Hypertherm HPR800XD User Manual

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HyPerformance® Plasma

HPR800XD®

Auto Gas

Instruction Manual

806500 – Revision 2

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HyPerformance Plasma

HPR800

Auto Gas

Instruction Manual

(P/N 806500)

Revision 2 – June, 2015

Hypertherm Inc.

Hanover, NH USA

www.hypertherm.com

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.

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)

866-643-7711 Tel (Return Materials Authorization) 877-371-2876 Fax (Return Materials Authorization)

return.materials@hypertherm.com (RMA email)

Hypertherm Plasmatechnik GmbH

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

49 6181 58 2123 (Technical Service)

Hypertherm (S) Pte Ltd.

82 Genting Lane Media Centre Annexe Block #A01-01 Singapore 349567, Republic of Singapore 65 6841 2489 Tel 65 6841 2490 Fax

65 6841 2489 (Technical Service)

Hypertherm (Shanghai) Trading Co., Ltd.

Unit 301, South Building 495 ShangZhong Road Shanghai, 200231 PR China 86-21-60740003 Tel 86-21-60740393 Fax

Hypertherm Europe B.V.

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

31 165 596900 Tel (Technical Service) 00 800 4973 7843 Tel (Technical Service)

Hypertherm Japan Ltd.

Level 9, Edobori Center Building 2-1-1 Edobori, Nishi-ku Osaka 550-0002 Japan 81 6 6225 1183 Tel 81 6 6225 1184 Fax

Hypertherm Brasil Ltda.

Rua Bras Cubas, 231 – Jardim Maia Guarulhos, SP - Brasil CEP 07115-030 55 11 2409 2636 Tel 55 11 2408 0462 Fax

Hypertherm México, S.A. de C.V.

Avenida Toluca No. 444, Anexo 1, Colonia Olivar de los Padres Delegación Álvaro Obregón México, D.F. C.P. 01780 52 55 5681 8109 Tel 52 55 5683 2127 Fax

Hypertherm Korea Branch

#3904 Centum Leaders Mark B/D, 1514 Woo-dong, Haeundae-gu, Busan Korea, 612-889 82 51 747 0358 Tel 82 51 701 0358 Fax

12/2/13

ELECTROMAGNETIC COMPATIBILITY 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 the 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, signaling 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 as set forth in and in accordance with the manufacturer’s written instructions. For example, 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.

Safety and Compliance SC-1

Compliance Information EMC-1

7/ 10

ELECTROMAGNETIC COMPATIBILITY EMC

Earthing of the workpiece

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

Note: The cutting circuit may or may not be earthed for safety reasons. Changing the earthing arrangements should only be authorized by a person who is competent to assess whether the changes will in crease the risk of injury, for example, by allowing parallel cutting current return paths which may damage the earth circuits of other equipment. Further guidance is provided in IEC 60974-9, Arc Welding Equipment, Part 9: Installation and Use.

Screening and shielding

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

SC-2 Safety and Compliance

WARRANTY

Attention

Genuine Hypertherm parts are the factory-recommended replacement parts for your Hypertherm system. Any damage or injury caused by the use of other than genuine Hypertherm parts may not be covered by the Hypertherm warranty, and will constitute misuse of the Hypertherm Product.

You are solely 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 for the specific periods of time set forth herein and as follows: if Hypertherm is notified of a defect (i) with respect to the plasma power supply within a period of two (2) years from the date of its delivery to you, with the exception of Powermax brand 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, with the exception of the HPRXD short torch with integrated lead, which shall be within a period of six (6) months from the 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 Automation products one (1) year from its date of delivery to you, with the exception of the EDGE Pro CNC, EDGE Pro Ti CNC, MicroEDGE Pro CNC, and ArcGlide THC, which shall be within a period of two (2) years from the date of delivery to you, and (iii) with respect to HyIntensity fiber laser components within a period of two (2) years from the date of its delivery to you, with the exception of laser heads and beam delivery cables, which shall be within a period of one (1) year from its date of delivery to you.

All third-party engines, engine accessories, alternators, and alternator accessories are covered by the respective manufacturers’ warranties and not covered by this warranty.

This warranty shall not apply to any Powermax brand power supplies that have been used with phase converters. In addition, Hypertherm does not warranty systems that have been damaged as a result of poor power quality, whether from phase converters or incoming line power. This warranty shall not apply to any product which has been incorrectly installed, modified, or otherwise damaged.

Hypertherm provides repair, replacement or adjustment of the Product as the sole and exclusive remedy, if and only if the warranty set forth herein properly is invoked and applies. 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 pre paid by the customer. Hypertherm shall not be liable for any repairs, replacement, or adjustments of Products covered by this warranty, except those made pursuant to this paragraph and with Hypertherm’s prior written consent.

The warranty set forth 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.

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 have the right to 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 in any event no longer than fourteen (14) days after learning of any action or threat of action), and Hypertherm’s obligation to defend 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 direct, indirect, punitive or exemplary damages (including but not limited to lost profits) regardless of whether such liability is based on breach of contract, tort, strict liability, breach of warranty, failure of essential purpose, or otherwise, and even if advised of the possibility of such damages.

National and local codes

National and local codes governing plumbing and electrical installation shall take precedence 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.

Safety and Compliance SC-3

Compliance Information W-1

8/10

WARRANTY

Liability cap

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

Insurance

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

Transfer of rights

You may transfer any remaining rights you may have hereunder only in connection with the sale of all or substantially all of your assets or capital stock to a successor in interest who agrees to be bound by all of the terms and conditions of this Warranty. Within thirty (30) days before any such transfer occurs, you agree to notify in writing Hypertherm, which reserves the right of approval. Should you fail timely to notify Hypertherm and seek its approval as set forth herein, the Warranty set forth herein shall be null and void and you will have no further recourse against Hypertherm under the Warranty or otherwise.

SC-4 Safety and Compliance

Table of ConTenTs

ELECTROMAGNETIC COMPATIBILITY EMC ........................................................................................................EMC1

WARRANTY ............................................................................................................................................................................ W1

Section 1

SAFETY ................................................................................................................................................................................ SC1

Recognize safety information ..............................................................................................................................................................SC-2

Follow safety instructions ..................................................................................................................................................................... SC-2

Inspect equipment before using ......................................................................................................................................................... SC-2

Responsibility for safety ........................................................................................................................................................................ SC-2

A plasma arc can damage frozen pipes ...........................................................................................................................................SC-2

Static electricity can damage printed circuit boards ..................................................................................................................... SC-2

Grounding safety....................................................................................................................................................................................SC-3

Electrical hazards ................................................................................................................................................................................... SC-3

Electric shock can kill ............................................................................................................................................................................ SC-3

Cutting can cause fire or explosion ...................................................................................................................................................SC-4

Machine motion can cause injury ....................................................................................................................................................... SC-4

Compressed gas equipment safety ................................................................................................................................................... SC-5

Gas cylinders can explode if damaged ............................................................................................................................................. SC-5

Toxic fumes can cause injury or death .............................................................................................................................................. SC-5

A plasma arc can cause injury and burns ......................................................................................................................................... SC-6

Arc rays can burn eyes and skin ......................................................................................................................................................... SC-6

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

Noise can damage hearing .................................................................................................................................................................. SC-7

Dry dust collection information ...........................................................................................................................................................SC-7

Laser radiation ........................................................................................................................................................................................SC-8

Additional safety information ...............................................................................................................................................................SC-8

Section 2

SPECIFICATIONS ...................................................................................................................................................................21

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

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

Power supplies ................................................................................................................................................................................2-3

Chiller ................................................................................................................................................................................................2-3

Chiller interface console ................................................................................................................................................................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 supplies ................................................................................................................................................................................2-5

Chiller interface console – 078537 ..........................................................................................................................................2-7

Ignition console – 078536 ............................................................................................................................................................2-8

Torch lead junction box (Optional) – 078619 ................................................................................................................................. 2-10

Selection console – 078533 .....................................................................................................................................................2-11

Metering console – 078535 ......................................................................................................................................................2-12

HPR800XD Auto Gas – 806500 i

Table of ConTenTs

Torch – 228599 ........................................................................................................................................................................... 2-13

IEC symbols ............................................................................................................................................................................................. 2-14

Symbols and Marks ................................................................................................................................................................................ 2-15

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

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

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

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

Customer-supplied power cables ...............................................................................................................................................3-5

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

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

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

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

Grounding practices .......................................................................................................................................................................3-6

Grounding diagram .........................................................................................................................................................................3-9

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

Placement of the secondary power supply ....................................................................................................................................... 3-12

Lifting the power supply ..............................................................................................................................................................3-13

Install the ignition console .....................................................................................................................................................................3-15

Placement of the chiller ......................................................................................................................................................................... 3-17

Install the chiller interface console ...................................................................................................................................................... 3-18

Install the metering console .................................................................................................................................................................. 3-19

Placement of the selection console ....................................................................................................................................................3-20

Primary power supply to secondary power supply cables ............................................................................................................ 3-21

Interface (on/off) cable ................................................................................................................................................................ 3-21

Communication cable ..................................................................................................................................................................3-22

Power supply to ignition console leads ............................................................................................................................................. 3-23

Pilot arc lead .................................................................................................................................................................................. 3-23

Negative leads ...............................................................................................................................................................................3-23

Ignition console power cable (from primary power supply) ................................................................................................3-25

Coolant hose set (chiller to chiller-interface console) ......................................................................................................... 3-26

Coolant hose set (chiller-interface console to ignition console) ....................................................................................... 3-27

Primary power supply to chiller interface console ........................................................................................................................... 3-28

Chiller interface power cable ..................................................................................................................................................... 3-28

Secondary power supply to chiller interface console .....................................................................................................................3-29

Chiller interface communication cable ....................................................................................................................................3-29

Primary Power supply to selection console cables .........................................................................................................................3-30

Selection console communication cable ................................................................................................................................ 3-30

Selection console power cable ................................................................................................................................................. 3-30

Selection console to metering console hose and lead assembly ................................................................................................3-32

Cable and gas hose assembly .................................................................................................................................................. 3-32

ii HPR800XD Auto Gas – 806500

Table of ConTenTs

Power supply to CNC interface cable ............................................................................................................................................... 3-34

Optional multi-system CNC interface cable .......................................................................................................................... 3-34

Examples of output circuits ........................................................................................................................................................ 3-36

Examples of input circuits ........................................................................................................................................................... 3-37

Remote ON/OFF switch (provided by customer) ........................................................................................................................... 3-38

Torch lead assembly ..............................................................................................................................................................................3-39

Torch lead junction box (Optional)......................................................................................................................................................3-40

Install the junction box ................................................................................................................................................................. 3-41

Connect the leads ........................................................................................................................................................................ 3-42

Work lead .................................................................................................................................................................................................3-46

Torch connections .................................................................................................................................................................................. 3-47

Connect the torch to the torch lead assembly ...................................................................................................................... 3-47

Connect the torch to the quick-disconnect ........................................................................................................................... 3-51

Torch mounting and alignment ............................................................................................................................................................3-52

Mounting the torch ....................................................................................................................................................................... 3-52

Torch alignment ............................................................................................................................................................................3-52

Torch lifter requirement .........................................................................................................................................................................3-53

HyperNet ................................................................................................................................................................................................... 3-53

Power requirements (for each power supply) .................................................................................................................................. 3-54

Line disconnect switch ...............................................................................................................................................................3-55

Main power cable (power supplies) ................................................................................................................................................... 3-55

Main power cable (chiller) .....................................................................................................................................................................3-55

Connect the power .................................................................................................................................................................................3-56

Torch coolant requirements ..................................................................................................................................................................3-57

Premixed coolant for standard operating temperatures ...................................................................................................... 3-57

Custom Coolant mix for cold operating temperatures .........................................................................................................3-58

Custom Coolant mix for hot operating temperatures ...........................................................................................................3-59

Water purity requirements .................................................................................................................................................................... 3-59

Fill the chiller with coolant .....................................................................................................................................................................3-60

Gas requirements ...................................................................................................................................................................................3-61

Setting the supply regulators .....................................................................................................................................................3-61

Gas regulators ......................................................................................................................................................................................... 3-62

Supply gas plumbing .............................................................................................................................................................................3-63

Connect the supply gases .........................................................................................................................................................3-64

Supply gas hoses ...................................................................................................................................................................................3-65

Section 4

OPERATION .............................................................................................................................................................................41

Daily start-up ...............................................................................................................................................................................................4-3

Check torch ......................................................................................................................................................................................4-3

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

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

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

Chiller interface console ................................................................................................................................................................4-4

HPR800XD Auto Gas – 806500 iii

Table of ConTenTs

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

CNC controller requirements ..................................................................................................................................................................4-5

CNC screen examples ..............................................................................................................................................................................4-6

Main (control) screen ......................................................................................................................................................................4-6

Diagnostic screen ...........................................................................................................................................................................4-7

Test screen .......................................................................................................................................................................................4-8

Cut chart screen ..............................................................................................................................................................................4-9

Consumable selection ........................................................................................................................................................................... 4-10

Standard cutting (0°) ................................................................................................................................................................... 4-10

Bevel cutting (0° to 45°) ............................................................................................................................................................. 4-10

PowerPierce technology ............................................................................................................................................................. 4-10

Marking ...........................................................................................................................................................................................4-10

Consumables for mirror-image cutting ....................................................................................................................................4-10

SilverPlus electrodes ................................................................................................................................................................... 4-10

Mild steel ........................................................................................................................................................................................ 4-11

Stainless steel ............................................................................................................................................................................... 4-12

Aluminum ........................................................................................................................................................................................ 4-13

Mild steel bevel cutting ...............................................................................................................................................................4-14

Mild steel, thick piercing, bevel cutting ................................................................................................................................... 4-14

Stainless steel bevel cutting ...................................................................................................................................................... 4-15

Install and Inspect consumables ......................................................................................................................................................... 4-16

Torch maintenance ................................................................................................................................................................................. 4-19

Routine maintenance ................................................................................................................................................................... 4-19

Quick-disconnect maintenance ................................................................................................................................................ 4-19

Maintenance kit ............................................................................................................................................................................. 4-19

Replace torch water tube ......................................................................................................................................................................4-20

Common cutting faults ..........................................................................................................................................................................4-21

How to optimize cut quality ..................................................................................................................................................................4-22

Tips for table and torch ............................................................................................................................................................... 4-22

Plasma set-up tips........................................................................................................................................................................4-22

Maximize the life of consumable parts ..................................................................................................................................... 4-22

Additional factors of cut quality ................................................................................................................................................. 4-23

Additional improvements ............................................................................................................................................................4-25

Cut charts ................................................................................................................................................................................................. 4-26

Thin stainless steel with HDi technology ...........................................................................................................................................4-26

Overview .........................................................................................................................................................................................4-26

Thick stainless steel piercing technique ............................................................................................................................................ 4-27

Overview .........................................................................................................................................................................................4-27

Fine Feature cutting ................................................................................................................................................................................4-29

Overview .........................................................................................................................................................................................4-29

Recommendations .......................................................................................................................................................................4-29

Bevel cutting ............................................................................................................................................................................................ 4-30

Consumables ................................................................................................................................................................................4-30

Bevel compensation tables ........................................................................................................................................................ 4-30

Bevel cutting definitions ........................................................................................................................................................................ 4-31

iv HPR800XD Auto Gas – 806500

Table of ConTenTs

Cutting thick material ............................................................................................................................................................................. 4-32

Underwater cut charts ........................................................................................................................................................................... 4-33

Overview .........................................................................................................................................................................................4-33

Estimated kerf-width compensation ................................................................................................................................................... 4-35

Section 5

MAINTENANCE ........................................................................................................................................................................51

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

Power 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

Power supply troubleshooting ................................................................................................................................................................5-9

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

Error code troubleshooting – error codes 000 to 018 .....................................................................................................5-11

Error code troubleshooting – error codes 020 to 028, 224 to 228 .............................................................................. 5-12

Error code troubleshooting – error codes 030 to 042, 231 to 234 .............................................................................. 5-13

Error code troubleshooting – error codes 044 to 046 .....................................................................................................5-14

Error code troubleshooting – error codes 047 to 053, 248 to 250 .............................................................................. 5-15

Error code troubleshooting – error codes 054 to 061 .....................................................................................................5-16

Error code troubleshooting – error codes 062 to 067, 265 to 267 .............................................................................. 5-17

Error code troubleshooting – error codes 071 to 075, 273 to 275 .............................................................................. 5-18

Error code troubleshooting – error codes 076 to 101, 276 to 301 .............................................................................. 5-19

Error code troubleshooting – error codes 102 to 111, 302 to 308 .............................................................................. 5-20

Error code troubleshooting – error codes 116 to 133, 316 ............................................................................................5-21

Error code troubleshooting – error codes 134 to 140, 334 and 338 ...........................................................................5-22

Error code troubleshooting – error codes 141 to 152, 346 to 351 .............................................................................. 5-23

Error code troubleshooting – error codes 153 to 156, 354 to 356 .............................................................................. 5-24

Error code troubleshooting – error codes 157 to 159, 357 to 359 .............................................................................. 5-25

Error code troubleshooting – error codes 160 to 180 .....................................................................................................5-26

Error code troubleshooting – error code 181, 182, 298, and 383 ................................................................................5-27

Power supply states ............................................................................................................................................................................... 5-28

Plasma system operation with pump time-out ................................................................................................................................. 5-29

CNC operation with pump time-out ................................................................................................................................................... 5-30

Initial checks ............................................................................................................................................................................................. 5-31

Power measurement ..............................................................................................................................................................................5-32

Air filter element replacement ..............................................................................................................................................................5-33

Coolant system servicing ...................................................................................................................................................................... 5-34

Draining the coolant system .......................................................................................................................................................5-34

Chiller interface coolant filter ...............................................................................................................................................................5-36

Filter replacement ......................................................................................................................................................................... 5-36

Gas leak tests .......................................................................................................................................................................................... 5-37

Leak test 1 (inlet leak test) ......................................................................................................................................................... 5-37

HPR800XD Auto Gas – 806500 v

Table of ConTenTs

Leak test 2 (system leak test) .................................................................................................................................................... 5-38

Leak test 3 (proportional valve test in the metering console) ............................................................................................ 5-38

Power supply control board PCB3.....................................................................................................................................................5-39

Power supply power distribution board PCB2 ................................................................................................................................ 5-40

Start-circuit PCB1 .................................................................................................................................................................................. 5-41

Operation .......................................................................................................................................................................................5-41

Start circuit functional schematic .............................................................................................................................................5-41

Start circuit troubleshooting ......................................................................................................................................................5-41

Pilot arc current levels............................................................................................................................................................................5-43

Pump motor drive board PCB7 ........................................................................................................................................................... 5-44

Chiller interface power distribution board PCB1 ............................................................................................................................ 5-45

Coolant sensor board PCB2 ...............................................................................................................................................................5-46

Selection console control board PCB2.............................................................................................................................................5-47

Selection console power distribution board PCB1 ........................................................................................................................ 5-48

Selection console, AC valve-driver board PCB3 ............................................................................................................................ 5-49

Metering console control board PCB2 ..............................................................................................................................................5-50

Metering console power distribution board PCB1 ......................................................................................................................... 5-51

Chopper tests .......................................................................................................................................................................................... 5-52

Phase-loss detection test ..................................................................................................................................................................... 5-54

Torch lead test ......................................................................................................................................................................................... 5-55

Preventive maintenance .........................................................................................................................................................................5-56

Section 6

PARTS LIST ..............................................................................................................................................................................61

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

Chiller interface console ...........................................................................................................................................................................6-7

Ignition console ..........................................................................................................................................................................................6-8

Torch lead junction box (Optional).........................................................................................................................................................6-9

Ignition console to junction box leads .....................................................................................................................................6-10

Metering console ....................................................................................................................................................................................6-13

HyPerformance torch ............................................................................................................................................................................. 6-14

Torch assembly ............................................................................................................................................................................. 6-14

Torch leads ....................................................................................................................................................................................6-15

Ohmic contact wire ......................................................................................................................................................................6-15

Consumable parts kits ........................................................................................................................................................................... 6-16

Consumable parts kits ........................................................................................................................................................................... 6-18

Consumables for mirror-image cutting .............................................................................................................................................. 6-19

Straight cutting .............................................................................................................................................................................6-19

Bevel cutting .................................................................................................................................................................................. 6-21

Recommended spare parts .................................................................................................................................................................. 6-23

Warning Label – 110647 .........................................................................................................................................................6-26

vi HPR800XD Auto Gas – 806500

Table of ConTenTs

Section 7

WIRING DIAGRAMS ...............................................................................................................................................................71

Wiring diagram symbols ...........................................................................................................................................................................7-1

Discrete output functionality ....................................................................................................................................................................7-5

Appendix A

HYPERTHERM TORCH COOLANT SAFETY DATA ......................................................................................................A1

1 – Identification of the substance/mixture and of the company undertaking ........................................................................... a-2

2 – Hazards identification ...................................................................................................................................................................... a-2

3 – Composition/information on ingredients ..................................................................................................................................... a-3

4 – First aid measures ............................................................................................................................................................................ a-3

5 – Fire-fighting measures ..................................................................................................................................................................... a-3

6 – Accidental release measures ......................................................................................................................................................... a-3

7 – Handling and storage ...................................................................................................................................................................... a-4

8 – Exposure controls/personal protection .......................................................................................................................................a-4

9 – Physical and chemical properties ................................................................................................................................................. a-4

10 – Stability and reactivity ................................................................................................................................................................... a-5

11 – Toxicological information .............................................................................................................................................................. a-5

12 – Ecological information...................................................................................................................................................................a-5

13 – Disposal considerations ............................................................................................................................................................... a-6

14 – Transport information .................................................................................................................................................................... a-6

15 – Regulatory information .................................................................................................................................................................. a-6

16 – Other information ........................................................................................................................................................................... a-7

Freezing Point of Propylene Glycol Solution ....................................................................................................................................... a-8

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

Command table (1 of 14) ........................................................................................................................................................................b-6

Error responses ............................................................................................................................................................................b-20

Calculating checksums ............................................................................................................................................................... b-20

Status codes ............................................................................................................................................................................................ b-25

Gas type codes ....................................................................................................................................................................................... b-25

CNC requirements .................................................................................................................................................................................b-26

Auto gas console ..........................................................................................................................................................................b-26

Serial interface guidelines .....................................................................................................................................................................b-27

HPR800XD Auto Gas – 806500 vii

Table of ConTenTs

Checksum ...................................................................................................................................................................................... b-27

Message retries ............................................................................................................................................................................b-27

Cable shielding ............................................................................................................................................................................. b-27

Appendix C

ROBOTIC APPLICATIONS ...................................................................................................................................................C1

Components for robotic applications ....................................................................................................................................................c-2

Torch leads .......................................................................................................................................................................................c-2

Ohmic contact extension ...............................................................................................................................................................c-2

Rotational mounting sleeve (optional) – 220864 ..................................................................................................................c-3

Leather over wrap – 024866 .....................................................................................................................................................c-3

Robotic teaching torch (laser pointer) – 228394..................................................................................................................c-3

Torch and rotational mounting sleeve dimensions...................................................................................................................c-3

Rotational mounting sleeve clamp dimensions.........................................................................................................................c-4

HPR800XD AUTO GAS REVISION CHANGES 806500 ................................................................................................. 1

viii HPR800XD Auto Gas – 806500

Section 1

SAFETY

In this section:

Recognize safety information .............................................................................................................................................................. SC-2

Follow safety instructions .....................................................................................................................................................................SC-2

Inspect equipment before using .........................................................................................................................................................SC-2

Responsibility for safety........................................................................................................................................................................SC-2

A plasma arc can damage frozen pipes ...........................................................................................................................................SC-2

Static electricity can damage printed circuit boards ..................................................................................................................... SC-2

Grounding safety ...................................................................................................................................................................................SC-3

Cutting can cause fire or explosion ...................................................................................................................................................SC-4

Machine motion can cause injury .......................................................................................................................................................SC-4

Compressed gas equipment safety ................................................................................................................................................... SC-5

Gas cylinders can explode if damaged .............................................................................................................................................SC-5

Toxic fumes can cause injury or death ..............................................................................................................................................SC-5

A plasma arc can cause injury and burns .........................................................................................................................................SC-6

Arc rays can burn eyes and skin .........................................................................................................................................................SC-6

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

Noise can damage hearing .................................................................................................................................................................. SC-7

Dry dust collection information ........................................................................................................................................................... SC-7

Additional safety information ...............................................................................................................................................................SC-8

Safety and Compliance SC-1

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

Carefully read 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.

RESPONSIBILITY FOR SAFETY

The person or entity responsible for the safety of the workplace must:

• Make sure that operators and their supervisors are trained in the safeuse of their equipment, the safe use of the process, and emergency procedures.

• Make sure that all hazards and safety precautions identified herein are communicated to and understood by workers before the start ofwork.

• Designate approved cutting areas and establish procedures for safecutting.

• Be responsible for authorizing cutting operations in areas not specifically designed or approved for such processes.

• Make sure that only approved equipment, such as torches and personal protective equipment, are used.

DANGER WARNING CAUTION

American National Standards Institute (ANSI) guidelines are used for safety signal words and symbols. The signal word DANGER or WARNING is used with a safety symbol. DANGER identifies the most serious hazards.

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

• DANGER safety messages precede related instructions in the manual that will result in serious injury or death if not followed correctly.

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

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

INSPECT EQUIPMENT BEFORE USING

All cutting equipment must be inspected as required to make sure it is in safe operating condition. When found to be incapable of reliable and safe operation, the equipment must be repaired by qualified personnel prior to its next use or withdrawn from service.

• Select contractors who provide trained and qualified personnel, andwho have awareness of the risks involved, to do cutting.

• Tell contractors about flammable materials or hazardous conditions that are specific to the site, or hazardous conditions that they may not be aware of.

• Make sure that the quality and quantity of air for ventilation is such that personnel exposures to hazardous contaminants are below the allowable limits.

• Make sure that ventilation in confined spaces is sufficient to allow adequate oxygen for life support, to prevent accumulation of asphixiants or flammable explosive mixtures, to prevent oxygen-enriched atmospheres, and to keep airborne contaminants inbreathing atmospheres below allowable limits.

A PLASMA ARC CAN DAMAGE FROZEN PIPES

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

STATIC ELECTRICITY CAN DAMAGE PRINTED CIRCUIT BOARDS

Use proper precautions when handling printed circuit boards:

• Store printed circuit boards in anti-static containers.

• Wear a grounded wrist strap when handling printed circuit boards.

SC-2 Safety and Compliance

GROUNDING SAFETY

Safety

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

Cutting table Connect the cutting table to an earth ground, in accordance with appropriate national and local electrical regulations.

ELECTRICAL HAZARDS

• Only trained and authorized personnel may open this equipment.

• If the equipment is permanently connected, turn it off, and lock

out/ tag out power before the enclosure is opened.

• If power is supplied to the equipment with a cord, unplug the unit before the enclosure is opened.

• Lockable disconnects or lockable plug covers must be provided byothers.

• Wait 5 minutes after removal of power before entering the enclosure to allow stored energy to discharge.

Input power

• Make 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, make sure to connect the power cord ground wire properly.

• Place the power cord’s ground wire on the stud first, then place any other ground wires on top of the power cord ground. Tighten the retaining nut.

• Tighten all electrical connections to avoid excessive heating.

• If the equipment must have power when the enclosure is open for

servicing, arc flash explosion hazards may exist. Follow all local requirements (NFPA 70E in the USA) for safe work practices and for personal protective equipment when servicing energized equipment.

• Prior to operating the equipment after moving, opening, or servicing, make sure to close the enclosure and make sure that there is proper earth ground continuity to the enclosure.

• Always follow these instructions for disconnecting power before inspecting or changing torch consumable parts.

ELECTRIC SHOCK CAN KILL

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

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

• In machine torch applications, never touch the torch body, workpiece, or water in a water table when the plasma system is operating.

Electric shock prevention

All 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 the work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground. If you must cut 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, make sure that it is correctly connected to an earth ground.

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

• 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 lead 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 a proper grounding conductor first.

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

Safety and Compliance SC-3

Safety

CUTTING CAN CAUSE FIRE OR EXPLOSION

Fire prevention

• Make sure the cutting 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 containers.

• Do not cut containers that have held combustible materials.

WARNING

Explosion Hazard

Hydrogen Detonation with Aluminum Cutting

When you use a plasma torch to cut aluminum alloys under water or on a water table, a chemical reaction between the water and the workpiece, parts, fine particles, or molten aluminum droplets generates significantly more hydrogen gas than occurs with other metals. This hydrogen gas may get trapped under the workpiece. If exposed to oxygen or air, the plasma arc or a spark from any source can ignite this trapped hydrogen gas, causing an explosion that may result in death, personal injury, loss of property, or equipment damage.

Consult with the table manufacturer and other experts prior to cutting aluminum to implement a risk assessment and mitigation plan that eliminates the risk of detonation by preventing hydrogen accumulation.

WARNING

Explosion Hazard

Argon-Hydrogen and Methane

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

WARNING

Explosion Hazard

Underwater Cutting with Fuel Gases

ContainingHydrogen

• Do not cut underwater with fuel gases containing hydrogen.

• Cutting underwater with fuel gases containing hydrogen can result

in an explosive condition that can detonate during plasma cutting operations.

Also, make sure that the water table, fume extraction (ventilation), and other parts of the cutting system have been designed with aluminum cutting in mind.

Do not cut aluminum alloys underwater or on a water table unless you can prevent the accumulation of hydrogen gas.

Note: With proper mitigation, most aluminum alloys can be plasma cut on a water table. An exception is aluminum-lithium alloys. Never cut aluminum-lithium alloys in the presence of water. Contact your

aluminum supplier for additional safety information regarding hazards associated with aluminum-lithium alloys.

MACHINE MOTION CAN CAUSE INJURY

When an original equipment manufacturer (OEM) makes a cutting system by combining Hypertherm equipment with other equipment, the end-use customer and the OEM are responsible for providing protection against the hazardous moving parts of this cutting system. However, weadvise the following to prevent operator injury and equipment damage:

• Read and follow the instruction manual provided by the OEM.

• Maintain a restricted-access area larger than the maximum

movement range of the cutting system’s moving parts.

• Where there is a risk of collision, do not allow personnel or equipment near the cutting system’s moving parts.

• Avoid accidental contact with the CNC touchscreen or joystick. Accidental contact can activate commands and result in unintended motion.

• Do not service or clean the machinery during operation.

• If servicing is required, enable the safety interlock or disconnect and

lock out/tag out power to disable the motors and prevent motion.

• Allow only qualified personnel to operate, maintain, and service the machinery.

SC-4 Safety and Compliance

Safety

COMPRESSED GAS EQUIPMENT SAFETY

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

• Use only correct gas cylinders, regulators, hoses, and fittings

designed for the specific application.

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

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

TOXIC FUMES CAN CAUSE INJURY OR DEATH

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

The 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.

The 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 on 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 cutting area and to make sure that the air quality in the workplace meets all local and national standards and regulations.

GAS CYLINDERS CAN EXPLODE IF DAMAGED

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

• Handle and use compressed gas cylinders in accordance with applicable national and local regulations.

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

• Keep the protective cap in place over the 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.

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 workplace.

• Personal protective equipment.

• Number of welding and cutting systems in operation.

• Other workplace 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 workplace 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.

• Make sure 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 make sure air

quality is safe.

Safety and Compliance SC-5

Safety

A PLASMA ARC CAN CAUSE INJURY AND BURNS

Instant-on torches

• A plasma arc ignites immediately when the torch switch is activated.

The plasma arc will cut quickly through gloves and skin.

• Keep away from the torch tip.

• Do not hold metal near the cutting path.

• Never point the torch toward yourself or others.

ARC RAYS CAN BURN EYES AND SKIN

Eye protection Plasma arc rays produce intense visible and

invisible (ultraviolet and infrared) rays that can burn eyes and skin.

• Use eye protection in accordance with applicable national and local regulations.

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

Skin protection Wear protective clothing to protect against burns caused by ultraviolet light, sparks, and hot metal.

• Wear gauntlet gloves, safety shoes, and hat.

Minimum protective shade

number

Arc current

Less than 40 A 5 5 8 9 41 A to 60 A 6 6 8 9 61 A to 80 A 8 8 8 9 81 A to 125 A 8 9 8 9 126 A to 150 A 8 9 8 10 151 A to 175 A 8 9 8 11 176 A to 250 A 8 9 8 12 251 A to 300 A 8 9 8 13 301 A to 400 A 9 12 9 13 401 A to 800 A 10 14 10 N/A

(ANSIZ49.1:2012)

Suggested shade

number for comfort

(ANSI Z49.1:2012)

• Wear flame-retardant clothing to cover all exposed areas.

• Wear cuffless trousers to prevent entry of sparks and slag.

Also, 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.

OSHA 29CFR

1910.133(a)(5)

EN168:2002

Europe

PACEMAKER AND HEARING AID OPERATION

Pacemaker and hearing aid operation can be affected by magnetic fields from high currents.

Pacemaker and hearing aid wearers should consult a doctor before going near any plasma arc cutting and gouging operations.

To reduce magnetic field hazards:

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

• Route the torch leads as close as possible to the work lead.

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

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

SC-6 Safety and Compliance

NOISE CAN DAMAGE HEARING

Safety

Cutting with a plasma arc can exceed acceptable noise levels as defined by local regulations in many applications. Prolonged exposure to excessive noise can damage hearing. Always wear proper ear protection when cutting or gouging, unless sound pressure level measurements taken at the site have verified personal hearing protection is not necessary per relevant international, regional, andlocal regulations.

Significant noise reduction can be obtained by adding simple engineering controls to cutting tables such as barriers or curtains positioned between the plasma arc and the workstation, and/ or locating the workstation away from the plasma arc. Implement administrative controls in the workplace to restrict access and limit operator exposure time, and screen off noisy areas and/or take measures to reduce reverberation in cutting areas by putting up noiseabsorbers.

DRY DUST COLLECTION INFORMATION

In some workplaces, dry dust can represent a potential explosion hazard.

The U.S. National Fire Protection Association’s NFPA standard 68, “Explosion Protection by Deflagration Venting,” provides requirements for the design, location, installation, maintenance, and use of devices and systems to vent combustion gases and pressures after any deflagration event. Consult with the manufacturer or installer of any dry dust collection system for applicable requirements before you install a new dry dust collection system or make significant changes in the process or materials used with an existing dry dust collection system.

Consult your local “Authority Having Jurisdiction” (AHJ) to determine whether any edition of NFPA standard 68 has been “adopted by reference” in your local building codes.

Refer to NFPA standard 68 for definitions and explanations of regulatory terms such as deflagration, AHJ, adopted by reference, theKst value, deflagration index, and other terms.

Use ear protectors if the noise is disruptive or if there is a risk of hearing damage after all other engineering and administrative controls have been implemented. If hearing protection is required, wear only approved personal protective equipment such as ear muffs or ear plugs with a noise reduction rating appropriate for the situation. Warnothers near the cutting area of possible noise hazards. Inaddition, ear protection can prevent hot splatter from entering theear.

Note 1 – Unless a site-specific evaluation has been completed that determines that none of the dust generated is combustible, then NFPA standard 68 requires the use of explosion vents. Design the explosion vent size and type to conform to the worst-case Kst value as described in Annex F of NFPA standard 68. NFPA standard 68 does not specifically identify plasma cutting or other thermal cutting processes as requiring deflagration venting systems, but it does apply these new requirements to all dry dust collection systems.

Note 2 – Users should consult and comply with all applicable national, state, and local regulations. Publications do not intend to urge action that is not in compliance with all applicable regulations and standards, and this manual may never be construed as doing so.

Safety and Compliance SC-7

Safety

LASER RADIATION

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

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

Additional laser safety instructions:

• Consult with an expert on local laser regulations. Laser safety training may be required.

• Do not allow untrained persons to operate the laser. Lasers can be dangerous in the hands of untrained users.

• Do not look into the laser aperture or beam at any time.

• Position the laser as instructed to avoid unintentional eye contact.

• Do not use the laser on reflective workpieces.

• Do not use optical tools to view or reflect the laser beam.

• Do not disassemble or remove the laser or aperture cover.

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

• Modifying the laser or product in any way can increase the risk of laser radiation.

• Use of adjustments or performance of procedures other than those specified in this manual may result in hazardous laser radiation exposure.

• Do not operate in explosive atmospheres, such as in the presence of flammable liquids, gases, or dust.

• Use only laser parts and accessories that are recommended or provided by the manufacturer for your model.

• Repairs and servicing must be performed by qualified personnel.

• Do not remove or deface the laser safety label.

6. CGA Pamphlet P-1, Safe Handling of Compressed Gases in

Cylinders, Compressed Gas Association, 1235 Jefferson Davis Highway, Arlington, VA 22202

7. CSA Standard W117.2, Code for Safety in Welding and Cutting,

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

8. NFPA Standard 51B, Cutting and Welding Processes, National

Fire Protection Association, 1 Batterymarch Park, Quincy, MA 02169-7471

9. NFPA Standard 70, National Electrical Code, National Fire

Protection Association, 1 Batterymarch Park, Quincy, MA 02169-7471

10. OSHA, Safety and Health Standards, 29FR 1910 U.S.

Government Printing Office, Washington, D.C. 20402

11. AWS Safety and Health Fact Sheets, American Welding Society,

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

www. aws.org/technical/facts/

SC-8 Safety and Compliance

Section 2

SPECIFICATIONS

In this section