Hypertherm HyIntensity Fiber Laser User Manual

HyIntensity Fiber Laser

HFL010

HFL015

HFL020

Instruction Manual

807090 – Revision 3

HFL030

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HyIntensity Fiber Laser

HFL010, HFL015, HFL020, and HFL030

Instruction Manual

(P/N 807090)

Revision 3 – November, 2012

Hypertherm, Inc.

Hanover, NH USA

www.hypertherm.com

Hypertherm, HyIntensity Fiber Laser, HFL010, HFL015, HFL020 and HFL030 are trademarks of Hypertherm, Inc.

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

Hypertherm, Inc.

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

800-643-9878 Tel (Technical Service)

technical.service@hypertherm.com (Technical Service Email)

800-737-2978 Tel (Customer Service)

customer.service@hypertherm.com (Customer Service Email)

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

return.materials@hypertherm.com (RMA email)

Hypertherm Plasmatechnik GmbH

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

49 6181 58 2123 (Technical Service)

Hypertherm (S) Pte Ltd.

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

65 6841 2489 (Technical Service)

Hypertherm (Shanghai) Trading Co., Ltd.

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

Hypertherm Europe B.V.

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

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

Hypertherm Japan Ltd.

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

Hypertherm Brasil Ltda.

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

Hypertherm México, S.A. de C.V.

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

Hypertherm Korea Branch

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

07/18/12

table of contents

Safety ......................................................................................................................................................S-1

Introduction ................................................................................................................................................................................................ S-1

Operating instructions, guidelines, and rules ..................................................................................................................................... S-2

Protection of personnel ........................................................................................................................................................................... S-3

Laser safety officer ................................................................................................................................................................................... S-3

Condition of laser beam equipment ..................................................................................................................................................... S-3

Laser safety ................................................................................................................................................................................................ S-4

Laser safety warnings .............................................................................................................................................................................. S-5

Health concerns ........................................................................................................................................................................................ S-9

Laser safety eyewear (LSE) .................................................................................................................................................................... S-9

Acoustical noise ........................................................................................................................................................................................ S-9

Warning signs ............................................................................................................................................................................................ S-9

Gas, fumes and air quality....................................................................................................................................................................... S-9

Confined spaces ..................................................................................................................................................................................... S-10

Oxygen gas distribution for laser cutting ...........................................................................................................................................S-11

Public exhibitions and demonstrations ..............................................................................................................................................S-11

Large area viewing ..................................................................................................................................................................................S-11

Training ......................................................................................................................................................................................................S-12

Product stewardship ........................................................................................................................ PS-1

National and local safety regulations ................................................................................................................................................. PS-1

Certification test marks ......................................................................................................................................................................... PS-1

Differences in national standards ....................................................................................................................................................... PS-1

Safe installation and use of shape cutting equipment .................................................................................................................. PS-1

Procedures for periodic inspection and testing .............................................................................................................................. PS-2

Qualification of test personnel .................................................................................................................................................. PS-2

Residual current devices (RCDs) ...................................................................................................................................................... PS-2

Higher-level systems ............................................................................................................................................................................. PS-3

Environmental stewardship ........................................................................................................... ES-1

National and local environmental regulations .................................................................................................................................. ES-1

The RoHS directive ............................................................................................................................................................................... ES-1

Proper disposal of Hypertherm products ......................................................................................................................................... ES-1

The WEEE directive .............................................................................................................................................................................. ES-1

The REACH regulation ......................................................................................................................................................................... ES-1

Proper handling and safe use of chemicals ..................................................................................................................................... ES-2

Fumes emission and air quality ........................................................................................................................................................... ES-2

Electromagnetic Compatibility (EMC) ................................................................................... EMC-1

Installation and use ............................................................................................................................................................................ EMC-1

Assessment of area ........................................................................................................................................................................... EMC-1

Methods of reducing emissions ..................................................................................................................................................... EMC-1

Mains supply ............................................................................................................................................................................. EMC-1

HyIntensity Fiber Laser Instruction Manual – 807090 Revision 2 i

table of contents

Maintenance of cutting equipment ................................................................................................................................................ EMC-2

Cutting cables .................................................................................................................................................................................... EMC-2

Equipotential bonding ....................................................................................................................................................................... EMC-2

Earthing of the workpiece ................................................................................................................................................................ EMC-2

Screening and shielding ................................................................................................................................................................... EMC-2

Warranty ................................................................................................................................................W-1

Attention .....................................................................................................................................................................................................W-1

General .......................................................................................................................................................................................................W-1

Patent indemnity .......................................................................................................................................................................................W-2

Limitation of liability .................................................................................................................................................................................W-2

National and local codes ........................................................................................................................................................................W-2

Liability cap ................................................................................................................................................................................................W-2

Insurance....................................................................................................................................................................................................W-2

Transfer of rights.......................................................................................................................................................................................W-2

Speciﬁcations ........................................................................................................................................1-1

Fiber laser supply .......................................................................................................................................................................................1-1

Overview ............................................................................................................................................................................................1-1

Requirements ...................................................................................................................................................................................1-2

Optical specifications .....................................................................................................................................................................1-3

Dimensions – HFL010, HFL015, and HFL020 ........................................................................................................................1-4

Dimensions – HFL030 ...................................................................................................................................................................1-5

LF150 laser head – 051025 .................................................................................................................................................................1-6

Mounting dimensions .....................................................................................................................................................................1-7

Collimator dimensions ....................................................................................................................................................................1-8

Collimator dimensions ....................................................................................................................................................................1-9

System gas requirements ..................................................................................................................................................................... 1-10

Gas quality and pressure requirements .................................................................................................................................. 1-10

Chiller requirements ............................................................................................................................................................................... 1-11

Coolant ...........................................................................................................................................................................................1-11

Flow rates ....................................................................................................................................................................................... 1-11

Cooling capacity ........................................................................................................................................................................... 1-11

Gas control console – 051024 .........................................................................................................................................................1-12

Overview .........................................................................................................................................................................................1-12

Beam delivery optical cable (BDO) .................................................................................................................................................... 1-13

Laser head controller – 051026 ........................................................................................................................................................1-14

Overview .........................................................................................................................................................................................1-14

CNC Requirements ................................................................................................................................................................................ 1-15

Hypertherm CNC ......................................................................................................................................................................... 1-15

Generic CNC ................................................................................................................................................................................ 1-16

Installation ..............................................................................................................................................2-1

Upon receipt ...............................................................................................................................................................................................2-1

Claims ...........................................................................................................................................................................................................2-1

Installation requirements ..........................................................................................................................................................................2-2

ii HyIntensity Fiber Laser Instruction Manual – 807090 Revision 2

table of contents

Noise levels .................................................................................................................................................................................................2-2

Placement of system components .........................................................................................................................................................2-2

Site preparation before startup ...............................................................................................................................................................2-3

Installation requirements ..........................................................................................................................................................................2-4

System components .......................................................................................................................................................................2-5

Cables and hoses ...........................................................................................................................................................................2-5

Power cables (customer-supplied) .............................................................................................................................................2-5

Supply gas hoses (customer supplied) ......................................................................................................................................2-5

Recommended grounding and shielding practices ...........................................................................................................................2-6

Types of grounding ..........................................................................................................................................................................2-6

Steps to take ....................................................................................................................................................................................2-7

Placement of the fiber laser supply .....................................................................................................................................................2-11

Lifting the fiber laser supply ....................................................................................................................................................... 2-12

Fiber laser supply preparation ..............................................................................................................................................................2-13

General information ......................................................................................................................................................................2-13

Emergency stop (E-Stop) switch installation .........................................................................................................................2-14

Electrical diagram for external safety switches ......................................................................................................................2-15

Stack Light installation ................................................................................................................................................................ 2-16

Dehumidifier drain installation .................................................................................................................................................... 2-17

Mounting the laser head controller (LHC) ........................................................................................................................................ 2-19

Mounting the gas console.....................................................................................................................................................................2-20

Chiller considerations ............................................................................................................................................................................ 2-21

Mounting the laser head ........................................................................................................................................................................ 2-22

Install the laser head mounting bracket ...................................................................................................................................2-22

Laser head grounding .................................................................................................................................................................2-23

Laser head mounting dimensions ............................................................................................................................................. 2-23

Beam delivery optical cable connection ............................................................................................................................................ 2-25

General Precautions .................................................................................................................................................................... 2-26

Unpacking Instructions ................................................................................................................................................................ 2-26

Beam delivery optical cable installation .................................................................................................................................. 2-27

Collimator installation .............................................................................................................................................................................2-28

General precautions ....................................................................................................................................................................2-28

Collimator proximity sensor ........................................................................................................................................................ 2-33

Laser head connectors .......................................................................................................................................................................... 2-35

Coolant hose connections .................................................................................................................................................................... 2-36

Fiber laser supply to laser head ................................................................................................................................................ 2-37

Beam delivery optical cable and collimator coolant hoses ................................................................................................. 2-38

Fiber laser supply to chiller .........................................................................................................................................................2-40

Cable connections..................................................................................................................................................................................2-41

Hypernet cable: fiber laser supply to a Hypertherm CNC – 223171 ..............................................................................2-41

Hypernet cable: fiber laser supply to laser head controller – 223171 ............................................................................2-42

Gas console control cable – 223138 ..................................................................................................................................... 2-43

Laser head I/O cable – 223169 ............................................................................................................................................2-44

Gas hoses ................................................................................................................................................................................................2-45

Gas control console to laser head ........................................................................................................................................... 2-45

HyIntensity Fiber Laser Instruction Manual – 807090 Revision 2 iii

table of contents

Laser head controller power cable – (customer supplied) ......................................................................................................... 2-46

Line disconnect switch ................................................................................................................................................................2-47

Main power cables (fiber laser supply and chiller) .......................................................................................................................... 2-47

Connect the power ................................................................................................................................................................................. 2-48

Gas requirements ...................................................................................................................................................................................2-49

Gas regulators ......................................................................................................................................................................................... 2-50

Supply gas plumbing .............................................................................................................................................................................2-51

Connect the supply gases .........................................................................................................................................................2-52

Initial setup ..................................................................................................................................................................................... 2-53

CNC setups ............................................................................................................................................................................................. 2-54

Hypertherm CNC setup ..............................................................................................................................................................2-54

Lens assembly installation ....................................................................................................................................................................2-58

General precautions ....................................................................................................................................................................2-58

Set-up and Operation ..........................................................................................................................3-1

Safe operation ............................................................................................................................................................................................3-2

Sequence of operation with a Hypertherm CNC ....................................................................................................................3-3

Sequence of operation with a generic CNC ............................................................................................................................3-4

Marking and cutting mild steel with a generic CNC ...............................................................................................................3-5

H2O valve ..........................................................................................................................................................................................3-6

Flow meters ......................................................................................................................................................................................3-6

Fiber-to-fiber coupling unit ............................................................................................................................................................3-6

Laser power supply operation diagrams ..............................................................................................................................................3-7

Power ON sequence ......................................................................................................................................................................3-7

Laser power supply – faulted state ...........................................................................................................................................3-8

Laser power supply – laser beam OFF state .........................................................................................................................3-9

Laser power supply – laser beam ON state ........................................................................................................................ 3-10

Operating the laser head controller .................................................................................................................................................... 3-11

Navigating the Display Screen .................................................................................................................................................. 3-12

Changing the value of a parameter: ......................................................................................................................................... 3-12

Laser head controller screen navigation ................................................................................................................................. 3-13

Operating parameters .................................................................................................................................................................3-13

Calibration screen navigation .................................................................................................................................................... 3-14

Diagnostics screen navigation ..................................................................................................................................................3-15

Setup screen navigation ............................................................................................................................................................. 3-16

Laser head controller faults ........................................................................................................................................................ 3-18

Laser head controller setup .................................................................................................................................................................. 3-19

Calibration ................................................................................................................................................................................................3-21

Nozzle position calibration ..........................................................................................................................................................3-21

Capacitive height sensor (CHS) calibration .......................................................................................................................... 3-23

Laser head operation .............................................................................................................................................................................3-28

Pointing laser ................................................................................................................................................................................. 3-28

Beam centering .............................................................................................................................................................................3-28

Hypertherm CNC beam centering ...................................................................................................................................................... 3-29

Using the “Tape shot” method for beam centering...............................................................................................................3-29

Tape shot procedure .................................................................................................................................................................... 3-29

iv HyIntensity Fiber Laser Instruction Manual – 807090 Revision 2

table of contents

Hypertherm CNC interface ........................................................................................................................................................ 3-30

Setting pulse laser time and pulse laser power ....................................................................................................................3-31

Generic CNC beam centering ............................................................................................................................................................ 3-32

Pulsing the fiber laser using a generic CNC .................................................................................................................................... 3-33

Pulsing the laser with a custom waveform .............................................................................................................................3-34

Gas console operation ..........................................................................................................................................................................3-35

Test cut gas pressures ................................................................................................................................................................ 3-35

Adjust side jet pressure ..............................................................................................................................................................3-36

Focal position ................................................................................................................................................................................ 3-37

Laser Cutting ...........................................................................................................................................................................................3-38

Mild steel – oxygen assisted ......................................................................................................................................................3-38

Mild steel – air and nitrogen assisted ...................................................................................................................................... 3-39

Stainless steel – nitrogen assisted ..........................................................................................................................................3-39

Aluminum – nitrogen assisted ................................................................................................................................................... 3-39

Optimizing fiber laser cut quality ......................................................................................................................................................... 3-40

Surface of a laser cut ..................................................................................................................................................................3-40

General steps for optimizing laser cut quality ........................................................................................................................ 3-41

Mild steel ................................................................................................................................................................................................... 3-42

Optimizing cut quality for 6 mm (0.25 inch) mild steel (oxygen assisted) .......................................................................3-42

Consumables ........................................................................................................................................................................................... 3-50

Cut charts ................................................................................................................................................................................................. 3-51

HFL010 (1.0 kW) Mild Steel* cut chart - Metric .............................................................................................................................3-51

HFL010 (1.0 kW) Mild Steel* cut chart - English ...........................................................................................................................3-52

HFL010 (1.0 kW) Stainless Steel* cut chart - Metric .................................................................................................................... 3-53

HFL010 (1.0 kW) Stainless Steel* cut chart - English .................................................................................................................. 3-54

HFL010 (1.0 kW) Aluminum* cut chart - Metric .............................................................................................................................. 3-55

HFL010 (1.0 kW) Aluminum* cut chart - English ............................................................................................................................ 3-55

HFL015 (1.5 kW) Mild Steel* cut chart - Metric ............................................................................................................................. 3-56

HFL015 (1.5 kW) Mild Steel* cut chart - English ........................................................................................................................... 3-57

HFL015 (1.5 kW) Stainless Steel* cut chart - Metric ....................................................................................................................3-58

HFL015 (1.5 kW) Stainless Steel* cut chart - English .................................................................................................................. 3-59

HFL015 (1.5 kW) Aluminum* cut chart - Metric .............................................................................................................................3-60

HFL015 (1.5 kW) Aluminum* cut chart - English ...........................................................................................................................3-61

HFL020 (2.0 kW) Mild Steel* cut chart - Metric ............................................................................................................................. 3-62

HFL020 (2.0 kW) Mild Steel* cut chart - English ........................................................................................................................... 3-63

HFL020 (2.0 kW) Stainless Steel* cut chart - Metric ...................................................................................................................3-64

HFL020 (2.0 kW) Stainless Steel* cut chart - English ..................................................................................................................3-65

HFL020 (2.0 kW) Aluminum* cut chart - Metric ............................................................................................................................. 3-66

HFL020 (2.0 kW) Aluminum* cut chart - English ........................................................................................................................... 3-67

HFL020 (2.0 kW) Brass* cut chart - Metric .....................................................................................................................................3-68

HFL020 (2.0 kW) Brass* cut chart - English ...................................................................................................................................3-69

HFL020 (2.0 kW) Copper* cut chart - Metric ................................................................................................................................. 3-70

HFL020 (2.0 kW) Copper* cut chart - English ............................................................................................................................... 3-71

HFL030 (3.0 kW) Mild Steel* cut chart - Metric ............................................................................................................................. 3-72

HFL030 (3.0 kW) Mild Steel* cut chart - English ........................................................................................................................... 3-73

HFL030 (3.0 kW) Stainless Steel* cut chart - Metric ....................................................................................................................3-74

HyIntensity Fiber Laser Instruction Manual – 807090 Revision 2 v

table of contents

HFL030 (3.0 kW) Stainless Steel* cut chart - English ................................................................................................................. 3-75

HFL030 (3.0 kW) Aluminum* cut chart - Metric ............................................................................................................................. 3-76

HFL030 (3.0 kW) Aluminum* cut chart - English ........................................................................................................................... 3-77

HFL030 (3.0 kW) Brass* cut chart - Metric .................................................................................................................................... 3-78

HFL030 (3.0 kW) Brass* cut chart - English ................................................................................................................................... 3-79

HFL030 (3.0 kW) Copper* cut chart - Metric ................................................................................................................................. 3-80

HFL030 (3.0 kW) Copper* cut chart - English ............................................................................................................................... 3-81

Firmware upgrade procedure ...............................................................................................................................................................3-82

Setting the IP address ................................................................................................................................................................ 3-82

Upgrading the firmware ..............................................................................................................................................................3-84

Maintenance ...........................................................................................................................................4-1

Routine Maintenance ................................................................................................................................................................................4-2

Dehumidifier ......................................................................................................................................................................................4-2

Inspection and cleaning of the collimator ..................................................................................................................................4-2

Cleaning the quartz block ..............................................................................................................................................................4-4

Nozzle inspection ............................................................................................................................................................................4-6

Lens inspection ................................................................................................................................................................................4-6

Lens removal .....................................................................................................................................................................................4-7

Lens cleaning ...................................................................................................................................................................................4-8

Lens installation ............................................................................................................................................................................ 4-10

Air filter element replacement .................................................................................................................................................... 4-15

LHC error messages .............................................................................................................................................................................. 4-16

Troubleshooting ....................................................................................................................................................................................... 4-18

Troubleshooting the gas console ..............................................................................................................................................4-19

Troubleshooting routines ....................................................................................................................................................................... 4-20

Mild steel O2 cutting .................................................................................................................................................................... 4-20

Stainless steel and aluminum N2 cutting.................................................................................................................................4-22

Troubleshoot the nozzle extension calibration .................................................................................................................................. 4-24

Troubleshoot CHS calibration errors ................................................................................................................................................. 4-24

LPC service mode parameters ............................................................................................................................................................ 4-25

LHC diagnostics parameters ............................................................................................................................................................... 4-29

HyIntensity Fiber Laser Machine Interface ........................................................................................................................................ 4-31

LPC 1 .............................................................................................................................................................................................. 4-31

LPC 2 .............................................................................................................................................................................................. 4-32

Parts List..................................................................................................................................................5-1

Fiber laser components ............................................................................................................................................................................5-3

Starter kit .....................................................................................................................................................................................................5-4

LF150 cutting head - lower parts ..........................................................................................................................................................5-6

Lens assembly parts ..................................................................................................................................................................................5-7

Collimator .....................................................................................................................................................................................................5-8

Beam delivery optical cable .....................................................................................................................................................................5-9

Cables and hoses ................................................................................................................................................................................... 5-10

vi HyIntensity Fiber Laser Instruction Manual – 807090 Revision 2

SAFETY

Introduction

The Hypertherm HFL015 Fiber Laser consists of 4 assemblies.

1. HFL015 Fiber Laser Supply, part number 051023

Note: The HFL015 fiber laser supply, part number 051023, was certified to IEC 61010-1 Safety requirements

for electrical equipment for measurement, control, and laboratory use which covers electrical safety.

2. Fiber Laser Gas Console, part number 051024

3. Fiber Laser Head Controller, part number 051026

4. Fiber Laser Head LF150, part number 051025

“Machine builder” in this context is meant to include any person that integrates the Hypertherm HFL015 Fiber Laser into their final laser cutting system.

The Hypertherm HFL015 Fiber Laser is designed as COMPONENTS FOR INCORPORATION into a laser cutting system for industrial and manufacturing environments. The machine builder is responsible for proper adherence to any and all laser and machine safety regulations and certifications for the laser cutting system designed and manufactured by the machine builder. If required by local code, the machine builder or customer shall make arrangements for the final laser cutting system to be inspected and approved for compliance with local codes and standards by an accredited testing laboratory or third party expert acceptable to the regulatory authority having jurisdiction for the final installation.

Laser beam cutting is a thermal cutting process that uses heat from a laser beam with high-pressure assist gas to augment the removal of metal material. There are general hazards associated with metal cutting and specific hazards using lasers for metal cutting that need to be evaluated and mitigated. The following information provided with the Hypertherm HFL015 fiber laser is intended to inform the machine builder and the body responsible for the implementation of workplace and laser safety at the installed site of their responsibilities for safe design, installation and use. The appropriate local codes and standards for the final installation shall be consulted. Should any information in this document be in contravention to local codes and standards, the local codes and standards shall take precedence.

Hypertherm Fiber Laser Instruction Manual – 807090 Revision 3 S-1

safety

HFL015 fiber laser intended for use in laser cutting systems

The Fiber Laser as sold by Hypertherm is a component intended for sale to machine builders designing and installing the final laser cutting systems. The machine builder has to mount the laser head and enclose the beam and fiber laser cable in a manner that satisfies all applicable standards and regulations. The machine builder has responsibility for the safe design, safe installation, safe use and safe maintenance of the final laser cutting system including but not limited to the provisions to prevent access to the fiber laser beam in the final laser cutting system.

All equipment shall be installed in compliance with the local regulations ( electrical safety, laser safety, workplace safety, etc.) and any verification required by local regulatory authorities having jurisdiction for the site(s) where the final laser cutting system with Hypertherm Fiber Laser components are installed and operated. Voltages inside the Hypertherm HFL015 Fiber Laser Supply enclosure are sufficient to cause fatal injury. The equipment shall be installed by competent and qualified personnel in accordance with the final laser cutting system instructions. In addition to these instructions, ANSI Z136.1 and IEC EN 60825-1 are the recommended primary sources for laser safety information.

Operating instructions, guidelines, and rules

Instructions, guidelines, and rules covering operation and maintenance of final laser system, supplied by the machine builder shall be made available to the laser safety officer and operator and shall be strictly followed. This document for the Hypertherm fiber laser components may supplement but does not satisfy this requirement for the final laser cutting system documentation.

Note 1: In addition to the machine builders’s instructions and these instructions, the following references may be of

assistance:

• EN 60825-1 - Safety of laser products -- Part 1: Equipment classiﬁcation and requirements

• ANSI Z136.1; American National Standard for Safe Use of Lasers

• The Laser Institute of America’s (LIA) Guide for the Selection of Laser Eye Protection;

• LIA’s Laser Safety Manual is designed to help those responsible for laser safety at their facility.

• US Code of Federal Regulation of 21CFR1040.10 and 21CFR1040.11 for a complete laser product,

• The USA Occupational Safety Health Administration’s (OSHA) Technical Manual, Section III, Chapter 6, “Laser

Hazards”

Note 2: The following reference documents provide basic requirements for metal cutting

• In Canada, CAN/CSA-W117.2-06 Safety in welding, cutting, and allied processes

• In the USA, see ANSI Z49.1:2005 Safety in welding, cutting, and allied processes

Note 3: The following reference documents will help determine welding and cutting particulate/fume sampling:

• ANSI/AWS F1.1 for airborne particulates;

• ANSI/AWS F1.2 for fume generation rates and total fume emission

• ANSI/AWS F1.3 for contaminants.

S-2 Hypertherm Fiber Laser Instruction Manual – 807090 Revision 3

safety

Protection of personnel

Good housekeeping with areas free from trip and fall hazards shall be maintained in the workplace so that the final laser cutting system, automated and semi-automated material transport machines, fiber laser and electrical cables, and other apparatus do not create a hazard to operators, service and other personnel including visitors. Appropriate safeguards and warning signs shall be provided to prevent slips, falls, electric shock, burns, inhalation of gases and fumes, and exposure to noise, vibration and heat. Refer to the Safety and Compliance Manual published by Hypertherm for Plasma Cutting Systems which covers many of the same hazards for metal cutting and protection of personnel in the workplace except for Laser Safety aspects which are covered in ANSI Z136.1 and IEC EN 60825-al.

Note: The employer should conduct a physical demands analysis to ensure that any personal protective equipment does not

create a health hazard (e.g., neck , back and wrist problems associated with prolonged or repetitive use)

Laser safety officer

A Laser Safety Officer (LSO) shall be appointed at each facility using a fiber laser for welding or cutting. The duties and responsibilities of the LSO should be as outlined in ANSI Z136.1, Section 1.3 in the US or other laser safety regulations applicable to the OEM laser cutting systems at the final installation site.

Note: The LSO is responsible for ensuring that all operators are properly trained and fully aware of the safe

operation and hazards of operating a laser welding or cutting system. The LSO is also responsible for communicating and enforcing safety procedures to ensure all personnel (operator, service and visitors) understand the theory of operation for the OEM laser cutting end product and site safety instructions before entering a restricted area or room where a laser can be operating.

The Laser Safety Officer (LSO) shall with support from the final laser cutting system manufacturer conduct a hazard evaluation at the site that takes at least the following into consideration:

A. the potential hazards produced by the operation of the laser equipment;

B. the inherent hazards in the environment in which the equipment is to be operated;

C. the hazards that may occur with operation of the equipment in that environment; and

D. the individuals who may be affected by the hazards.

After completion of this hazard evaluation, the Laser Safety Officer (LSO) shall define the specific laser safety personal protective equipment requirements and procedures.

Condition of laser beam equipment

All laser beam equipment shall be maintained in good mechanical and electrical condition by competent or qualified maintenance personnel as specified by the machine builder. The operator shall report any equipment malfunction, defect, or safety hazard to the laser safety officer, and the use of the equipment shall be discontinued until its safeness has been ensured by the laser safety officer. Repairs shall be made only by competent or qualified maintenance personnel.

Hypertherm Fiber Laser Instruction Manual – 807090 Revision 3 S-3

safety

Laser safety

This product is a Class 4 laser capable of cutting metal. The Hypertherm HFL015 Fiber Laser is specifically designed for incorporation or integration into other equipment. As such, it DOES NOT MEET the full requirements for a standalone laser system as defined by 21 CFR 1040.10 and IEC/EN 60825-1. Within the EU, the equipment is supplied with a Certificate of Incorporation indicating harmonized standards considered in the design.

“Machine builder” in this context is meant to include any person that integrates the Hypertherm HFL015 Fiber Laser into their final laser cutting system, or any person who uses the Hypertherm HFL015 Fiber Laser in the form as supplied by Hypertherm.

The label shown below has been affixed to the HFL015 Fiber Laser Supply, part number 051023 to satisfy the US Code of Federal Regulations which indicates equipment does not need to comply with the requirements of 21CFR1040.10 and 21CFR1040.11 for a complete laser product, provided the equipment is labeled with a statement that it is designated for use solely as a component.

S-4 Hypertherm Fiber Laser Instruction Manual – 807090 Revision 3

safety

Laser safety warnings

It is the responsibility of the machine builder to meet all of the regulatory requirements for the final laser cutting system. Nonetheless, many of the electronic and labeling requirements have been incorporated into the Hypertherm HyIntensity Fiber Laser to facilitate the final laser cutting system compliance with regulatory requirements.

The following laser safety warning labels are located on the Hypertherm HyIntensity Fiber Laser when the Hypertherm HyIntensity Fiber Laser leaves the Hypertherm factory.

Labels on the front door

On the 1.0 kW laser

(HFL010)

On the 2.0 kW laser

(HFL020)

Labels on the top cover

On the 1.5 kW laser

(HFL015)

On the 3.0 kW laser

(HFL030)

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Label on the Beam delivery outlet

Label on the left side

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Label on the right side

safety

Labels on the rear door

On the 1.0 kW laser

(HFL010)

On the 2.0 kW laser

(HFL020)

On the 1.5 kW laser

(HFL015)

On the 3.0 kW laser

(HFL030)

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Label on the laser head

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During installation it is vital that the laser hazard is fully managed. In particular, the machine builder is required to implement the engineering requirements detailed in IEC/EN 60825-1. Based on the evaluation or certification of the final laser cutting system, additional laser safety warnings may be provided by the machine builder or by the laser safety officer at the installed site.

Health concerns

Personnel assigned to operate or maintain laser beam cutting equipment shall have been properly trained by the machine builders representative or by a qualified instructor and shall understand the safety requirements of metal cutting using lasers.

Laser safety eyewear (LSE)

Laser safety eyewear (LSE) is designed to reduce the amount of incident light of specific wavelengths to a safe level, while transmitting sufficient light for good vision. As LSE often looks alike in style and color, it is important to specifically check both the wavelength and optical density imprinted on all LSE prior to laser use, especially in multi-wavelength facilities where more than one laser may be located. In the USA reference to ANSI Z136.1 is recommended for the selection of appropriate eye wear to protect against reflections of laser radiation.

Acoustical noise

The noise generated by laser beam welding, cutting, or gouging may impair hearing. Hearing protection shall be worn where the noise level exceeds limits as specified by the regulatory authority having jurisdiction Since operators and nearby personnel can be exposed to noise levels in excess of 85 dB(A), it is important that their hearing be protected. The most direct way to control excessive noise is to reduce the intensity at the source or install barriers in the final laser cutting system between the source and the operator station(s). When engineering or administrative control methods fail to bring noise exposure within levels established by the appropriate regulatory authority having jurisdiction, personal protective devices such as earmuffs or earplugs shall be used. It is the responsibility of the machine builder and the body responsible for the implementation of workplace / laser safety at the installed site to measure the acoustical noise in application and ensure personnel are protected from noise levels that exceed limits.

Warning signs

Warning signs shall be posted in conspicuous areas to indicate laser and cutting hazards. The signs shall indicate the need for the appropriate types of protective equipment.

Gas, fumes and air quality

Fumes and gases are generated by removal of metal from the workpiece being cut during laser beam cutting. The body responsible for workplace / laser safety at the installed site needs to control the materials being cut. Before cutting any unfamiliar materials or using any unfamiliar cleaning materials, the Material Safety Data Sheet (MSDS) shall be read to determine whether any hazards may exist when the material removed will be converted to a gas by laser cutting.

Personnel shall not be exposed to concentrations of airborne contaminants above acceptable limits as established by the authority having jurisdiction. The most direct way to control fumes and gases is by ventilation. Air Quality permits may be needed to release fumes outside the building. Consult a local expert for information on local air quality permits, ventilation and fume extraction. Where ventilation alone cannot protect personnel, appropriate personal respiratory protection shall be used as required by the authority having jurisdiction. Where respirators are employed, requirements for the selection and use of respirators shall include, as a minimum, the following:

A. Written procedures for the proper care, use, maintenance, and storage of respirators shall be provided, and the

employer shall ensure that these procedures are followed. These procedures shall be developed and set down in writing in consultation with the joint health and safety committee or the health and safety representative, as applicable; and made readily accessible, along with related schedules, to the welder andwelding personnel.

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B. The OEM laser cutting end product recommended maintenance and cleaning schedules and procedures shall

be followed.

C. Adequate and suitable storage facilities for respirators shall be provided.

D. A person with the appropriate skills and knowledge shall be assigned to examine respirators and carry out the

tests or procedures necessary to ensure that they serve their intended purpose; and ensure that the respirators ﬁt the individual workers correctly and are appropriate for their intended purpose.

E. The employer shall provide training and instruction for workers and supervisors on the proper use, care,

maintenance, and storage of respirators.

For fume and gases air sampling, where concentrations of airborne fume contaminants are to be determined by sampling of the atmosphere, sampling shall be tested using the NIOSH methodology, other recognized methods, or the guidelines of the authority having jurisdiction. When a helmet is worn, the samples shall be collected inside the helmet in the operator’s breathing zone. The occupational exposure limits shall comply with the regulatory authority having jurisdiction. Contaminant and fume analysis in the lab is covered under two areas:

A. Total welding fume particulate (mg/m3).

B. An elemental analysis of each contaminant (mg/m3). The contaminant particulate and fume testing is important

to determine the exposure risk to personnel.

Confined spaces

Confined spaces are defined specifically in the codes and regulations that apply to each work project. Confined spaces need to be considered when the access or egress of personnel is restricted and there is a potential for the accumulation of a hazardous gas, fume, vapor, and dust, or the development of an oxygen-deficient or oxygen-enriched atmosphere that is likely to affect the health and safety of a worker.

If needed, the body responsible for the implementation of workplace / laser safety at the installed site shall have written rescue procedures for confined space emergencies. Before the operator or service personnel enters a confined space to undertake any welding, cutting, or allied process, the personnel shall be informed of and understand the hazards of the confined space and receive instruction on safe procedures for entering, working in, and exiting from theconfinedspace.

Before a person enters a confined space, a leak test should be done on all joints of any hose or pipelines that have the potential to introduce gases into the confined space. This leak test is done in order to eliminate the possibility of gases being introduced into the confined space.

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Oxygen gas distribution for laser cutting

Oxygen distribution system including connections and valves shall be approved by the regulatory authority having jurisdiction.

• Each outlet on the service piping from which oxygen is withdrawn to supply a portable outlet header shall be equipped with a readily accessible shutoff valve.

• Each service outlet on portable outlet headers shall be provided with a check valve, a readily accessible shutoff valve, and a detachable outlet seal cap that is chained or otherwise attached to the body of the valve.

• Master shutoff valves for oxygen shall be provided at the entry end of the portable outlet header.

• Portable outlet headers for fuel gas service shall be provided with an approved hydraulic backpressure valve

installed at the inlet and preceding the service outlets, unless an approved pressure-reducing regulator, an approved backﬂow check valve, or an approved hydraulic backpressure valve is installed at each outlet. Outlets provided on headers for oxygen service may be ﬁtted for use with pressure-reducing regulators or for direct hoseconnection.

• Hose for oxygen-fuel gas service shall meet the requirements of RMA IP-7 and CGA E-1.

• Cylinder manifolds, shutoff valves, pressure-reducing regulators, backpressure valves, hoses and connections

shall be installed under the supervision of someone properly trained in their assembly and use.

In North America, hose diameters of 19 mm (3/4 in) or smaller are color-coded green for oxygen and red for fuel gases (acetylene, liquefied petroleum gases (LPG), natural gas, hydrogen, etc.). Black hose is used for inert gases, compressed air, and water services.

Note: ISO standard colors are blue for oxygen hose and orange for LPG hose.

Public exhibitions and demonstrations

Safety precautions specific to welding and cutting performed at public demonstrations and exhibits shall protect viewers, demonstrators, and the public. Installation and operation of welding, cutting, and related equipment shall be under the supervision of a competent person designated to ensure the safety of the public. The site shall be so constructed, equipped, and operated as to minimize the possibility of injury to viewers at the site. Materials and equipment on-site shall be located so as not to interfere with evacuation of people during an emergency. Sites shall be provided with an appropriate type of portable fire extinguisher. Combustible materials at the site shall be shielded from flames, sparks, and molten metal or moved to a safe distance, i.e., 15 m (50 ft). The fire department shall be notified in advance of the public exhibition and demonstration. The public shall be shielded from flames, flying sparks, molten metal, harmful laser radiation, inhalation of hazardous concentrations of fumes and gases and contact with live electrical arts.

Large area viewing

For large area viewing, such as training, demonstrations, shows, and certain automatic laser welding and cutting operations, a large filter window or curtain may be used rather than individual helmets, hand shields, or goggles. It is important to specifically check both the wavelength and optical density for a large filter window or curtain. Acombination of windows or curtains and laser safety eye wear (LSE) may be used.

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Training

The laser safety and basic safety training shall be in accordance with the requirements of the authority having jurisdiction. The course contents should include, as a minimum, elements covering:

A. laser safety

B. basic safety

C. hazard identiﬁcation, including:

a. electrical hazards

b. ﬁre protection and prevention

c. burns

d. radiation

e. fumes and gases

f. noise

g. explosions

D. hazard controls

E. personal protective equipment

F. process-speciﬁc welding and cutting safety

G. ergonomic issues

H. care and maintenance of OEM laser cutting end product

Additional training shall be provided on the following subjects if applicable to the nature of work being performed:

A. elevated work and fall protection

B. material handling (basic rigging, hoisting, forklift, etc.)

C. conﬁned spaces

D. welding or cutting of drums and containers

E. work permit systems and policies

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PRODUCT STEWARDSHIP

Introduction

Hypertherm maintains a global Regulatory Management System to ensure that products comply with regulatory and environmental requirements.

National and local safety regulations

National and Local safety regulations shall take precedence over any instructions provided with the product. The product shall be imported, installed, operated and disposed of in accordance with national and local regulations applicable to the installed site.

Certification test marks

Certified products are identified by one or more certification test marks from accredited testing laboratories. The certification test marks are located onornear the data plate.

Each certification test mark means that the product and its safety-critical components conform to the relevant national safety standards as reviewed and determined by that testing laboratory. Hypertherm places a certification test mark on its products only after that product is manufactured with safety-critical components that have been authorized by the accredited testing laboratory.

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

• Theproductismodifiedinamannerthatcreates

a hazard or non-conformance with the applicable standards.

• Safety-criticalcomponentsarereplacedwith

unauthorized spare parts.

• Anyunauthorizedassembly,oraccessorythatusesor

generates a hazardous voltage is added.

• Thereisanytamperingwithasafetycircuitorother

feature that is designed into the product as part of the certification, or otherwise.

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

are incorporated within versions of the power supply with a CE Marking.

Certificates of compliance for Hypertherm products are available fromthe Downloads Library on the Hypertherm web site at

https://www.hypertherm.com.

Differences in national standards

Nations may apply different performance, safety or other standards. National differences in standards include, but are not limited to:

• Voltages

• Plugandcordratings

• Languagerequirements

• Electromagneticcompatibilityrequirements

These differences in national or other standards may make it impossible or impractical for all certification test marks to be placed on the same version of a product. For example, the CSA versions of Hypertherm’s products do not comply with European EMC requirements, and therefore do not have a CE marking on the data plate.

Countries that require CE marking or have compulsory EMC regulations must use CE versions of Hypertherm products with the CE marking on the data plate. These include, but are not limited to:

• Australia

• NewZealand

• CountriesintheEuropeanUnion

• Russia

It is important that the product and its certification test mark be suitable for the end-use installation site. When Hypertherm products are shipped to one country for export to another country; the product must be configured and certified properly for the end-use site.

Safe installation and use of shape cutting equipment

IEC 60974-9, titled Arc Welding Equipment – Installation and use, provides guidance in the safe installation and use of shape cutting equipment and the safe performance of cutting operations. The requirements of national and local regulations shall be taken into consideration during installation, including, but not limited to, grounding or

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protective earth connections, fuses, supply disconnecting device, and type of supply circuit. Read these instructions before installing the equipment. The first and most important step is the safety assessment of the installation.

The safety assessment must be performed by an expert, and determines what steps are necessary to create a safe environment, and what precautions should be adopted during the actual installation and operation.

Procedures for periodic inspection and testing

Where required by local national regulations, IEC60974-4 specifies test procedures for periodic inspection and after repair or maintenance, to ensure electrical safety for plasma cutting power sources built in conformity with IEC 60974-1. Hypertherm performs the continuity of the protective circuit and insulation resistance tests in the factory as non-operating tests. The tests are performed with the power and ground connections removed.

Hypertherm also removes some protective devices that would cause false test results. Where required by local national regulations, a label shall be attached to the equipment to indicate that it has passed the tests prescribed by IEC60974-4. The repair report shall indicate the results of all tests unless an indication is made that a particular test has not been performed.

Qualification of test personnel

Electrical safety tests for shape cutting equipment can be hazardous and shall be carried out by an expert in the field of electrical repair, preferably someone also familiar with welding, cutting, and allied processes. The safety risks to personnel and equipment, when unqualified personnel are performing these tests, may be much greater than the benefit of periodic inspection and testing.

Hypertherm recommends that only visual inspection be performed unless the electrical safety tests are specifically required by local national regulations in the country where the equipment is installed.

Residual current devices (RCDs)

In Australia and some other countries, local codes may require the use of a Residual Current Devices (RCD) when portable electrical equipment is used in the workplace or at construction sites to protect operators from electrical faults in the equipment. RCDs are designed to safely disconnect the mains electrical supply when an imbalance is detected between the supply and return current (there is a leakage current to earth). RCDs are available with both fixed and adjustable trip currents between 6to 40 milliamperes and a range of trip times up to 300milliseconds selected for the equipment installation, application and intended use. Where RCDs are used, the trip current and trip time on RCDs should be selected or adjusted high enough to avoid nuisance tripping during normal operation of the plasma cutting equipment and low enough in the extremely unlikely event of an electrical fault in the equipment to disconnect the supply before the leakage current under a fault condition can pose a life threatening electrical hazard to operators.

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

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

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Higher-level systems

When a system integrator adds additional equipment; such as cutting tables, motor drives, motion controllers or robots; to a Hypertherm plasma cutting system, the combined system may be considered a higher-level system. A higher-level system with hazardous moving parts may constitute industrial machinery or robotic equipment, in which case the OEM or end-use customer may be subject to additional regulations and standards than those relevant to the plasma cutting system as manufactured by Hypertherm.

It is the responsibility of the end-use customer and the OEM to perform a risk assessment for the higher-level system, and to provide protection against hazardous moving parts. Unless the higher-level system is certified when the OEM incorporates Hypertherm products into it, the installation also may be subject to approval by local authorities. Seek advice from legal counsel and local regulatory experts if you are uncertain about compliance.

External interconnecting cables between component parts of the higher level system must be suitable for contaminants and movement as required by the final end use installation site. When the external interconnecting cables are subject to oil, dust, water, or other contaminants, hard usage ratings may be required.

Product stewardshiP

When external interconnecting cables are subject to continuous movement, constant flexing ratings may be required. It is the responsibility of the end-use customer or the OEM to ensure the cables are suitable for the application. Since there are differences in the ratings and costs that can be required by local regulations for higher level systems, it is necessary to verify that any external interconnecting cables are suitable for the end-use installation site.

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ENVIRONMENTAL STEWARDSHIP

Introduction

The Hypertherm Environmental Specification requires RoHS, WEEE and REACH substance information to be provided by Hypertherm’s suppliers.

Product environmental compliance does not address the indoor air quality or environmental release of fumes by the end user. Any materials that are cut by the end user are not provided by Hypertherm with the product. The end user is responsible for the materials being cut as well as for safety and air quality in the workplace. The end user must be aware of the potential health risks of the fumes released from the materials being cut and comply with all local regulations.

National and local environmental regulations

National and local environmental regulations shall take precedence over any instructions contained in this manual.

The product shall be imported, installed, operated and disposed of in accordance with all national and local environmental regulations applicable to the installed site.

The European Environmental regulations are discussed later in TheWEEE Directive.

The RoHS directive

Hypertherm is committed to complying with all applicable laws and regulations, including the European Union Restriction of Hazardous Substances (RoHS) Directive that restricts the use of hazardous materials in electronics products. Hypertherm exceeds RoHS Directive compliance obligations on a global basis.

Hypertherm continues to work toward the reduction of RoHS materials in our products, which are subject to the RoHS Directive, except where it is widely recognized that there is no feasible alternative.

Declarations of RoHS Conformity have been prepared for the current CE versions of Powermax plasma cutting systems manufactured by Hypertherm. There is also a “RoHS mark” on the Powermax CE versions below the “CE Marking” on the data plate of CE versions of Powermax series units shipped since 2006. Parts used in CSA versions of Powermax and other products manufactured by Hypertherm that are either out of scope or exempt from RoHS are continuously being converted to RoHS compliance in anticipation of future requirements.

Proper disposal of Hypertherm products

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

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

laws.

• IntheEuropeanUnion,checktheEUdirectives,

national, and local laws. For more information, visit www. hypertherm.com/weee.

• Inothercountries,checknationalandlocallaws.

• Consultwithlegalorothercomplianceexpertswhen

appropriate.

The WEEE directive

On January 27, 2003, the European Parliament and the Council of the European Union authorized Directive 2002/96/EC or WEEE (Waste Electrical and Electronic Equipment).

As required by the legislation, any Hypertherm product covered by the directive and sold in the EU after August 13, 2005 is marked with the WEEE symbol. This directive encourages and sets specific criteria for the collection, handling, and recycling of EEE waste. Consumer and business-to-business wastes are treated differently (all Hypertherm products are considered business-tobusiness). Disposal instructions for the CE versions of Powermax plasma systems can be found at www.hypertherm.com/weee.

The URL is printed on the symbol-only warning label for each of these CE version Powermax series units shipped since 2006. The CSA versions of Powermax and other products manufactured by Hypertherm are either out of scope or exempt from WEEE.

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The REACH regulation

The REACH regulation (1907/2006), in force since June1, 2007, has an impact on chemicals available to the European market. The REACH regulation requirements for component manufacturers states that the component shall not contain more than 0.1% by weight of the Substances of Very High Concern (SVHC).

Component manufacturers and other downstream users, such as Hypertherm, are obligated to obtain assurances from its suppliers that all chemicals used in or on Hypertherm products will have a European Chemical Agency (ECHA) registration number. To provide chemical information as required by the REACH regulation, Hypertherm requires suppliers to provide REACH declarations and identify any known use of REACH SVHC. Any use of SVHC in amounts exceeding 0.1% w/w of the parts has been eliminated. The MSDS contains a full disclosure of all substances in the chemical and can be used to verify REACH SVHC compliance.

The lubricants, sealants, coolants, adhesives, solvents, coatings and other preparations or mixtures used by Hypertherm in, on, for, or with its shape cutting equipment are used in very small quantities (except the coolant) and are commercially available with multiple sources that can and will be replaced in the event of a supplier problem associated with REACH Registration or REACH Authorization (SVHCs).

Proper handling and safe use of chemicals

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

Fumes emission and air quality

Note: The following information on air quality is

intended for general information only and should not be used as a substitute for reviewing and implementing applicable government regulations or legal standards in the country where the cutting equipment will be installed and operated.

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

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

Where applicable, Hypertherm also uses a third party industrial hygienist to obtain air and water permits.

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

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

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

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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 cutting 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 workpiece. 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.

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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.

Cutting cables

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

Equipotential bonding

Bonding of all metallic components in the cutting installation and adjacent to it should be considered.

However, metallic components bonded to the workpiece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode (nozzle for laser heads) at the same time.

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

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

The operator should be insulated from all such bonded metallic components.

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