Hypertherm Powermax190c Troubleshooting
Plasma Arc
Cutting System
Operator Manual
803650 Revision 3
powermax190c
®
Operator Manual
(P/N 803650)
© Copyright 2004 Hypertherm, Inc.
All Rights Reserved
Hypertherm and Powermax are trademarks of Hypertherm, Inc.
and may be registered in the United States and/or other countries.
Hypertherm, Inc.
Hanover, NH USA
www.hypertherm.com
Revision 3 – January, 2004
powermax190c
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)
service@hypertherm.com (Technical Service Email)
800-737-2978 Tel (Customer Service)
customer.service@hypertherm.com (Customer Service Email)
Hypertherm Automation, LLC
5 Technology Drive, Suite 300
West Lebanon, NH 03755 USA
603-298-7970 Tel
603-298-7977 Fax
Hypertherm Plasmatechnik, GmbH
Technologiepark Hanau
Rodenbacher Chaussee 6
63457 Hanau-Wolfgang, Deutschland
49 6181 58 2100 Tel
49 6181 58 2134 Fax
49 6181 58 2123 (Technical Service)
Hypertherm (S) Pte Ltd.
No. 19 Kaki Bukit Road 2
K.B. Warehouse Complex
Singapore 417847, Republic of Singapore
65 6 841 2489 Tel
65 6 841 2490 Fax
65 6 841 2489 (Technical Service)
Hypertherm UK, Ltd.
9 Berkeley Court, Manor Park
Runcorn, Cheshire, England WA7 1TQ
44 1928 579 074 Tel
44 1928 579 604 Fax
France
15 Impasse des Rosiers
95610 Eragny, France
00 800 3324 9737 Tel
00 800 4973 7329 Fax
Hypertherm S.r.l.
Via Torino 2
20123 Milano, Italia
39 02 725 46 312 Tel
39 02 725 46 400 Fax
39 02 725 46 314 (Technical Service)
Hypertherm Europe B.V.
Vaartveld 9
4704 SE Roosendaal, Nederland
31 165 596907 Tel
31 165 596901 Fax
31 165 596908 Tel (Marketing)
31 165 596900 Tel (ETSO – Technical Service)
00 800 49 73 7843 Tel (ETSO – Technical Service
toll-free in Europe)
Japan
1952-14 Yata-Natsumegi
Mishima City, Shizuoka Pref.
411-0801 Japan
81 0 559 75 7387 Tel
81 0 559 75 7376 Fax
Hypertherm Brasil Ltda.
Rua Visconde de Santa Isabel, 20 – Sala 611
Vila Isabel, RJ
Brasil CEP 20560-120
55 21 2278 6162 Tel
55 21 2578 0947 Fax
5/23/03
ELECTROMAGNETIC COMPATIBILITY (EMC)
Hypertherm Plasma Systems i
EMC INTRODUCTION
Hypertherm's CE-marked equipment is built
in compliance with standard EN50199. The
equipment should be installed and used in
accordance with the information below to
achieve electromagnetic compatibility.
The limits required by EN50199 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 plasma equipment is designed for use
only in an industrial environment.
INSTALLATION AND USE
The user is responsible for installing and
using the plasma equipment according to
the manufacturer's instructions. If electromagnetic disturbances are detected then it
shall be the responsibility of the user to resolve the situation with the technical assistance of the manufacturer. In some cases
this remedial action may be as simple as
earthing the cutting circuit, see Earthing of
Workpiece. In other cases it could involve
constructing an electromagnetic screen
enclosing the power source and the work
complete with associated input filters. In all
cases electromagnetic disturbances must
be reduced to the point where they are no
longer troublesome.
ASSESSMENT OF AREA
Before installing the equipment the user
shall make an assessment of potential
electromagnetic problems in the surrounding area. The following shall be taken into
account:
a. Other supply cables, control cables, signalling and telephone cables; above, below
and adjacent to the cutting equipment.
b. Radio and television transmitters and
receivers.
c. Computer and other control equipment.
d. Safety critical equipment, for example
guarding of industrial equipment.
e. Health of the people around, for example
the use of pacemakers and hearing aids.
f. Equipment used for calibration or measurement.
g. Immunity of other equipment in the environment. User shall ensure that other
equipment being used in the environment is
compatible. This may require additional protection measures.
h. Time of day that cutting or other activities are to be carried out.
The size of the surrounding area to be considered will depend on the structure of the
building and other activities that are taking
place. The surrounding area may extend
beyond the boundaries of the premises.
METHODS OF REDUCING EMISSIONS
Mains Supply
Cutting equipment must be connected to
the mains supply according to the manufacturer's recommendations. If interference
occurs, it may be necessary to take additional precautions such as filtering of the
mains supply. Consideration should be
given to shielding the supply cable of permanently installed cutting equipment, in
metallic conduit or equivalent. Shielding
should be electrically continuous throughout its length. The shielding should be connected to the cutting mains supply so that
good electrical contact is maintained between the conduit and the cutting power
source enclosure.
Maintenance of Cutting Equipment
The cutting equipment must be routinely
maintained according to the manufacturer's
recommendations. All access and service
doors and covers should be closed and
properly fastened when the cutting equipment is in operation. The cutting equipment
should not be modified in any way except for
those changes and adjustments covered in
the manufacturer's instructions. In particular, the spark gaps of arc striking and stabilizing devices should be adjusted and
maintained according to the manufacturer's
recommendations.
Cutting Cables
The cutting cables should be kept as short
as possible and should be positioned close
together, running at or close to the floor
level.
Equipotential Bonding
Bonding of all metallic components in the
cutting installation and adjacent to it should
be considered. However, metallic components bonded to the workpiece will increase
the risk that the operator could receive a
shock by touching these metallic compo-
nents and the electrode at the same time.
The operator should be insulated from all
such bonded metallic components.
Earthing of Workpiece
Where the workpiece is not bonded to earth
for electrical safety, nor connected to earth
because of its size and position, for example, ship's hull or building steelwork, a connection bonding the workpiece to earth may
reduce emissions in some, but not all
instances. Care should be taken to prevent
the earthing of the workpiece increasing the
risk of injury to users, or damage to other
electrical equipment. Where necessary, the
connection of the workpiece to earth should
be made by a direct connection to the workpiece, but in some countries where direct
connection is not permitted, the bonding
should be achieved by suitable capacitances
selected according to national regulations.
Note. The cutting circuit may or may not be
earthed for safety reasons. Changing the
earthing arrangements should only be authorized by a person who is competent to
assess whether the changes will increase
the risk of injury, for example, by allowing
parallel cutting current return paths which
may damage the earth circuits of other
equipment. Further guidance is given in IEC
TC26 (sec)94 and IEC TC26/108A/CD Arc
Welding Equipment Installation and Use.
Screening and Shielding
Selective screening and shielding of other
cables and equipment in the surrounding
area may alleviate problems of interference.
Screening of the entire plasma cutting
installation may be considered for special
applications.
WARRANTY
9-01
ii Hypertherm Plasma Systems
WARNING
Genuine Hypertherm parts are the factory-recommended
replacement parts for your Hypertherm system. Any
damage caused by the use of other than genuine
Hypertherm parts may not be covered by the Hypertherm
warranty.
WARNING
You are responsible for the safe use of the Product.
Hypertherm does not and cannot make any guarantee or
warranty regarding the safe use of the Product in your
environment.
GENERAL
Hypertherm, Inc. warrants that its Products shall be
free from defects in materials and workmanship, if
Hypertherm is notified of a defect (i) with respect to the
power supply within a period of two (2) years from the date
of its delivery to you, with the exception of G3 Series power
supplies, which shall be within a period of three (3) years
from the date of delivery to you, and (ii) with respect to the
torch and leads within a period of one (1) year from its date
of delivery to you. This warranty shall not apply to any
Product which has been incorrectly installed, modified, or
otherwise damaged. Hypertherm, at its sole option, shall
repair, replace, or adjust, free of charge, any defective
Products covered by this warranty which shall be returned
with Hypertherm’s prior authorization (which shall not be
unreasonably withheld), properly packed, to Hypertherm’s
place of business in Hanover, New Hampshire, or to an
authorized Hypertherm repair facility, all costs, insurance
and freight prepaid. Hypertherm shall not be liable for any
repairs, replacement, or adjustments of Products covered
by this warranty, except those made pursuant to this
paragraph or with Hypertherm’s prior written consent. The
warranty above is exclusive and is in lieu of all other
warranties, express, implied, statutory, or otherwise
with respect to the Products or as to the results which
may be obtained therefrom, and all implied warranties
or conditions of quality or of merchantability or fitness
for a particular purpose or against infringement. The
foregoing shall constitute the sole and exclusive
remedy for any breach by Hypertherm of its warranty.
Distributors/OEMs may offer different or additional
warranties, but Distributors/OEMs are not authorized to
give any additional warranty protection to you or make any
representation to you purporting to be binding upon
Hypertherm.
PATENT INDEMNITY
Except only in cases of products not manufactured by
Hypertherm or manufactured by a person other than
Hypertherm not in strict conformity with Hypertherm’s
specifications and in cases of designs, processes,
formulae, or combinations not developed or purported
to be developed by Hypertherm, Hypertherm will defend or
settle, at its own expense, any suit or proceeding brought
against you alleging that the use of the Hypertherm
product, alone and not in combination with any other
product not supplied by Hypertherm, infringes any patent
of any third party. You shall notify Hypertherm promptly
upon learning of any action or threatened action in
connection with any such alleged infringement, and
Hypertherm’s obligation to indemnify shall be conditioned
upon Hypertherm’s sole control of, and the indemnified
party’s cooperation and assistance in, the defense of
the claim.
LIMITATION OF LIABILITY
In no event shall Hypertherm be liable to any person
or entity for any incidental, consequential, indirect, or
punitive damages (including but not limited to lost
profits) regardless of whether such liability is based
on breach of contract, tort, strict liability, breach of
warranties, failure of essential purpose or otherwise
and even if advised of the possibility of such damages.
LIABILITY CAP
In no event shall Hypertherm’s liability, whether such
liability is based on breach of contract, tort, strict
liability, breach of warranties, failure of essential
purpose or otherwise, for any claim action suit or
proceeding arising out of or relating to the use of the
Products exceed in the aggregate the amount paid for
the Products that gave rise to such claim.
INSURANCE
At all times you will have and maintain insurance in such
quantities and types, and with coverage sufficient and
appropriate to defend and to hold Hypertherm harmless in
the event of any cause of action arising from the use of the
Products.
NATIONALAND LOCAL CODES
National and Local codes governing plumbing and
electrical installation shall take precedent over any
instructions contained in this manual. In no event shall
Hypertherm be liable for injury to persons or property
damage by reason of any code violation or poor work
practices.
TRANSFER OF RIGHTS
You may transfer any remaining rights you may have
hereunder only in connection with the sale of all or
substantially all of your assets or capital stock to a
successor in interest who agrees to be bound by all of the
terms and conditions of this Warranty.
TABLE OF CONTENTS
0
powermax19 0 c Operator Manual iii
Electromagnetic Compatibility .......................................................................................................................i
Warranty .......................................................................................................................................................ii
Section 1 Safety
Recognize Safety Information ...................................................................................................................1-2
Follow Safety Instructions .........................................................................................................................1-2
Cutting Can Cause Fire or Explosion........................................................................................................1-2
Electric Shock Can Kill ..............................................................................................................................1-3
Cutting Can Produce Toxic Fumes............................................................................................................1-3
A Plasma Arc Can Cause Injury and Burns...............................................................................................1-4
Arc Rays Can Burn Eyes and Skin ...........................................................................................................1-4
Grounding Safety ......................................................................................................................................1-4
Compressed Gas Equipment Safety.........................................................................................................1-5
Gas Cylinders Can Explode If Damaged ..................................................................................................1-5
Noise Can Damage Hearing .....................................................................................................................1-5
Pacemaker and Hearing Aid Operation.....................................................................................................1-5
A Plasma Arc Can Damage Frozen Pipes ................................................................................................1-5
Additional Safety Information ....................................................................................................................1-5
Warning Label ...........................................................................................................................................1-6
Section 1a Sécurité
Identifier les consignes de sécurité .........................................................................................................1a-2
Suivre les instructions de sécurité...........................................................................................................1a-2
Danger Avertissement Précaution.........................................................................................................1a-2
Le coupage peut provoquer un incendie ou une explosion.....................................................................1a-2
Prévention des incendies, Prévention des explosions ..................................................................1a-2
Risque d’explosion argon-hydrogène et méthane .........................................................................1a-2
Détonation de l’hydrogène lors du coupage de l’aluminium ..........................................................1a-2
Les chocs électriques peuvent être fatals ...............................................................................................1a-3
Prévention des chocs électriques..................................................................................................1a-3
Le coupage peut produire des vapeurs toxiques ....................................................................................1a-3
L’arc plasma peut provoquer des blessures ou des brûlures..................................................................1a-4
Torches à allumage instantané ......................................................................................................1a-4
Les rayons de l’arc peuvent brûler les yeux et la peau ...........................................................................1a-4
Protection des yeux, Protection de la peau, Zone de coupage ...................................................1a-4
Mise à la masse et à la terre ...................................................................................................................1a-4
Câble de retour, Table de travail, Alimentation ..............................................................................1a-4
Sécurité des bouteilles de gaz comprimé ...............................................................................................1a-5
Les bouteilles de gaz comprimé peuvent exploser en cas de dommages..............................................1a-5
Le bruit peut provoquer des problèmes auditifs ......................................................................................1a-5
Pacemakers et prothèses auditives ........................................................................................................1a-5
Un arc plasma peut endommager les tuyaux gelés ................................................................................1a-5
Étiquette de sécurité ...............................................................................................................................1a-6
TABLE OF CONTENTS
0
iv powermax19 0 c Operator Manual
Section 2 Specifications
Introduction ...............................................................................................................................................2-2
Specifications ............................................................................................................................................2-2
Power Supply.....................................................................................................................................2-2
PAC105 Torch ....................................................................................................................................2-3
IEC Symbols Used ....................................................................................................................................2-4
Section 3 Setup
Upon Receipt ............................................................................................................................................3-2
Claims .......................................................................................................................................................3-2
Location of Power Supply .........................................................................................................................3-2
Grounding Requirements ..........................................................................................................................3-3
Power Cord Plugs .....................................................................................................................................3-3
Power Hookup...........................................................................................................................................3-4
System Circuit Recommendations.....................................................................................................3-4
Extension Cord Recommendations ...................................................................................................3-4
Section 4 Operation
Controls and Indicators ............................................................................................................................4-2
Operation ..................................................................................................................................................4-3
1. Install Torch Consumables .............................................................................................................4-3
2. Attach the Work Clamp ..................................................................................................................4-3
3. Turn on Power................................................................................................................................4-4
4. Check the Indicator Lamps ............................................................................................................4-4
5. Begin Cutting .................................................................................................................................4-5
Operating Tips...........................................................................................................................................4-6
Starting a Cut from the Edge of the Workpiece..................................................................................4-6
Piercing ..............................................................................................................................................4-7
Hand Torch Cutting Technique ...........................................................................................................4-8
Inspecting and Replacing Consumables...................................................................................................4-9
Correct Alignment of Consumables ...................................................................................................4-9
Common Cutting Faults ..........................................................................................................................4-10
Duty Cycle and Overheating ...................................................................................................................4-10
Section 5 Maintenance and Parts
Routine Maintenance ................................................................................................................................5-2
Before Each Use................................................................................................................................5-2
Every Week........................................................................................................................................5-2
3 Months ............................................................................................................................................5-2
6 Months ............................................................................................................................................5-2
Basic Troubleshooting...............................................................................................................................5-3
Torch Lead and Work Lead Replacement .................................................................................................5-4
Torch Lead Connections ....................................................................................................................5-4
Work Lead Connection.......................................................................................................................5-4
TABLE OF CONTENTS
0
powermax19 0 c Operator Manual v
Technical Questions ..................................................................................................................................5-5
Parts..........................................................................................................................................................5-6
Powermax190c Power Supplies ........................................................................................................5-6
Powermax190c Systems ...................................................................................................................5-6
Consumable Parts .............................................................................................................................5-6
PAC105 Torch Assembly and 20 ft (6.1 m) Torch Lead......................................................................5-7
Powermax190c Labels.......................................................................................................................5-8
Optional Parts ....................................................................................................................................5-8
TABLE OF CONTENTS
0
vi powermax19 0 c Operator Manual
Hypertherm Plasma Systems 1-1
Section 1
SAFETY
In this section:
Recognize Safety Information ...................................................................................................................1-2
Follow Safety Instructions .........................................................................................................................1-2
Cutting Can Cause Fire or Explosion........................................................................................................1-2
Electric Shock Can Kill ..............................................................................................................................1-3
Cutting Can Produce Toxic Fumes............................................................................................................1-3
A Plasma Arc Can Cause Injury and Burns...............................................................................................1-4
Arc Rays Can Burn Eyes and Skin ...........................................................................................................1-4
Grounding Safety ......................................................................................................................................1-4
Compressed Gas Equipment Safety.........................................................................................................1-5
Gas Cylinders Can Explode If Damaged ..................................................................................................1-5
Noise Can Damage Hearing .....................................................................................................................1-5
Pacemaker and Hearing Aid Operation.....................................................................................................1-5
A Plasma Arc Can Damage Frozen Pipes ................................................................................................1-5
Additional Safety Information ....................................................................................................................1-5
Warning Label ...........................................................................................................................................1-6
SAFETY
11-98
1-2 Hypertherm Plasma Systems
RECOGNIZE SAFETY INFORMATION
The symbols shown in this section are used to
identify potential hazards. When you see a safety
symbol in this manual or on your machine,
understand the potential for personal injury, and
follow the related instructions to avoid the hazard.
FOLLOW SAFETY INSTRUCTIONS
Read carefully all safety messages in this manual
and safety labels on your machine.
• Keep the safety labels on your machine in good
condition. Replace missing or damaged labels
immediately.
• Learn how to operate the machine and how to use
the controls properly. Do not let anyone operate it
without instruction.
• Keep your machine in proper working condition.
Unauthorized modifications to the machine may
affect safety and machine service life.
DANGER WARNING CAUTION
A signal word DANGER or WARNING is used with a
safety symbol. DANGER identifies the most serious
hazards.
• DANGER and WARNING safety labels are located
on your machine near specific hazards.
• WARNING safety messages precede related
instructions in this manual that may result in injury
or death if not followed correctly.
• CAUTION safety messages precede related
instructions in this manual that may result in
damage to equipment if not followed correctly.
Fire Prevention
• Be sure the area is safe before doing any cutting.
Keep a fire extinguisher nearby.
• Remove all flammables within 35 feet (10 m) of the
cutting area.
• Quench hot metal or allow it to cool before handling
or before letting it touch combustible materials.
• Never cut containers with potentially flammable
materials inside – they must be emptied and
properly cleaned first.
• Ventilate potentially flammable atmospheres before
cutting.
• When cutting with oxygen as the plasma gas, an
exhaust ventilation system is required.
Explosion Prevention
• Do not use the plasma system if explosive dust or
vapors may be present.
• Do not cut pressurized cylinders, pipes, or any
closed container.
• Do not cut containers that have held combustible
materials.
CUTTING CAN CAUSE FIRE OR EXPLOSION
WARNING
Explosion Hazard
Argon-Hydrogen and Methane
Hydrogen and methane are flammable gases that
present an explosion hazard. Keep flames away from
cylinders and hoses that contain methane or hydrogen
mixtures. Keep flames and sparks away from the torch
when using methane or argon-hydrogen plasma.
WARNING
Hydrogen Detonation with
Aluminum Cutting
• When cutting aluminum underwater, or with the
water touching the underside of the aluminum, free
hydrogen gas may collect under the workpiece and
detonate during plasma cutting operations.
• Install an aeration manifold on the floor of the water
table to eliminate the possibility of hydrogen
detonation. Refer to the Appendix section of this
manual for aeration manifold details.
SAFETY
8-98
Hypertherm Plasma Systems 1-3
Touching live electrical parts can cause a fatal shock
or severe burn.
• Operating the plasma system completes an
electrical circuit between the torch and the
workpiece. The workpiece and anything touching
the workpiece are part of the electrical circuit.
• Never touch the torch body, workpiece or the water
in a water table when the plasma system is
operating.
Electric Shock Prevention
All Hypertherm plasma systems use high voltage
in the cutting process (200 to 400 VDC are
common). Take the following precautions when
operating this system:
• Wear insulated gloves and boots, and keep your
body and clothing dry.
• Do not stand, sit or lie on – or touch – any wet
surface when using the plasma system.
• Insulate yourself from work and ground using dry
insulating mats or covers big enough to prevent any
physical contact with the work or ground. If you
must work in or near a damp area, use extreme
caution.
• Provide a disconnect switch close to the power
supply with properly sized fuses. This switch allows
the operator to turn off the power supply quickly in
an emergency situation.
• When using a water table, be sure that it is correctly
connected to earth ground.
ELECTRIC SHOCK CAN KILL
• Install and ground this equipment according to the
instruction manual and in accordance with national
and local codes.
• Inspect the input power cord frequently for damage
or cracking of the cover. Replace a damaged power
cord immediately. Bare wiring can kill.
• Inspect and replace any worn or damaged torch
leads.
• Do not pick up the workpiece, including the waste
cutoff, while you cut. Leave the workpiece in place
or on the workbench with the work cable attached
during the cutting process.
• Before checking, cleaning or changing torch parts,
disconnect the main power or unplug the power
supply.
• Never bypass or shortcut the safety interlocks.
• Before removing any power supply or system
enclosure cover, disconnect electrical input power.
Wait 5 minutes after disconnecting the main power
to allow capacitors to discharge.
• Never operate the plasma system unless the power
supply covers are in place. Exposed power supply
connections present a severe electrical hazard.
• When making input connections, attach proper
grounding conductor first.
• Each Hypertherm plasma system is designed to be
used only with specific Hypertherm torches. Do not
substitute other torches which could overheat and
present a safety hazard.
Cutting can produce toxic fumes and gases that
deplete oxygen and cause injury or death.
• Keep the cutting area well ventilated or use an
approved air-supplied respirator.
• Do not cut in locations near degreasing, cleaning or
spraying operations. The vapors from certain
chlorinated solvents decompose to form phosgene
gas when exposed to ultraviolet radiation.
• Do not cut metal coated or containing toxic materials, such as zinc (galvanized), lead, cadmium or
CUTTING CAN PRODUCE TOXIC FUMES
beryllium, unless the area is well ventilated and the
operator wears an air-supplied respirator. The
coatings and any metals containing these elements
can produce toxic fumes when cut.
• Never cut containers with potentially toxic materials
inside – they must be emptied and properly cleaned
first.
• This product, when used for welding or cutting,
produces fumes or gases which contain chemicals
known to the State of California to cause birth
defects and, in some cases, cancer.
SAFETY
5/6/02
1-4 Hypertherm Plasma Systems
Instant-On Torches
Plasma arc comes on immediately when the torch
switch is activated.
A PLASMA ARC CAN CAUSE INJURY AND BURNS
The plasma arc will cut quickly through gloves and
skin.
• Keep away from the torch tip.
• Do not hold metal near the cutting path.
• Never point the torch toward yourself or others.
Work Cable Attach the work cable securely to the
workpiece or the work table with good metal-tometal contact. Do not connect it to the piece that will
fall away when the cut is complete.
Work Table Connect the work table to an earth
ground, in accordance with appropriate national or
local electrical codes.
GROUNDING SAFETY
Input Power
• Be sure to connect the power cord ground wire to
the ground in the disconnect box.
• If installation of the plasma system involves
connecting the power cord to the power supply, be
sure to connect the power cord ground wire
properly.
• Place the power cord's ground wire on the stud
first, then place any other ground wires on top of
the power cord ground. Fasten the retaining nut
tightly.
• Tighten all electrical connections to avoid
excessive heating.
Eye Protection Plasma arc rays produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin.
• Use eye protection in accordance with applicable
national or local codes.
• Wear eye protection (safety glasses or goggles
with side shields, and a welding helmet) with
appropriate lens shading to protect your eyes from
the arc’s ultraviolet and infrared rays.
Lens Shade
Arc Current AWS (USA) ISO 4850
Up to 100 A No. 8 No. 11
100-200 A No. 10 No. 11-12
200-400 A No. 12 No. 13
Over 400 A No. 14 No. 14
ARC RAYS CAN BURN EYES AND SKIN
Skin Protection Wear protective clothing to protect
against burns caused by ultraviolet light, sparks and
hot metal.
• Gauntlet gloves, safety shoes and hat.
• Flame-retardant clothing to cover all exposed
areas.
• Cuffless trousers to prevent entry of sparks and
slag.
• Remove any combustibles, such as a butane
lighter or matches, from your pockets before
cutting.
Cutting Area Prepare the cutting area to reduce
reflection and transmission of ultraviolet light:
• Paint walls and other surfaces with dark colors to
reduce reflection.
• Use protective screens or barriers to protect others
from flash and glare.
• Warn others not to watch the arc. Use placards or
signs.
SAFETY
11-98
Hypertherm Plasma Systems 1-5
• Never lubricate cylinder valves or regulators with
oil or grease.
• Use only correct gas cylinders, regulators, hoses
and fittings designed for the specific application.
• Maintain all compressed gas equipment and
associated parts in good condition.
• Label and color-code all gas hoses to identify the
type of gas in each hose. Consult applicable
national or local codes.
GAS CYLINDERS CAN
EXPLODE IF DAMAGED
COMPRESSED GAS EQUIPMENT SAFETY
Gas cylinders contain gas under high pressure. If
damaged, a cylinder can explode.
• Handle and use compressed gas cylinders in
accordance with applicable national or local codes.
• Never use a cylinder that is not upright and
secured in place.
• Keep the protective cap in place over valve except
when the cylinder is in use or connected for use.
• Never allow electrical contact between the plasma
arc and a cylinder.
• Never expose cylinders to excessive heat, sparks,
slag or open flame.
• Never use a hammer, wrench or other tool to open
a stuck cylinder valve.
ADDITIONAL SAFETY INFORMATION
1. ANSI Standard Z49.1, Safety in Welding and Cutting, American
Welding Society, 550 LeJeune Road
P.O. Box 351020, Miami, FL 33135
2. ANSI Standard Z49.2, Fire Prevention in the Use of Cutting and
Welding Processes, American National Standards Institute
1430 Broadway, New York, NY 10018
3. ANSI Standard Z87.1, Safe Practices for Occupation and
Educational Eye and Face Protection, American National Standards
Institute, 1430 Broadway, New York, NY 10018
4. AWS F4.1, Recommended Safe Practices for the Preparation for
Welding and Cutting of Containers and Piping That Have Held
Hazardous Substances, American Welding Society
550 LeJeune Road, P.O. Box 351040, Miami, FL 33135
5. AWS F5.2, Recommended Safe Practices for Plasma Arc
Cutting, American Welding Society
550 LeJeune Road, P.O. Box 351040, Miami, FL 33135
6. CGA Pamphlet P-1, Safe Handling of Compressed Gases in
Cylinders, Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202
7. CSA Standard W117.2, Code for Safety in Welding and Cutting,
Canadian Standards Association Standard Sales
178 Rexdale Boulevard, Rexdale, Ontario M9W 1R3, Canada
8. NFPA Standard 51B, Cutting and Welding Processes, National Fire
Protection Association
470 Atlantic Avenue, Boston, MA 02210
9. NFPA Standard 70–1978, National Electrical Code, National Fire
Protection Association, 470 Atlantic Avenue, Boston, MA 02210
10. OSHA, Safety and Health Standards, 29FR 1910
U.S. Government Printing Office, Washington, D.C. 20402
Prolonged exposure to noise from cutting or
gouging can damage hearing.
• Use approved ear protection when using plasma
system.
• Warn others nearby about the noise hazard.
Frozen pipes may be damaged or can burst if you
attempt to thaw them with a plasma torch.
NOISE CAN DAMAGE HEARING
A PLASMA ARC CAN
DAMAGE FROZEN PIPES
Pacemaker and hearing aid operation can be
affected by magnetic fields from high currents.
Pacemaker and hearing aid wearers should
consult a doctor before going near any plasma arc
cutting and gouging operations.
To reduce magnetic field hazards:
• Keep both the work cable and the torch lead to
one side, away from your body.
• Route the torch leads as close as possible to the
work cable.
• Do not wrap or drape the torch lead or work
cable around your body.
• Keep as far away from the power supply as
possible.
PACEMAKER AND HEARING
AID OPERATION
SAFETY
8-01
1-6 Hypertherm Plasma Systems
WARNING LABEL
This warning label is affixed to some power supplies. It is important that the operator and maintenance
technician understand the intent of these warning symbols as described. The numbered text corresponds to
the numbered boxes on the label.
1. Cutting sparks can cause explosion or fire.
1.1 Keep flammables away from cutting.
1.2 Keep a fire extinguisher nearby, and have a
watchperson ready to use it.
1.3 Do not cut on any closed containers.
2. The plasma arc can cause injury and burns.
2.1 Turn off power before disassembling torch.
2.2 Do not hold the material near cutting path.
2.3 Wear complete body protection.
3. Electric shock from torch or wiring can kill.
Protect yourself from electric shock.
3.1 Wear insulating gloves. Do not wear wet or
damaged gloves.
3.2 Insulate yourself from work and ground.
3.3 Disconnect input plug or power before working
on machine.
4. Breathing cutting fumes can be hazardous to
your health.
4.1 Keep your head out of the fumes.
4.2 Use forced ventilation or local exhaust to remove
the fumes.
4.3 Use ventilating fan to remove the fumes.
5. Arc rays can burn eyes and injure skin.
5.1 Wear hat and safety glasses. Use ear protection
and button shirt collar. Use welding helmet with
correct shade of filter. Wear complete body
protection.
6. Become trained and read the instructions before
working on the machine or cutting.
7. Do not remove or paint over (cover) warning
labels.
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