Hypertherm HSD130 User Manual
HySpeed® Plasma
HSD130
™
Remote High Frequency (RHF)
Instruction Manual
805510 – Revision 1
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HySpeed HSD130
Remote High Frequency (RHF)
Instruction Manual
(P/N 805510)
Revision 1 – April, 2011
Hypertherm, Inc.
Hanover, NH USA
www.hypertherm.com
© Copyright 2011 Hypertherm, Inc.
All Rights Reserved
Hypertherm, HySpeed, and HSD130 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)
Hypertherm Automation
5 Technology Drive, Suite 300
West Lebanon, NH 03784 USA
603-298-7970 Tel
603-298-7977 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 Ser vice)
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 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 A, 5th Floor, Careri Building
432 West Huai Hai Road
Shanghai, 200052
PR China
86-21 5258 3330/1 Tel
86-21 5258 3332 Fax
Hypertherm Brasil Ltda.
Avenida Doutor Renato de
Andrade Maia 350
Parque Renato Maia
CEP 07114-000
Guarulhos, SP Brasil
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
03/08/11
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.
Compliance Information EMC-1
7/10
ELECTROMAGNETIC COMPATIBILITY
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.
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 Equip ment, Part 9:
Installation and Use.
Screening and shielding
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.
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.
EMC-2 Compliance Information
7/10
WARRANTY
Attention
Genuine Hypertherm parts are the factoryrecommended 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 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,
and with respect to torch lifter assemblies within a
period of one (1) year from its date of delivery to you,
and with respect to laser heads within a period of one
(1) year from its date of delivery to you, and with respect
to Automation products one (1) year from its date of
delivery to you, with the exception of the EDGE Pro
CNC and ArcGlide THC, which shall be within a period
of two (2) years from the date of delivery to you.
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.
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.
Compliance Information W-1
9/10
ELECTROMAGNETIC COMPATIBILITY
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.
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 Equip ment, Part 9:
Installation and Use.
Screening and shielding
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.
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.
EMC-2 Compliance Information
7/10
TABLE OF CONTENTS
Electromagnetic compatibility (EMC) .............................................................................................................................................EMC-1
Warranty.....................................................................................................................................................................................................W-1
Section 1 SAFETY ................................................................................................................................................................1-1
Recognize safety information ..................................................................................................................................................................1-2
Follow safety instructions .........................................................................................................................................................................1-2
Electrical hazards .......................................................................................................................................................................................1-2
Electric shock can kill ................................................................................................................................................................................1-3
Cutting can cause fire or explosion .......................................................................................................................................................1-4
Toxic fumes can cause injury or death ..................................................................................................................................................1-5
Grounding safety........................................................................................................................................................................................1-6
Static electricity can damage circuit boards .......................................................................................................................................1-6
Compressed gas equipment safety .......................................................................................................................................................1-6
Gas cylinders can explode if damaged .................................................................................................................................................1-6
A plasma arc can cause injury and burns .............................................................................................................................................1-7
Arc rays can burn eyes and skin .............................................................................................................................................................1-7
Pacemaker and hearing aid operation ..................................................................................................................................................1-8
Noise can damage hearing ......................................................................................................................................................................1-8
A plasma arc can damage frozen pipes ...............................................................................................................................................1-8
Dry dust collection information ...............................................................................................................................................................1-9
Laser radiation .........................................................................................................................................................................................1-10
Symbols and marks ................................................................................................................................................................................1-11
Additional safety information ................................................................................................................................................................1-11
Warning labels ......................................................................................................................................................................................... 1-12
Section 1a SÉCURITÉ ...................................................................................................................................................... 1a-1
Identifier les consignes de sécurité .................................................................................................................................................... 1a-2
Suivre les instructions de sécurité ...................................................................................................................................................... 1a-2
Risques électriques ................................................................................................................................................................................ 1a-2
Les chocs électriques peuvent être fatals ......................................................................................................................................... 1a-3
Le coupage peut provoquer un incendie ou une explosion .......................................................................................................... 1a-4
Les vapeurs toxiques peuvent provoquer des blessures ou la mort ........................................................................................... 1a-5
Mise à la masse et à la terre ................................................................................................................................................................. 1a-6
L’électricité statique peut endommager les cartes de circuits imprimés ................................................................................... 1a-6
Sécurité des bouteilles de gaz comprimé ......................................................................................................................................... 1a-6
Les bouteilles de gaz comprimé peuvent exploser en cas de dommages ................................................................................ 1a-6
L’arc plasma peut provoquer des blessures ou des brûlures ....................................................................................................... 1a-7
Les rayons de l’arc peuvent brûler les yeux et la peau ................................................................................................................... 1a-7
Pacemakers et prothèses auditives .................................................................................................................................................... 1a-8
Le bruit peut provoquer des problèmes auditifs .............................................................................................................................. 1a-8
Un arc plasma peut endommager les tuyaux gelés ........................................................................................................................ 1a-8
Information sur le dépoussièrage ........................................................................................................................................................ 1a-9
Radiation au laser .................................................................................................................................................................................1a-10
Symboles et marquage ........................................................................................................................................................................1a-11
Étiquettes de sécurité ..........................................................................................................................................................................1a-12
HySpeed HSD130 RHF Instruction Manual i
TABLE OF CONTENTS
Section 1b SEGURIDAD .................................................................................................................................................. 1b-1
Reconocimiento de información de seguridad ................................................................................................................................ 1b-2
Cumplimiento de instrucciones de seguridad..................................................................................................................................1b-2
Riesgos de electrocución ..................................................................................................................................................................... 1b-2
Las descargas eléctricas pueden matar ............................................................................................................................................1b-3
Los cortes pueden producir incendios o explosiones ....................................................................................................................1b-4
Los vapores tóxicos pueden producir lesiones o la muerte ..........................................................................................................1b-5
Seguridad de toma a tierra ...................................................................................................................................................................1b-6
La electricidad estática puede dañar las placas de circuitos .......................................................................................................1b-6
Seguridad de equipos de gas comprimido ......................................................................................................................................1b-6
Los cilindros de gas pueden explotar si están dañados ................................................................................................................1b-6
El arco de plasma puede producir lesiones y quemaduras .......................................................................................................... 1b-7
Los rayos del arco pueden quemar los ojos y la piel ......................................................................................................................1b-7
Funcionamiento de marcapasos y audífonos ................................................................................................................................... 1b-8
Los ruidos pueden dañar la audición ................................................................................................................................................. 1b-8
El arco de plasma puede dañar las tuberías congeladas ..............................................................................................................1b-8
Información acerca de la recolección de polvo seco ..................................................................................................................... 1b-9
Radiación láser ......................................................................................................................................................................................1b-10
Símbolos y marcas ...............................................................................................................................................................................1b-11
Etiquetas de advertencia .....................................................................................................................................................................1b-12
Section 2 SPECIFICATIONS..............................................................................................................................................2-1
System description ....................................................................................................................................................................................2-2
General ..............................................................................................................................................................................................2-2
Power supply ...................................................................................................................................................................................2-2
Ignition console ................................................................................................................................................................................2-2
Fuel-gas console .............................................................................................................................................................................2-2
Off-valve ............................................................................................................................................................................................2-2
Torch ..................................................................................................................................................................................................2-2
System diagram 1 — without a fuel gas console .....................................................................................................................2-3
System diagram 2 — with a fuel-gas console ..........................................................................................................................2-4
Specifications .............................................................................................................................................................................................2-5
System gas requirements ..............................................................................................................................................................2-5
Noise levels .......................................................................................................................................................................................2-6
Power supply ....................................................................................................................................................................................2-7
Fuel gas console — 078201 ........................................................................................................................................................2-8
Ignition console — 078172 ..........................................................................................................................................................2-9
Standard off-valve — 229105 ...................................................................................................................................................2-10
Fuel-gas off-valve — 229130 .................................................................................................................................................... 2-11
Torch – 228144 ...........................................................................................................................................................................2-12
Section 3 INSTALLATION ...................................................................................................................................................3-1
Upon receipt ...............................................................................................................................................................................................3-3
Claims ...........................................................................................................................................................................................................3-3
Installation requirements...........................................................................................................................................................................3-3
Placement of system components .........................................................................................................................................................3-3
Torque specifications .....................................................................................................................................................................3-3
ii HySpeed HSD130 RHF Instruction Manual
TABLE OF CONTENTS
Installation requirements – standard system .....................................................................................................................................3-4
System components .......................................................................................................................................................................3-5
Cables and hoses ...........................................................................................................................................................................3-5
Customer-supplied power cable .................................................................................................................................................3-5
Supply gas hoses ............................................................................................................................................................................3-5
Installation requirements — system with optional fuel gas console ...............................................................................................3-6
System components .......................................................................................................................................................................3-7
Cables and hoses ...........................................................................................................................................................................3-7
Customer-supplied power cable .................................................................................................................................................3-7
Supply gas hoses ............................................................................................................................................................................3-7
System integration diagram .....................................................................................................................................................................3-8
Components .....................................................................................................................................................................................3-9
Recommended grounding and shielding practices ........................................................................................................................3-10
Introduction ..............................................................................................................................................................................................3-10
Types of grounding ...................................................................................................................................................................... 3-10
Steps to take ................................................................................................................................................................................. 3-11
Grounding diagram ......................................................................................................................................................................3-14
Placement of the power supply ...........................................................................................................................................................3-15
Install the ignition console ..................................................................................................................................................................... 3-16
Install the off-valve ..................................................................................................................................................................................3-18
Torch mounting and alignment ............................................................................................................................................................ 3-19
Mounting the torch ....................................................................................................................................................................... 3-19
Torch alignment ............................................................................................................................................................................ 3-19
Torch lifter requirement ............................................................................................................................................................... 3-19
Install the fuel-gas console (optional component) ..........................................................................................................................3-20
Cable and hose assembly from power supply to off-valve............................................................................................................3-21
Power supply to off-valve connections ...................................................................................................................................3-22
Fuel-gas console to off-valve connections ....................................................................................................................................... 3-23
Fuel-gas console to power supply connections ..............................................................................................................................3-24
Power supply to ignition console leads .............................................................................................................................................3-26
Ignition console power cable .....................................................................................................................................................3-28
Ignition console coolant hoses ..................................................................................................................................................3-29
Torch lead assembly ..............................................................................................................................................................................3-30
Connect the torch to the torch lead assembly ......................................................................................................................3-31
Work lead .................................................................................................................................................................................................3-34
Arc voltage connection ..........................................................................................................................................................................3-35
Power supply to CNC interface cable ...............................................................................................................................................3-36
Notes to CNC interface cable run list ..................................................................................................................................... 3-37
Examples of output circuits ........................................................................................................................................................ 3-38
Examples of input circuits ...........................................................................................................................................................3-40
Power requirements ............................................................................................................................................................................... 3-41
General ........................................................................................................................................................................................... 3-41
Line disconnect switch ...............................................................................................................................................................3-42
Power cable ...................................................................................................................................................................................3-42
Connect the power ................................................................................................................................................................................. 3-43
Torch coolant requirements ..................................................................................................................................................................3-44
HySpeed HSD130 RHF Instruction Manual iii
TABLE OF CONTENTS
Premixed coolant for standard operating temperatures ......................................................................................................3-44
Custom coolant mix for cold operating temperatures .......................................................................................................... 3-45
Custom coolant mix hot operating temperatures ..................................................................................................................3-46
Water purity requirements ..........................................................................................................................................................3-46
Fill the power supply with coolant .......................................................................................................................................................3-47
Gas requirements ...................................................................................................................................................................................3-48
Setting the supply regulators .....................................................................................................................................................3-48
Gas regulators ..............................................................................................................................................................................3-49
Supply gas plumbing .............................................................................................................................................................................3-50
Connect the supply gases ....................................................................................................................................................................3-51
Standard system ...........................................................................................................................................................................3-51
Fuel-gas system ............................................................................................................................................................................3-51
Supply gas hoses ...................................................................................................................................................................................3-52
Section 4 OPERATION ........................................................................................................................................................4-1
Controls and indicators ............................................................................................................................................................................4-2
Main power switch .........................................................................................................................................................................4-2
Daily start-up ...............................................................................................................................................................................................4-3
Check torch ......................................................................................................................................................................................4-3
System operation .......................................................................................................................................................................................4-4
Amps display ....................................................................................................................................................................................4-4
Fuel-gas console operation .....................................................................................................................................................................4-5
Consumable selection ..............................................................................................................................................................................4-6
Mild steel ...........................................................................................................................................................................................4-6
Stainless steel ..................................................................................................................................................................................4-6
Aluminum ...........................................................................................................................................................................................4-7
IInstall and Inspect consumables ...........................................................................................................................................................4-8
Torch maintenance .................................................................................................................................................................................4-10
Torch connections ........................................................................................................................................................................ 4-10
Replace torch water tube ...................................................................................................................................................................... 4-11
Common cutting faults ..........................................................................................................................................................................4-12
How to optimize cut quality .................................................................................................................................................................. 4-13
Tips for table and torch ............................................................................................................................................................... 4-13
Plasma set-up tips........................................................................................................................................................................4-13
Maximize the life of consumable parts ..................................................................................................................................... 4-13
Additional factors of cut quality .................................................................................................................................................4-14
Additional improvements ............................................................................................................................................................4-15
Estimated kerf width compensation ...................................................................................................................................................4-16
Cut charts ................................................................................................................................................................................................. 4-18
Section 5 MAINTENANCE ..................................................................................................................................................5-1
Introduction .................................................................................................................................................................................................5-3
Routine maintenance.................................................................................................................................................................................5-3
System description ....................................................................................................................................................................................5-4
Control and signal cables ..............................................................................................................................................................5-4
Sequence of operation .............................................................................................................................................................................5-5
Gas system purge cycle ...........................................................................................................................................................................5-6
iv HySpeed HSD130 RHF Instruction Manual
TABLE OF CONTENTS
Gas system valve usage ...........................................................................................................................................................................5-6
Systems without a fuel-gas console ...........................................................................................................................................5-6
Systems with a fuel-gas console .................................................................................................................................................5-7
PCB block diagram ...................................................................................................................................................................................5-8
Error codes ..................................................................................................................................................................................................5-9
Error code troubleshooting – Error codes 000 to 024 .......................................................................................................5-10
Error code troubleshooting – Error codes 026 to 042 .......................................................................................................5-11
Error code troubleshooting – Error codes 043 to 047 .......................................................................................................5-12
Error code troubleshooting – Error codes 050 to 063 .......................................................................................................5-13
Error code troubleshooting – Error codes 065 to 075 .......................................................................................................5-14
Error code troubleshooting – Error codes 093 to 103 .......................................................................................................5-15
Error code troubleshooting – Error codes 195 to 116 .......................................................................................................5-16
Error code troubleshooting – Error codes 134 to 157 .......................................................................................................5-17
Power supply states ............................................................................................................................................................................... 5-18
Plasma system operation with pump timeout ...................................................................................................................................5-19
CNC operation with pump timeout .....................................................................................................................................................5-20
Initial checks .............................................................................................................................................................................................5-21
Automated diagnostic tests ..................................................................................................................................................................5-22
Power measurement ..............................................................................................................................................................................5-23
Power supply coolant system servicing .............................................................................................................................................5-24
Draining the coolant system. ...................................................................................................................................................... 5-24
Coolant system filter replacement ......................................................................................................................................................5-25
Air filter replacement .............................................................................................................................................................................. 5-26
Coolant flow test procedure ................................................................................................................................................................. 5-27
Testing the flow switch ...............................................................................................................................................................5-28
Gas leak test procedure ........................................................................................................................................................................5-29
PCB4: Power supply control board ...................................................................................................................................................5-30
PCB3: Power supply power distribution board ...............................................................................................................................5-31
PCB2: Start circuit .................................................................................................................................................................................5-32
Operation .......................................................................................................................................................................................5-32
Start-circuit functional schematic ............................................................................................................................................. 5-32
Start-circuit troubleshooting ...................................................................................................................................................... 5-32
Pilot arc current levels ................................................................................................................................................................. 5-34
PCB2: Fuel-gas console control board ............................................................................................................................................. 5-35
PCB1: Fuel-gas console power distribution board ........................................................................................................................5-36
PCB3: Fuel-gas console AC valve-driver board ............................................................................................................................. 5-37
Chopper tests ..........................................................................................................................................................................................5-38
Phase-loss detection test ..................................................................................................................................................................... 5-42
Torch lead test .........................................................................................................................................................................................5-44
Preventive maintenance ......................................................................................................................................................................... 5-45
Section 6 PARTS LIST ........................................................................................................................................................6-1
Power supply ..............................................................................................................................................................................................6-2
RHF Ignition console ................................................................................................................................................................................6-8
Fuel-gas console ........................................................................................................................................................................................6-9
Off-valve (standard) ................................................................................................................................................................................ 6-10
HySpeed HSD130 RHF Instruction Manual v
TABLE OF CONTENTS
Off-valve (fuel-gas) .................................................................................................................................................................................6-10
HySpeed torch ........................................................................................................................................................................................6-11
Torch assembly ............................................................................................................................................................................. 6-11
Torch leads .................................................................................................................................................................................... 6-11
Mild steel consumable parts kit ...........................................................................................................................................................6-12
Stainless steel / Aluminum consumable parts kit ............................................................................................................................ 6-13
Recommended spare parts ..................................................................................................................................................................6-14
Section 7 WIRING DIAGRAMS .........................................................................................................................................7-1
Introduction .................................................................................................................................................................................................7-1
Wiring diagrams .........................................................................................................................................................................................7-5
Appendix A HYPERTHERM TORCH COOLANT SAFETY DATA.............................................................................. a-1
Section 1 Chemical Product and Company Identification .......................................................................................................... a-2
Section 2 Information on Ingredients ...............................................................................................................................................a-2
Section 3 Hazards Identification .......................................................................................................................................................a-2
Section 4 First Aid Measures ............................................................................................................................................................a-3
Section 5 Fire Fighting Measures .....................................................................................................................................................a-3
Section 6 Accidental Release Measures ........................................................................................................................................a-3
Section 7 Handling and Storage ......................................................................................................................................................a-3
Section 8 Exposure Controls / Personal Protection .................................................................................................................... a-4
Section 9 Physical and Chemical Properties ................................................................................................................................. a-4
Section 10 Stability and Reactivity .....................................................................................................................................................a-4
Section 11 Toxicological Information .................................................................................................................................................a-4
Section 12 Ecological Information ......................................................................................................................................................a-5
Section 13 Disposal Considerations .................................................................................................................................................a-5
Section 14 Transport Information ....................................................................................................................................................... a-5
Section 15 Regulatory Information .....................................................................................................................................................a-5
Section 16 Other Information ..............................................................................................................................................................a-5
vi HySpeed HSD130 RHF Instruction Manual
Section 1
SAFETY
In this section:
Recognize safety information ..................................................................................................................................................................1-2
Follow safety instructions .........................................................................................................................................................................1-2
Electrical hazards .......................................................................................................................................................................................1-2
Electric shock can kill ................................................................................................................................................................................1-3
Cutting can cause fire or explosion .......................................................................................................................................................1-4
Toxic fumes can cause injury or death ..................................................................................................................................................1-5
Grounding safety........................................................................................................................................................................................1-6
Static electricity can damage circuit boards .......................................................................................................................................1-6
Compressed gas equipment safety .......................................................................................................................................................1-6
Gas cylinders can explode if damaged .................................................................................................................................................1-6
A plasma arc can cause injury and burns .............................................................................................................................................1-7
Arc rays can burn eyes and skin .............................................................................................................................................................1-7
Pacemaker and hearing aid operation ..................................................................................................................................................1-8
Noise can damage hearing ......................................................................................................................................................................1-8
A plasma arc can damage frozen pipes ...............................................................................................................................................1-8
Dry dust collection information ...............................................................................................................................................................1-9
Laser radiation ......................................................................................................................................................................................... 1-10
Symbols and marks ................................................................................................................................................................................ 1-11
Additional safety information ................................................................................................................................................................ 1-11
Warning labels ......................................................................................................................................................................................... 1-12
Hypertherm 1-1
03/10
SAFETY
RECOGNIZE SAFETY
INFORMATION
The symbols shown in this section are used to identify
potential hazards. When you see a safety symbol in this
manual or on your machine, understand the potential
for personal injury, and follow the related instructions to
avoid the hazard.
FOLLOW SAFETY
INSTRUCTIONS
Read carefully all safety messages in this manual and
safety labels on your machine.
• Keep the safety labels on your machine in good
condition. Replace missing or damaged labels
immediately.
• Learn how to operate the machine and how to use
thecontrols properly. Do not let anyone operate it
without instruction.
• Keep your machine in proper working condition.
Unauthorized modifications to the machine may affect
safety and machine service life.
DANGER WARNING CAUTION
Hypertherm uses American National Standards Institute
guidelines for safety signal words and symbols. A signal
word DANGER or WARNING is used with a safety
symbol. DANGER identifies the most serious hazards.
• DANGER and WARNING safety labels are located on
your machine near specific hazards.
• 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
ordeath if not followed correctly.
• CAUTION safety messages precede related
instructions in this manual that may result in
minorinjury or damage to equipment if not
followedcorrectly.
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.
• 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.
• The enclosure shall be closed and the proper earth
ground continuity to the enclosure verified prior to
operating the equipment after moving, opening, or
servicing.
• Always follow these instructions for disconnecting
power before inspecting or changing torch
consumable parts.
1-2 Hypertherm
03/10
ELECTRIC SHOCK CAN KILL
SAFETY
Touching live electrical parts can cause a fatal shock or
severe burn.
• Operating the plasma system completes an electrical
circuit between the torch and the workpiece. The
workpiece and anything touching the workpiece are
part of the electrical circuit.
• Never touch the torch body, workpiece or the waterin
awater table when the plasma system isoperating.
Electric shock prevention
All Hypertherm plasma systems use high voltage
in the cutting process (200 to 400 VDC are
common). Take the following precautions when
operating this system:
• Wear insulated gloves and boots, and keep your body
and clothing dry.
• Do not stand, sit or lie on – or touch – any wet surface
when using the plasma system.
• Insulate yourself from work and ground using dry
insulating mats or covers big enough to prevent any
physical contact with the work or ground. If you must
work in or near a damp area, use extreme caution.
• Provide a disconnect switch close to the power
supply with properly sized fuses. This switch allows
the operator to turn off the power supply quickly in
anemergency situation.
• When using a water table, be sure that it is correctly
connected to earth ground.
• Install and ground this equipment according to the
instruction manual and in accordance with national
and local codes.
• Inspect the input power cord frequently for damage or
cracking of the cover. Replace a damaged power cord
immediately. Bare wiring can kill.
• Inspect and replace any worn or damaged torch leads.
• Do not pick up the workpiece, including the waste
cutoff, while you cut. Leave the workpiece in place or
on the workbench with the work cable attached during
the cutting process.
• Before checking, cleaning or changing torch parts,
disconnect the main power or unplug the power
supply.
• Never bypass or shortcut the safety interlocks.
• Before removing any power supply or system
enclosure cover, disconnect electrical input power.
Wait 5 minutes after disconnecting the main power
toallow capacitors to discharge.
• Never operate the plasma system unless the power
supply covers are in place. Exposed power supply
connections present a severe electrical hazard.
• When making input connections, attach proper
grounding conductor first.
• Each Hypertherm plasma system is designed to be
used only with specific Hypertherm torches. Do not
substitute other torches which could overheat and
present a safety hazard.
Hypertherm 1-3
03/10
SAFETY
CUTTING CAN CAUSE FIRE OR EXPLOSION
Fire prevention
• Be sure the area is safe before doing any cutting.
Keep a fire extinguisher nearby.
• Remove all flammables within 35 feet (10 m) of the
cutting area.
• Quench hot metal or allow it to cool before handling
or before letting it touch combustible materials.
• Never cut containers with potentially flammable
materials inside – they must be emptied and
properlycleaned first.
• Ventilate potentially flammable atmospheres
beforecutting.
• 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
closedcontainer.
• Do not cut containers that have held combustible
materials.
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
• Do not cut aluminum underwater or with water
touching the underside of the aluminum.
• Cutting aluminum underwater or with the water
touching the underside of the aluminum can result
in an explosive condition that can detonate during
plasma cutting operations.
WARNING
Hydrogen Detonation with
Aluminum Cutting
• Do not cut under water with fuel gases containing
hydrogen.
• Cutting under water with fuel gases containing
hydrogen can result in an explosive condition that can
detonate during plasma cutting operations.
1-4 Hypertherm
03/10
TOXIC FUMES CAN CAUSE INJURY OR DEATH
SAFETY
The plasma arc by itself is the heat source used for
cutting. Accordingly, although the plasma arc has not
been identified as a source of toxic fumes, the material
being cut can be a source of toxic fumes or gases that
deplete oxygen.
Fumes produced vary depending on the metal that is
cut. Metals that may release toxic fumes include, but
arenot 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 coatingsinclude,
but are not limited to, lead (in some paints), cadmium
(insome paints and fillers), and beryllium.
Gases produced by plasma cutting vary based on the
material to be cut and the method of cutting, but may
include ozone, oxides of nitrogen, hexavalent chromium,
hydrogen, and other substances if such are contained
inor released by the material being cut.
Caution should be taken to minimize exposure to fumes
produced by any industrial process. Depending upon
the chemical composition and concentration of the
fumes (as well as other factors, such as ventilation),
there may be a risk of physical illness, such as birth
defects or cancer.
It is the responsibility of the equipment and site owner
totest the air quality in the area where the equipment is
used and to ensure that the air quality in the workplace
meets all local and national standards andregulations.
• Size, air volume, ventilation and filtration of the
workarea.
• Personal protective equipment.
• Number of welding and cutting systems in operation.
• Other site processes that may produce fumes.
If the workplace must conform to national or local
regulations, only monitoring or testing done at the
site can determine whether the site is above or below
allowable levels.
To reduce the risk of exposure to fumes:
• Remove all coatings and solvents from the metal
before cutting.
• Use local exhaust ventilation to remove fumes from
theair.
• Do not inhale fumes. Wear an air-supplied respirator
when cutting any metal coated with, containing, or
suspected to contain toxic elements.
• Assure that those using welding or cutting equipment,
as well as air-supplied respiration devices, are
qualified and trained in the proper use of such
equipment.
• Never cut containers with potentially toxic materials
inside. Empty and properly clean the container first.
• Monitor or test the air quality at the site as needed.
• Consult with a local expert to implement a site plan
toensure safe air quality.
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.
Hypertherm 1-5
03/10
SAFETY
GROUNDING SAFETY
Work cable Attach the work cable securely to the
workpiece or the work table with good metal-to-metal
contact. Do not connect it to the piece that will fall away
when the cut is complete.
Work table Connect the work table to an earth
ground, in accordance with appropriate national and
local electrical codes.
Input power
• Be sure to connect the power cord ground wire to the
ground in the disconnect box.
STATIC ELECTRICITY CAN DAMAGE CIRCUIT BOARDS
Use proper precautions when handling printed circuit boards:
• Store PC boards in anti-static containers.
• Wear a grounded wrist strap when handling PCboards.
• If installation of the plasma system involves connecting
the power cord to the power supply, be sure to
connect the power cord ground wire properly.
• Place the power cord’s ground wire on the stud first,
then place any other ground wires on top of the power
cord ground. Fasten the retaining nut tightly.
• Tighten all electrical connections to avoid excessive
heating.
COMPRESSED GAS EQUIPMENT
SAFETY
• Never lubricate cylinder valves or regulators with oil
orgrease.
• 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 codes.
GAS CYLINDERS CAN
EXPLODE IF DAMAGED
Gas cylinders contain gas under high pressure.
Ifdamaged, a cylinder can explode.
• Handle and use compressed gas cylinders in
accordance with applicable national and local codes.
• Never use a cylinder that is not upright and secured
inplace.
• Keep the protective cap in place over valve except
when the cylinder is in use or connected for use.
• Never allow electrical contact between the plasma arc
and a cylinder.
• Never expose cylinders to excessive heat, sparks, slag
or open flame.
• Never use a hammer, wrench or other tool to open a
stuck cylinder valve.
1-6 Hypertherm
03/10
A PLASMA ARC CAN CAUSE INJURY AND BURNS
SAFETY
Instant-on torches
Plasma arc comes on immediately when the torch
switch is activated.
The plasma arc will cut quickly through gloves andskin.
• 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
burneyes and skin.
• Use eye protection in accordance with applicable national and local codes.
• Wear eye protection (safety glasses or goggles with side shields, and a welding helmet) with appropriate
lensshading 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
hotmetal.
• Gauntlet gloves, safety shoes and hat.
• Flame-retardant clothing to cover all exposed areas.
• Cuffless trousers to prevent entry of sparks and slag.
• Remove any combustibles, such as a butane lighter or matches, from your pockets before cutting.
Cutting area Prepare the cutting area to reduce reflection and transmission of ultraviolet light:
• Paint walls and other surfaces with dark colors to reduce reflection.
• Use protective screens or barriers to protect others from flash and glare.
• Warn others not to watch the arc. Use placards orsigns.
Arc current
(amps)
Less than 40 A 5 5 8 9
41 to 60 A 6 6 8 9
61 to 80 A 8 8 8 9
81 to 125 A 8 9 8
126 to 150 A 8 9 8 10
151 to 175 A 8 9
176 to 250 A 8 9 8 12
251 to 300 A 8 9 8 13
301 to 400 A 9 12 9 13
401 to 800 A 10 14 10
Minimum protective
shade number
(ANSIZ49.1:2005)
Suggested shade
number for comfort
(ANSI Z49.1:2005)
OSHA 29CFR
1910.133(a)(5)
8
Europe
EN168:2002
9
11
Hypertherm 1-7
03/10
SAFETY
PACEMAKER AND HEARINGAID 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 cable and the torch lead to one
side, away from your body.
• Route the torch leads as close as possible to the
workcable.
NOISE CAN DAMAGE HEARING
Cutting with a plasma arc can exceed acceptable noise
levels as defined by local codes 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 installed site have verified personal hearing
protection is not necessary per relevant international,
regional, and local codes.
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, limit
operator exposure time, screen off noisy working areas
and/or take measures to reduce reverberation in working
areas by putting up noise absorbers.
• Do not wrap or drape the torch lead or work cable
around your body.
• Keep as far away from the power supply as possible.
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 devices such as ear muffs or ear
plugs with a noise reduction rating appropriate for the
situation. Warn others in the area of possible noise
hazards. In addition, ear protection can prevent hot
splatter from entering the ear.
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.
1-8 Hypertherm
03/10
SAFETY
DRY DUST COLLECTION INFORMATION
SAFETY
At some sites, dry dust can represent a potential
explosion hazard.
The U.S. National Fire Protection Association’s 2007
edition of NFPA standard 68, “Explosion Protection by
Deflagration Venting,” provides requirements for the
design, location, installation, maintenance, and use of
devices and systems to vent combustion gases and
pressures after any deflagration event. Consult with
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 68 has been
“adopted by reference” in your local building codes.
Refer to NFPA68 for definitions and explanations of
regulatory terms such as deflagration, AHJ, adopted by
reference, the Kst value, deflagration index, and other
terms.
Note 1 – Hypertherm’s interpretation of these new
requirements is that unless a site-specific evaluation has
been completed to determine that all dust generated is
not combustible, the 2007 edition of NFPA 68 requires
the use of explosion vents designed to the worst-case
Kst value (see annex F) that could be generated from
dust so that the explosion vent size and type can be
designed. NFPA 68 does not specifically identify plasma
cutting or other thermal cutting processes as requiring
deflagration venting systems, but it does apply these
new requirements to all dry dust collection systems.
Note 2 – Users of Hypertherm manuals should consult
and comply with all applicable federal, state, and local
laws and regulations. Hypertherm does not, by the
publication of any Hypertherm manual, intend to urge
action that is not in compliance with all applicable
regulations and standards, and this manual may never
be construed as doing so.
Hypertherm 1-9
03/10
03/10
SAFETY
SAFETY
LASER RADIATION
Exposure to the laser output can result in serious eye injury. Avoid direct eye exposure.
For your convenience and safety, on Hypertherm products that use a laser, 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, the pulse duration is 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.
• 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.
1-10 Hypertherm
03/10
03/10
SAFETY
SYMBOLS AND MARKS
Your Hypertherm product may have one or more of the following markings on or near the data plate. Due to differences
and conflicts in national regulations, not all marks are applied to every version of a product.
S mark symbol
The S mark symbol indicates that the power supply and torch are suit able for operations carried out in en viron ments with in creased hazard of elec tri cal shock per IEC 60974-1.
CSA mark
Hypertherm products with a CSA mark meet the United States and Canadian regulations for product safety.
The products were evaluated, tested, and certified by CSA-International. Alternatively the product may have
amark by one of the other Nationally Recognized Testing Laboratories (NRTL) accredited in both the United
States and Canada, such as Underwriters Laboratories, Incorporated (UL) or TÜV.
CE marking
The CE marking signifies the manufacturer’s declaration of conformity to applicable European directives
andstandards. Only those versions of Hypertherm products with a CE marking located on or near the
dataplate have been tested for compliance with the European Low Voltage Directive and the European
Electromagnetic Compatibility (EMC) Directive. EMC filters needed to comply with the European EMC
Directive are incorporated within versions of the product with a CE marking.
GOST-R mark
CE versions of Hypertherm products that include a GOST-R mark of conformity meet the product safety
andEMC requirements for export to the Russian Federation.
c-Tick mark
CE versions of Hypertherm products with a c-Tick mark comply with the EMC regulations required for sale
inAustralia and New Zealand.
CCC mark
The China Compulsory Certification (CCC) mark indicates that the product has been tested and found
compliant with product safety regulations required for sale in China.
ADDITIONAL SAFETY INFORMATION
1. ANSI Standard Z49.1, Safety in Welding and Cutting, American
Welding Society, 550 LeJeune Road
P.O. Box 351020, Miami, FL 33135
2. ANSI Standard Z49.2, Fire Prevention in the Use of Cutting and
Welding Processes, American National Standards Institute
1430 Broadway, New York, NY 10018
3. ANSI Standard Z87.1, Safe Practices for Occupation and
Educational Eye and Face Protection, American National Standards
Institute, 1430 Broadway, New York, NY 10018
4. AWS F4.1, Recommended Safe Practices for the Preparation for
Welding and Cutting of Containers and Piping That Have Held
Hazardous Substances, American Welding Society
550 LeJeune Road, P.O. Box 351040, Miami, FL 33135
5. AWS F5.2, Recommended Safe Practices for Plasma Arc
Cutting, American Welding Society
550 LeJeune Road, P.O. Box 351040, Miami, FL 33135
6. CGA Pamphlet P-1, Safe Handling of Compressed Gases in Cylinders,
Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202
7. CSA Standard W117.2, Code for Safety in Welding and Cutting,
Canadian Standards Association Standard Sales
178 Rexdale Boulevard, Rexdale, Ontario M9W 1R3, Canada
8. NFPA Standard 51B, Cutting and Welding Processes, National Fire
Protection Association
470 Atlantic Avenue, Boston, MA 02210
9. NFPA Standard 70–1978, National Electrical Code, National Fire
Protection Association, 470 Atlantic Avenue, Boston, MA 02210
10. OSHA, Safety and Health Standards, 29FR 1910
U.S. Government Printing Office, Washington, D.C. 20402
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/
Hypertherm 1-11
03/10
SAFETY
WARNING LABELS
This warning label is affixed to some power supplies. It is important that the operator and maintenance technician
understand the intent of these warning symbols as described.
Read and follow these instructions, employer safety
practices, and material safety data sheets. Refer to
ANS Z49.1, “Safety in Welding, Cutting and Allied
Processes” from American Welding Society
(http://www.aws.org) and OSHA Safety and Health
Standards, 29 CFR 1910 (http://www.osha.gov).
WARNING
Plasma cutting can be injurious to operator and persons
in the work area. Consult manual before operating. Failure
to follow all these safety instructions can result in death.
1. Cutting sparks can cause explosion or fire.
1.1 Do not cut near flammables.
1.2 Have a fire extinguisher nearby and ready to use.
1.3 Do not use a drum or other closed container as a cutting table.
2. Plasma arc can injure and burn; point the nozzle away
from yourself. Arc starts instantly when triggered.
2.1 Turn off power before disassembling torch.
2.2 Do not grip the workpiece near the cutting path.
2.3 Wear complete body protection.
3. Hazardous voltage. Risk of electric shock or burn.
3.1 Wear insulating gloves. Replace gloves when wet or damaged.
3.2 Protect from shock by insulating yourself from work and ground.
3.3 Disconnect power before servicing. Do not touch live parts.
4. Plasma fumes can be hazardous.
4.1 Do not inhale fumes.
4.2 Use forced ventilation or local exhaust to remove the fumes.
4.3 Do not operate in closed spaces. Remove fumes with ventilation.
5. Arc rays can burn eyes and injure skin.
5.1 Wear correct and appropriate protective equipment to protect
head, eyes, ears, hands, and body. Button shirt collar. Protect ears
from noise. Use welding helmet with the correct shade of filter.
6. Become trained.
equipment. Use torches specified in the manual. Keep non-qualified
personnel and children away.
7. Do not remove, destroy, or cover this label.
Replace if it is missing, damaged, or worn (PN 110584 Rev C).
Only qualified personnel should operate this
AVERTISSEMENT
Le coupage plasma peut être préjudiciable pour l’opérateur et les personnes qui se
trouvent sur les lieux de travail. Consulter le manuel avant de faire fonctionner. Le
non respect des ces instructions de sécurité peut entraîner la mort.
1. Les étincelles de coupage peuvent provoquer une explosion
ou un incendie.
1.1 Ne pas couper près des matières inflammables.
1.2 Un extincteur doit être à proximité et prêt à être utilisé.
1.3 Ne pas utiliser un fût ou un autre contenant fermé comme table de coupage.
2. L’arc plasma peut blesser et brûler; éloigner la buse de soi.
Il s’allume instantanément quand on l’amorce;
2.1 Couper l’alimentation avant de démonter la torche.
2.2 Ne pas saisir la pièce à couper de la trajectoire de coupage.
2.3 Se protéger entièrement le corps.
3. Tension dangereuse. Risque de choc électrique ou de brûlure.
3.1 Porter des gants isolants. Remplacer les gants quand ils sont humides ou
endommagés.
3.2 Se protéger contre les chocs en s’isolant de la pièce et de la terre.
3.3 Couper l’alimentation avant l’entretien. Ne pas toucher les pièces sous tension.
4. Les fumées plasma peuvent être dangereuses.
4.1 Ne pas inhaler les fumées
4.2 Utiliser une ventilation forcée ou un extracteur local pour dissiper les fumées.
4.3 Ne pas couper dans des espaces clos. Chasser les fumées par ventilation.
5. Les rayons d’arc peuvent brûler les yeux et blesser la peau.
5.1 Porter un bon équipement de protection pour se protéger la tête, les yeux, les
oreilles, les mains et le corps. Boutonner le col de la chemise. Protéger les oreilles
contre le bruit. Utiliser un masque de soudeur avec un filtre de nuance appropriée.
6. Suivre une formation.
fonctionner cet équipement. Utiliser exclusivement les torches indiquées dans le
manual. Le personnel non qualifié et les enfants doivent se tenir à l’écart.
7. Ne pas enlever, détruire ni couvrir cette étiquette.
La remplacer si elle est absente, endommagée ou usée (PN 110584 Rev C).
Seul le personnel qualifié a le droit de faire
1-12 Hypertherm
03/10
SAFETY
WARNING LABELS
This warning label is affixed to some power supplies. It is important
that the operator and maintenance technician understand the intent of
these warning symbols as described. The numbered text corresponds
to the numbered boxes on the label.
1. Cutting sparks can cause explosion
or fire.
1.1 Do not cut near flammables.
1.2 Have a fire extinguisher nearby and
ready to use.
1.3 Do not use a drum or other closed
container as a cutting table.
2. Plasma arc can injure and burn; point
the nozzle away from yourself. Arc starts
instantly when triggered.
2.1 Turn off power before disassembling
torch.
2.2 Do not grip the workpiece near the
cutting path.
2.3 Wear complete body protection.
3. Hazardous voltage. Risk of electric
shock or burn.
3.1 Wear insulating gloves. Replace gloves
when wet or damaged.
3.2 Protect from shock by insulating yourself
from work and ground.
3.3 Disconnect power before servicing.
Donot touch live parts.
4. Plasma fumes can be hazardous.
4.1 Do not inhale fumes.
4.2 Use forced ventilation or local exhaust to
remove the fumes.
4.3 Do not operate in closed spaces.
Remove fumes with ventilation.
5. Arc rays can burn eyes and injure skin.
5.1 Wear correct and appropriate protective
equipment to protect head, eyes, ears,
hands, and body. Button shirt collar.
Protect ears from noise. Use welding
helmet with the correct shade of filter.
6. Become trained. Only qualified
personnel should operate this
equipment. Use torches specified in the
manual. Keep non-qualified personnel
and children away.
7. Do not remove, destroy, or cover this
label. Replace if it is missing, damaged,
or worn.
Hypertherm 1-13
03/10
SAFETY
1-14 Hypertherm
03/10
Section1a
SÉCURITÉ
Sommaire de cette section:
Identifier les consignes de sécurité .......................................................................................................................................................1-2
Suivre les instructions de sécurité .........................................................................................................................................................1-2
Risques électriques ...................................................................................................................................................................................1-2
Les chocs électriques peuvent être fatals ............................................................................................................................................1-3
Le coupage peut provoquer un incendie ou une explosion .............................................................................................................1-4
Les vapeurs toxiques peuvent provoquer des blessures ou la mort ..............................................................................................1-5
Mise à la masse et à la terre ....................................................................................................................................................................1-6
L’électricité statique peut endommager les cartes de circuits imprimés ......................................................................................1-6
Sécurité des bouteilles de gaz comprimé ............................................................................................................................................1-6
Les bouteilles de gaz comprimé peuvent exploser en cas de dommages ...................................................................................1-6
L’arc plasma peut provoquer des blessures ou des brûlures ..........................................................................................................1-7
Les rayons de l’arc peuvent brûler les yeux et la peau ......................................................................................................................1-7
Pacemakers et prothèses auditives .......................................................................................................................................................1-8
Le bruit peut provoquer des problèmes auditifs .................................................................................................................................1-8
Un arc plasma peut endommager les tuyaux gelés ...........................................................................................................................1-8
Information sur le dépoussièrage ...........................................................................................................................................................1-9
Radiation au laser ................................................................................................................................................................................... 1-10
Symboles et marquage ..........................................................................................................................................................................1-11
Étiquettes de sécurité ............................................................................................................................................................................ 1-12
Hypertherm 1a-1
03/10
SÉCURITÉ
IDENTIFIER LES
CONSIGNES DE SÉCURITÉ
Les symboles indiqués dans cette section sont utilisés
pour identifier les risques éventuels. Si vous trouvez un
symbole de sécurité, que ce soit dans ce manuel ou sur
l’équipement, soyez conscient des risques de blessures
et suivez les instructions correspondantes afin d’éviter
ces risques.
SUIVRE LES INSTRUCTIONS
DE SÉCURITÉ
Lire attentivement toutes les consignes de sécurité dans
le présent manuel et sur les étiquettes de sécurité se
trouvant sur l’équipement.
• Les étiquettes de sécurité sur l’équipement doivent
rester lisibles. Remplacer immédiatement les étiquettes
manquantes ou abîmées.
• Il est important d’apprendre à faire fonctionner
l’équipement et à utiliser correctement les commandes.
Ne laisser personne utiliser l’équipement sans
connaître son fonctionnement.
• Garder l’équipement en bon état. Des modifications
non autorisées sur l’équipement peuvent entraîner des
problèmes de sécurité et raccourcir la durée de vie
utile de l’équipement.
DANGER AVERTISSEMENT ATTENTION
Hypertherm adopte les lignes directrices de l’American
National Standards Institute relativement aux termes
et aux symboles de la signalisation de sécurité. Les
signaux DANGER ou AVERTISSEMENT sont utilisés
avec un symbole de sécurité. DANGER correspond aux
risques les plus sérieux.
• Les étiquettes de sécurité DANGER et
AVERTISSEMENT sont placées sur l’équipement
pour situer certains dangers spécifiques.
• Les messages de sécurité DANGER précèdent
les directives correspondantes dans le manuel
qui, sielles ne sont pas suivies scrupuleusement,
entraînent des blessures graves, voire mortelles.
• Les messages d’AVERTISSEMENT précèdent les
instructions d’utilisation présentées dans ce manuel
qui, si elles ne sont pas suivies scrupuleusement,
peuvent entraîner des blessures graves, voire
mortelles.
• Les messages de sécurité ATTENTION précèdent
les directives associées dans le manuel qui, si elles
ne sont pas suivies scrupuleusement, peuvent
entraîner des blessures mineures ou endommager
l’équipement.
RISQUES ÉLECTRIQUES
• Seul le personnel formé et autorisé peut ouvrir cet
équipement.
• Si l’équipement est branché en permanence, mettez-le
hors tension, puis coupez l’alimentation avant d’ouvrir
leboîtier.
• Si l’équipement est mis sous tension à l’aide d’un
cordon, débranchez-le avant d’ouvrir le boîtier.
• Dans un cas autre, des raccords ou des capots
d’obturateurs verrouillables doivent être fournis.
• Attendre ensuite 5minutes après la coupure de
l’alimentation électrique avant l’ouverture du capot
pourque l’énergie stockée se décharge.
• Si l’équipement doit être sous tension lorsque le
capot est ouvert pour l’entretien, le coup d’arc peut
seproduire. Respecter TOUTES les exigences locales
(NFPA 70E aux États-Unis) relatives aux pratiques
de travail sécuritaires et à l’équipement de protection
individuelle lors de l’entretien de l’équipement électrique.
1a-2 Hypertherm
• Vérifier que le boîtier est bien fermé et que la mise
àla terre est bien effectuée avant de faire fonctionner
l’équipement après l’avoir déplacé, ouvert ou après
avoir effectué un entretien.
• Toujours suivre ces instructions concernant le
débranchement de la source de courant avant
d’inspecter ou de remplacer des consommables
de la torche.
03/10
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