exhaust to remove the fumes.

4.3 Use ventilating fan to remove the fumes.

5. Arc rays can burn eyes and injure skin.

5.1 Wear hat and safety glasses. Use ear protection and button shirt collar. Use welding helmet with correct shade of filter. Wear complete body protection.

6. Become trained and read the instructions before working on the machine or cutting.

7. Do not remove or paint over (cover) warning labels.

8-06

Hypertherm Systèmes plasma 1a-1

Section 1a

SÉCURITÉ

Dans cette section :

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

Suivre les instructions de sécurité ..........................................................................................................................1a-2

Le coupage peut provoquer un incendie ou une explosion ....................................................................................1a-2

Les chocs électriques peuvent être fatals...............................................................................................................1a-3

L’électricité statique peut endommager les cartes de circuits imprimés.................................................................1a-3

Les vapeurs toxiques peuvent provoquer des blessures ou la mort.......................................................................1a-4

L’arc plasma peut provoquer des blessures ou des brûlures .................................................................................1a-5

Les rayons de l’arc peuvent brûler les yeux et la peau...........................................................................................1a-5

Mise à la masse et à la terre...................................................................................................................................1a-5

Sécurité des bouteilles de gaz comprimé...............................................................................................................1a-6

Les bouteilles de gaz comprimé peuvent exploser en cas de dommages .............................................................1a-6

Le bruit peut provoquer des problèmes auditifs......................................................................................................1a-6

Pacemakers et prothèses auditives........................................................................................................................1a-6

Un arc plasma peut endommager les tuyaux gelés................................................................................................1a-6

Étiquettes de sécurité .............................................................................................................................................1a-7

11-98

1a-2 Hypertherm Systèmes plasma

SÉCURITÉ

IDENTIFIER LES CONSIGNES DE SÉCURITÉ

Les symboles indiqués dans cette section sont utilisés pour identifier les risques éventuels. Si vous trouvez un symbole de sécurité, que ce soit dans ce manuel ou sur l’équipement, soyez conscient des risques de blessures et suivez les instructions correspondantes afin d’éviter ces risques.

SUIVRE LES INSTRUCTIONS DE SÉCURITÉ

Lire attentivement toutes les consignes de sécurité dans le présent manuel et sur les étiquettes de sécurité se trouvant sur la machine.

• Les étiquettes de sécurité doivent rester lisibles. Remplacer immédiatement les étiquettes manquantes ou abîmées.

• Apprendre à faire fonctionner la machine et à utiliser correctement les commandes. Ne laisser personne utiliser la machine sans connaître son fonctionnement.

• Garder la machine en bon état. Des modifications non autorisées sur la machine peuvent engendrer des problèmes de sécurité et raccourcir la durée d’utilisation de l’équipement.

DANGER AVERTISSEMENT PRÉCAUTION

Les signaux DANGER ou AVERTISSEMENT sont utilisés avec un symbole de sécurité, DANGER correspondant aux risques les plus sérieux.

• Les étiquettes de sécurité DANGER et AVERTISSEMENT sont situées sur la machine pour signaler certains dangers spécifiques.

• Les messages d’AVERTISSEMENT précèdent les instructions d’utilisation expliquées dans ce manuel et signalent les risques de blessures ou de mort au cas où ces instructions ne seraient pas suivies correctement.

• Les messages de PRÉCAUTION précèdent les instructions d’utilisation contenues dans ce manuel et signalent que le matériel risque d’être endommagé si les instructions ne sont pas suivies correctement.

Prévention des incendies

• Avant de commencer, s’assurer que la zone de coupage ne présente aucun danger. Conserver un extincteur à proximité.

• Éloigner toute matière inflammable à une distance d’au moins 10 m du poste de coupage.

• Tremper le métal chaud ou le laisser refroidir avant de le manipuler ou avant de le mettre en contact avec des matériaux combustibles.

• Ne jamais couper des récipients pouvant contenir des matières inflammables avant de les avoir vidés et nettoyés correctement.

• Aérer toute atmosphère potentiellement inflammable avant d’utiliser un système plasma.

• Lors de l’utilisation d’oxygène comme gaz plasma, un système de ventilation par aspiration est nécessaire.

Prévention des explosions

• Ne pas couper en présence de poussière ou de vapeurs.

• Ne pas couper de bouteilles, de tuyaux ou autres récipients fermés et pressurisés.

• Ne pas couper de récipients contenant des matières combustibles.

LE COUPAGE PEUT PROVOQUER UN INCENDIE

OU UNE EXPLOSION

AVERTISSEMENT

Risque d’explosion

argon-hydrogène et méthane

L’hydrogène et le méthane sont des gaz inflammables et potentiellement explosifs. Conserver à l’écart de toute flamme les bouteilles et tuyaux contenant des mélanges à base d’hydrogène ou de méthane. Maintenir toute flamme et étincelle à l’écart de la torche lors de l’utilisation d’un plasma d’argon-hydrogène ou de méthane.

AVERTISSEMENT

Détonation de l’hydrogène lors du

coupage de l’aluminium

• Lors du coupage de l’aluminium sous l’eau, ou si l’eau touche la partie inférieure de la pièce d’aluminium, de l’hydrogène libre peut s’accumuler sous la pièce à couper et détonner lors du coupage plasma.

• Installer un collecteur d’aération au fond de la table à eau afin d’éliminer les risques de détonation de l’hydrogène. Se référer à l’annexe du manuel pour plus de renseignements sur les collecteurs d’aération.

8-06

Toucher une pièce électrique sous tension peut provoquer un choc électrique fatal ou des brûlures graves.

• La mise en fonctionnement du système plasma ferme un circuit électrique entre la torche et la pièce à couper. La pièce à couper et tout autre élément en contact avec cette pièce font partie du circuit électrique.

• Ne jamais toucher le corps de la torche, la pièce à couper ou l’eau de la table à eau pendant le fonctionnement du système plasma.

Prévention des chocs électriques

Tous les systèmes plasma Hypertherm utilisent des hautes tensions pour le coupage (souvent de 200 à 400 V). On doit prendre les précautions suivantes quand on utilise le système plasma :

• Porter des bottes et des gants isolants et garder le corps et les vêtements au sec.

• Ne pas se tenir, s’asseoir ou se coucher sur une surface mouillée, ni la toucher quand on utilise le système plasma.

• S’isoler de la surface de travail et du sol en utilisant des tapis isolants secs ou des couvertures assez grandes pour éviter tout contact physique avec le travail ou le sol. S’il s’avère nécessaire de travailler dans ou près d’un endroit humide, procéder avec une extrême prudence.

• Installer un sectionneur avec fusibles appropriés, à proximité de la source de courant. Ce dispositif permet à l’opérateur d’arrêter rapidement la source de courant en cas d’urgence.

• En cas d’utilisation d’une table à eau, s’assurer que cette dernière est correctement mise à la terre.

LES CHOCS ÉLECTRIQUES PEUVENT ÊTRE FATALS

• Installer et mettre à la terre l’équipement selon les instructions du présent manuel et conformément aux codes électriques locaux et nationaux.

• Inspecter fréquemment le cordon d’alimentation primaire pour s’assurer qu’il n’est ni endommagé, ni fendu. Remplacer immédiatement un cordon endommagé. Un câble dénudé peut tuer.

• Inspecter et remplacer les câbles de la torche qui sont usés ou endommagés.

• Ne pas saisir la pièce à couper ni les chutes lors du coupage. Laisser la pièce à couper en place ou sur la table de travail, le câble de retour connecté lors du coupage.

• Avant de vérifier, de nettoyer ou de remplacer les pièces de la torche, couper l’alimentation ou débrancher la prise de courant.

• Ne jamais contourner ou court-circuiter les verrouillages de sécurité.

• Avant d’enlever le capot du système ou de la source de courant, couper l’alimentation électrique. Attendre en

suite

5 minutes pour que les condensateurs se déchargent.

• Ne jamais faire fonctionner le système plasma sans que les capots de la source de courant ne soient en place. Les raccords exposés de la source de courant sont extrêmement dangereux.

• Lors de l’installation des connexions, attacher tout d’abord la prise de terre appropriée.

• Chaque système plasma Hypertherm est conçu pour être utilisé uniquement avec des torches Hypertherm spécifiques. Ne pas utiliser des torches inappropriées qui pourraient surchauffer et présenter des risques pour la sécurité.

On doit prendre les précautions qui s’imposent quand on manipule les circuits imprimés.

L’ÉLECTRICITÉ STATIQUE PEUT ENDOMMAGER

LES CARTES DE CIRCUITS IMPRIMÉS

• On doit ranger les cartes de circuits imprimés dans

des contenants antistatiques.

• On doit porter un bracelet antistatique quand on

manipule les cartes de circuits imprimés.

Hypertherm Systèmes plasma 1a-3

SÉCURITÉ

8-06

1a-4 Hypertherm Systèmes plasma

SÉCURITÉ

L’arc plasma est lui-même la source de chaleur utilisée pour le coupage. Par conséquent, bien que l’arc plasma n’ait pas été reconnu comme une source de vapeurs toxiques, le matériau coupé peut être une source de vapeurs ou de gaz toxiques qui épuisent l’oxygène.

Les vapeurs produites varient selon le métal coupé. Les métaux qui peuvent dégager des vapeurs toxiques comprennent, entre autres, l’acier inoxydable, l’acier au carbone, le zinc (galvanisé) et le cuivre.

Dans certains cas, le métal peut être revêtu d’une substance susceptible de dégager des vapeurs toxiques. Les revêtements toxiques comprennent entre autres, le plomb (dans certaines peintures), le cadmium (dans certaines peintures et enduits) et le béryllium.

Les gaz produits par le coupage plasma varient selon le matériau à couper et la méthode de coupage, mais ils peuvent comprendre l’ozone, les oxydes d’azote, le chrome hexavalent, l’hydrogène et autres substances présentes dans le matériau coupé ou en émanent.

On doit prendre les précautions qui s’imposent pour réduire au minimum l’exposition aux vapeurs produites par tout processus industriel. Selon la composition chimique et la concentration des vapeurs (ainsi que d’autres facteurs comme la ventilation), il peut y avoir un risque de maladie physique, comme des malformations ou le cancer.

Il incombe au propriétaire du matériel et du site de vérifier la qualité de l’air dans le secteur où l’on utilise le matériel et de s’assurer que la qualité de l’air sur les lieux de travail répond aux normes et réglementation locales et nationales.

LES VAPEURS TOXIQUES PEUVENT PROVOQUER

DES BLESSURES OU LA MORT

Le niveau de qualité de l’air dans tout lieu de travail dépend des variables propres au site comme :

• Type de table (humide, sèche, sous l’eau).

• Composition du matériau, fini de la surface et composition des revêtements.

• Volume de matériau enlevé.

• Durée du coupage ou du gougeage.

• Dimensions, volume d’air, ventilation et filtration de la zone de travail.

• Équipement de protection individuelle.

• Nombre de systèmes de soudage et de coupage en fonctionnement.

• Autres procédés du site qui peuvent produire des vapeurs.

Si les lieux de travail doivent être conformes aux règlements nationaux ou locaux, seuls les contrôles ou les essais effectués au site peuvent déterminer si celui-ci se situe au-dessus ou au-dessous des niveaux admissibles.

Pour réduire le risque d’exposition aux vapeurs :

• Éliminer tout revêtement et solvant du métal avant le coupage.

• Utiliser la ventilation d’extraction locale pour éliminer les vapeurs de l’air.

• Ne pas inhaler les vapeurs. Porter un respirateur à adduction d’air quand on coupe des métaux revêtus d’éléments toxiques ou qui en contiennent ou sont susceptibles d’en contenir.

• S’assurer que les personnes qui utilisent un matériel de soudage ou de coupage ainsi que les dispositifs de respiration par adduction d’air sont qualifiés et ont reçu la formation sur la bonne utilisation d’un tel matériel.

• Ne jamais couper les contenants dans lesquels il peut y avoir des matériaux toxiques. En premier lieu, vider et nettoyer correctement le contenant.

• Contrôler ou éprouver la qualité de l’air au site selon les besoins.

• Consulter un expert local pour mettre en œuvre un plan du site afin d’assurer une qualité de l’air sûre.

5-02

Torches à allumage instantané

L’arc plasma s’allume immédiatement après que la torche soit mise en marche.

L’ARC PLASMAPEUT PROVOQUER DES BLESSURES OU DES BRÛLURES

L’arc plasma coupe facilement les gants et la peau.

• Rester éloigné de l’extrémité de la torche.

• Ne pas tenir de métal près de la trajectoire de coupe.

• Ne jamais pointer la torche vers soi ou d’autres personnes.

Protection des yeux Les rayons de l’arc plasma produisent de puissants rayons visibles ou invisibles (ultraviolets et infrarouges) qui peuvent brûler les yeux et la peau.

• Utiliser des lunettes de sécurité conformément aux codes locaux ou nationaux en vigueur.

• Porter des lunettes de protection (lunettes ou masque muni d’écrans latéraux et encore masque de soudure) avec des verres teintés appropriés pour protéger les yeux des rayons ultraviolets et infrarouges de l’arc.

Puissance des verres teintés

Courant de l’arc AWS (É.-U.) ISO 4850

Jusqu’à 100 A No8N

11 100-200 A No10 No11-12 200-400 A No12 No13 Plus de 400 A No14 No14

LES RAYONS DE L’ARC PEUVENT BRÛLER LES YEUX ET LA PEAU

Protection de la peau Porter des vêtements de sécurité

pour se protéger contre les brûlures que peuvent causer les rayons ultraviolets, les étincelles et le métal brûlant :

• Gants à crispin, chaussures et casque de sécurité.

• Vêtements ignifuges couvrant toutes les parties exposées du corps.

• Pantalon sans revers pour éviter que des étincelles ou des scories puissent s’y loger.

• Avant le coupage, retirer de ses poches tout objet combustible comme les briquets au butane ou les allumettes.

Zone de coupage Préparer la zone de coupage afin de réduire la réverbération et la transmission de la lumière ultraviolette :

• Peindre les murs et autres surfaces de couleur sombre pour réduire la réflexion de la lumière.

• Utiliser des écrans et autres dispositifs de protection afin de protéger les autres personnes de la lumière et de la réverbération.

• Prévenir les autres personnes de ne pas regarder l’arc. Utiliser des affiches ou des panneaux.

Câble de retour Bien fixer le câble de retour (ou de masse) à la pièce à couper ou à la table de travail de façon à assurer un bon contact métal-métal. Ne pas fixer le câble de retour à la partie de la pièce qui doit se détacher.

Table de travail Raccorder la table de travail à la terre, conformément aux codes de sécurité locaux ou nationaux appropriés.

MISE À LA MASSE ET À LATERRE

Alimentation

• S’assurer que le fil de terre du cordon d’alimentation est connecté à la terre dans le coffret du sectionneur.

• S’il est nécessaire de brancher le cordon d’alimentation à la source de courant lors de l’installation du système, s’assurer que le fil de terre est correctement branché.

• Placer tout d’abord le fil de terre du cordon d’alimentation sur le plot de mise à la terre puis placer les autres fils de terre par-dessus. Bien serrer l’écrou de retenue.

• S’assurer que toutes les connexions sont bien serrées pour éviter la surchauffe.

Hypertherm Systèmes plasma 1a-5

SÉCURITÉ

11-98

1a-6 Hypertherm Systèmes plasma

SÉCURITÉ

• Ne jamais lubrifier les robinets des bouteilles ou les régulateurs avec de l’huile ou de la graisse.

• Utiliser uniquement les bouteilles, régulateurs, tuyaux et accessoires appropriés et conçus pour chaque application spécifique.

• Entretenir l’équipement et les pièces d’équipement à gaz comprimé afin de les garder en bon état.

• Étiqueter et coder avec des couleurs tous les tuyaux de gaz afin d’identifier le type de gaz contenu dans chaque tuyau. Se référer aux codes locaux ou nationaux en vigueur.

LES BOUTEILLES DE GAZ COMPRIMÉ PEUVENT EXPLOSER EN CAS DE DOMMAGES

SÉCURITÉ DES BOUTEILLES DE GAZ COMPRIMÉ

Les bouteilles de gaz contiennent du gaz à haute pression. Si une bouteille est endommagée, elle peut exploser.

• Manipuler et utiliser les bouteilles de gaz comprimé conformément aux codes locaux ou nationaux.

• Ne jamais utiliser une bouteille qui n’est pas placée à la verticale et bien assujettie.

• Le capuchon de protection doit être placé sur le robinet sauf si la bouteille est en cours d’utilisation ou connectée pour utilisation.

• Éviter à tout prix le contact électrique entre l’arc plasma et une bouteille.

• Ne jamais exposer des bouteilles à une chaleur excessive, aux étincelles, aux scories ou aux flammes nues.

• Ne jamais utiliser des marteaux, des clés ou d’autres outils pour débloquer le robinet des bouteilles.

Les tuyaux gelés peuvent être endommagés ou éclater si l'on essaie de les dégeler avec une torche plasma.

LE BRUIT PEUT PROVOQUER DES

PROBLÈMES AUDITIFS

UN ARC PLASMA PEUT ENDOMMAGER LES TUYAUX GELÉS

Les champs magnétiques produits par les courants à haute tension peuvent affecter le fonctionnement des prothèses auditives et des pacemakers. Les personnes portant ce type d’appareil doivent consulter un médecin avant de s’approcher d’un lieu où s’effectue le coupage ou le gougeage plasma.

Pour réduire les risques associés aux champs magnétiques :

• Garder loin de soi et du même côté du corps le câble de retour et le faisceau de la torche.

• Faire passer le faisceau de la torche le plus près possible du câble de retour.

• Ne pas s’enrouler le faisceau de la torche ou le câble de retour autour du corps.

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

PACEMAKERS ET PROTHÈSES AUDITIVES

Une exposition prolongée au bruit du coupage ou du gougeage peut provoquer des problèmes auditifs.

• Utiliser un casque de protection homologué lors de l’utilisation du système plasma.

• Prévenir les personnes aux alentours des risques encourus en cas d’exposition au bruit.

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Étiquette de sécurité

Cette étiquette est affichée sur la source de courant. Il est important que l’utilisateur et le technicien de maintenance comprennent la signification des symboles de sécurité.

Hypertherm Systèmes plasma 1a-7

SÉCURITÉ

+ 287 hidden pages

Hypertherm HPR260 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

ELECTROMAGNETIC COMPATIBILITY (EMC)

WARRANTY

TABLE OF CONTENTS