Xnexus NXP35 Operating Manual
nexus
Plasma Cutting System
Model NXP35
November 21, 2005 Manual 0-4809
Number the art as Art # A-044??
Operating Manual
TABLE OF CONTENTS
SECTION 1:
GENERAL INFORMATION ................................................................................................ 1-1
1.01 Notes, Cautions and Warnings ...................................................................... 1-1
1.02 Important Safety Precautions ....................................................................... 1-1
1.03 Publications .................................................................................................. 1-3
1.04 STATEMENT OF WARRANTY FOR NEXUS MACHINES ............................. 1-4
SECTION 2:
INTRODUCTION ............................................................................................................... 2-1
2.01 Overview ...................................................................................................... 2-1
2.02 General Specifications .................................................................................. 2-1
2.03 Features ....................................................................................................... 2-1
2.04 Torch Specifications ..................................................................................... 2-2
2.05 System Contents .......................................................................................... 2-2
2.06 Transporting Methods ................................................................................... 2-2
SECTION 3:
INSTALLATION .................................................................................................................. 3-1
3.01 Site Selection ............................................................................................... 3-1
3.02 Electrical Input Connections ......................................................................... 3-1
3.03 Compressed Air Connection ......................................................................... 3-1
SECTION 4:
OPERATION ...................................................................................................................... 4-1
4.01 Front Control Panel ....................................................................................... 4-1
4.02 Preparations For Operating ........................................................................... 4-2
SECTION 5:
SERVICE .......................................................................................................................... 5-1
5.01 General Maintenance .................................................................................... 5-1
5.02 Basic Troubleshooting Guide ......................................................................... 5-1
5.03 Contact information ...................................................................................... 5-3
Appendix 1: Operating Sequence, Block Diagram ..................................................................... A-1
Appendix 2: Torch Connection ................................................................................................... A-2
Appendix 3: System Schematic ................................................................................................ A-3
SECTION 1:
GENERAL INFORMATION
1.01 Notes, Cautions and Warnings
To prevent possible injury, read, understand
and follow all warnings, safety precautions
and instructions before using the equipment.
Contact your local Nexus distributor if you
have any questions.
Throughout this manual, notes, cautions, and warnings are used to highlight important information. These
highlights are categorized as follows:
NOTE
An operation, procedure, or background information which requires additional emphasis or is helpful in efficient operation of the
system.
CAUTION
A procedure which, if not properly followed,
may cause damage to the equipment.
WARNING
A procedure which, if not properly followed,
may cause injury to the operator or others
in the operating area.
GASES AND FUMES
Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your
health.
• Keep all fumes and gases from the breathing area.
Keep your head out of the welding fume plume.
• Use an air-supplied respirator if ventilation is not
adequate to remove all fumes and gases.
• The kinds of fumes and gases from the plasma
arc depend on the kind of metal being used, coatings on the metal, and the different processes.
You must be very careful when cutting or welding any metals which may contain one or more
of the following:
Antimony Chromium Mercury
Arsenic Cobalt Nickel
Barium Copper Selenium
Beryllium Lead Silver
Cadmium Manganese Vanadium
1.02 Important Safety Precautions
WARNINGS
OPERATION AND MAINTENANCE OF PLASMA
ARC EQUIPMENT CAN BE DANGEROUS AND
HAZARDOUS TO YOUR HEALTH.
Plasma arc cutting produces intense electric and magnetic emissions that may interfere with the proper function of cardiac
pacemakers, hearing aids, or other electronic health equipment. Persons who work
near plasma arc cutting applications should
consult their medical health professional and
the manufacturer of the health equipment
to determine whether a hazard exists.
• Always read the Material Safety Data Sheets
(MSDS) that should be supplied with the material you are using. These MSDSs will give you
the information regarding the kind and amount
of fumes and gases that may be dangerous to
your health.
• The risks from fumes should be assessed in accordance with the HSE Guidance notes EH54 assessments of exposure to fumes from welding
and allied processes. (ISBN 0717 605701)
• Use special equipment, such as water or down
draft cutting tables, to capture fumes and gases.
• Do not use the plasma torch in an area where
combustible or explosive gases or materials are
located.
• Phosgene, a toxic gas, is generated from the vapors of chlorinated solvents and cleansers. Remove all sources of these vapors.
November 21, 2005 1-1 GENERAL INFORMATION
ELECTRIC SHOCK
NOISE
Electric Shock can injure or kill. The plasma arc process uses and produces high voltage electrical energy. This electric energy can cause severe or fatal
shock to the operator or others in the workplace.
• Never touch any parts that are electrically “live”
or “hot.”
• Wear dry gloves and clothing. Insulate yourself
from the work piece or other parts of the welding circuit.
• Repair or replace all worn or damaged parts.
• Extra care must be taken when the workplace is
moist or damp.
• Install and maintain equipment according
toH&SE Guidance HSG 118 : Electrical safety in
Arc Welding
• Disconnect power source before performing any
service or repairs.
• Read and follow all the instructions in the Operating Manual.
FIRE AND EXPLOSION
Fire and explosion can be caused by hot slag, sparks,
or the plasma arc.
• Be sure there is no combustible or flammable
material in the workplace. Any material that cannot be removed must be protected.
• Ventilate all flammable or explosive vapors from
the workplace.
• Do not cut or weld on containers that may have
held combustibles.
• Provide a fire watch when working in an area
where fire hazards may exist.
• Hydrogen gas may be formed and trapped under aluminum workpieces when they are cut underwater or while using a water table. DO NOT
cut aluminum alloys underwater or on a water
table unless the hydrogen gas can be eliminated
or dissipated. Trapped hydrogen gas that is ignited will cause an explosion.
Noise can cause permanent hearing loss. Plasma arc
processes can cause noise levels to exceed safe limits. You must protect your ears from loud noise to
prevent permanent loss of hearing.
• To protect your hearing from loud noise, wear
protective ear plugs and/or ear muffs. Protect
others in the workplace.
• Noise levels should be measured to be sure the
decibels (sound) do not exceed safe levels.
• For information on how to test for noise, see item
1 in Subsection 1.03, Publications, in this manual.
PLASMA ARC RAYS
Plasma Arc Rays can injure your eyes and burn your
skin. The plasma arc process produces very bright
ultra violet and infra red light. These arc rays will damage your eyes and burn your skin if you are not properly protected.
• To protect your eyes, always wear a welding helmet or shield. Also always wear safety glasses
with side shields, goggles or other protective eye
wear.
• Wear welding gloves and suitable clothing to protect your skin from the arc rays and sparks.
• Keep helmet and safety glasses in good condition. Replace lenses when cracked, chipped or
dirty.
• Protect others in the work area from the arc rays.
Use protective booths, screens or shields.
• Use the shade of lens as suggested in the following per BS EN 169 Personal Eye protection:
Minimum Protective Suggested
Arc Current Shade No. Shade No.
Less Than 300* 8 9
300 - 400* 9 12
400 - 800* 10 14
* These values apply where the actual arc
is clearly seen. Experience has shown that
lighter filters may be used when the arc is
hidden by the workpiece.
GENERAL INFORMATION 1-2 November 21, 2005
1.03 Publications
Refer to the following standards or their latest revisions for more information:
1. Reducing noise at work guidance on The Noise At Work
Regulations 1989 (ISBN: 0 7176 1511 1)
2. COSHH - Control Of Substances Hazardous To Health Regu-
lations 2002 (as amended) (ISBN: 0 7176 24813)
3. The Health and Safety at Work etc. Act 1974. http://
www.opsi.gov.uk/. The Office of Public Sector Information
4. Management of Health and Safety at Work. Management of Health and Safety at Work Regulations 1999.
Approved Code of Practice and guidance L21. http://
www.hsebooks.com/Books/. HSE Books, ISBNo 0 7176
2488 9
5. Control of substances hazardous to health. The Control of Substances Hazardous to Health Regulations
2002. ApprovedCode of Practice and guidance L5
(Fourth edition) http://www.hsebooks.com/Books/.
HSE Books, ISBN 0 7176 2534 6.
15. Job Knowledge for Welders 28 Health, Safety and Accident Prevention Electrical Hazards - power source and
installation. http://www.twi.co.uk/j32k/protected/
band_3/jk28.html. TWI.
16. Job Knowledge for Welders 29 Health, Safety and Accident Prevention - arc welding. http://www.twi.co.uk/
j32k/protected/band_3/jk29.html. TWI
Job Knowledge for Welders 30 Health, Safety and
17.
Accident Prevention - health risks of welding fumegases.
jk30.html. TWI.
18. Job Knowledge for Welders 31 Health, Safety and Accident Prevention - health risks from fume and gases during
welding. http://www.twi.co.uk/j32k/protected/band_3/
jk31.html. TWI
Job Knowledge for Welders 32 Health, Safety and
19.
http://www.twi.co.uk/j32k/protected/band_3/
Accident Prevention - control of welding fume.
http://www.twi.co.uk/j32k/protected/band_3/
jk32.html. TWI
6. Personal Protective Equipment at Work Regulations
1992. Guidance on Regulations L25 http://
hsebooks.com/Books/ HSE Books, ISBN 0 7176 6139
3.
7. Reducting Noise at Work. Guidance on Noise at Work
REgulations 1989. http://www.hsebooks.com/Books/
. HSE Books, ISBN 0 7176 1511 1.
8. BS EN 169 Personal Eye-Protection - Filters For Welding And Related Techniques - Transmittance Requirements And Recommended Use.
9. BS EN 169 Personal Protective Equipment - Safety Footwear.
10. EH54 Assessment of Exposure to Fumes from Welding
and Allied Processes. http://hsebooks.com/Books/.
HSE Books, ISBN 0 7176 0570 1.
11. EH55 The Control of Exposure to Fume s from Welding,
Brazing and Allied Processes. http://hsebooks.com/
Books/. HSE Books, ISBN 0 1188 5439 9.
12.HSG 118: Electrical Safety in Arc Welding. http://
hsebooks.com/Books/. HSE Books, ISBN 0 7176 0704
6.
13. HSG 139: Safe use of Compressed Gases in Welding,
Flame Cutting and Allied Processes. http://
hsebooks.com/Books/. HSE Books, ISBN 0 7176 0680
5.
14. Job Knowledge for Welders 26 Health, Safety and Accident Prevention - General Information. http://
www.twi.co.uk/j32k/protected/band_3/jk26.html. TWI.
November 21, 2005 1-3 GENERAL INFORMATION
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