pmx30 sm 805170r2.pdf

Plasma arc cutting system

Service Manual 805170Revision 2

Service Manual

(P/N 805170)

Revision 2 January, 2006

Hypertherm, Inc.Hanover, NH USA

www.hypertherm.com

Copyright 2007 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.

11/21/06

Hypertherm, Inc.Etna Road, P.O. Box 5010Hanover, NH 03755 USA603-643-3441 Tel (Main Office)603-643-5352 Fax (All Departments)[email protected] (Main Office Email)800-643-9878 Tel (Technical Service)[email protected] (Technical Service Email)800-737-2978 Tel (Customer Service)[email protected] (Customer Service Email)

Hypertherm Automation5 Technology Drive, Suite 300West Lebanon, NH 03784 USA603-298-7970 Tel 603-298-7977 Fax

Hypertherm Plasmatechnik, GmbHTechnologiepark HanauRodenbacher Chaussee 6 D-63457 Hanau-Wolfgang, Deutschland49 6181 58 2100 Tel49 6181 58 2134 Fax49 6181 58 2123 (Technical Service)

Hypertherm (S) Pte Ltd.No. 19 Kaki Bukit Road 2 K.B. Warehouse Complex Singapore 417847, Republic of Singapore65 6 841 2489 Tel65 6 841 2490 Fax 65 6 841 2489 (Technical Service)

Hypertherm (Shanghai) Trading Co., Ltd.Unit 1308-09, Careri Building432 West Huai Hai RoadShanghai, 200052PR China86-21 5258 3330/1 Tel86-21 5258 3332 Fax

HyperthermBranch of Hypertherm, UK, UCPO Box 244Wigan, Lancashire, England WN8 7WU00 800 3324 9737 Tel00 800 4973 7329 Fax00 800 4973 7843 (Technical Service)

France (Representative office)15 Impasse des Rosiers95610 Eragny, France00 800 3324 9737 Tel00 800 4973 7329 Fax

Hypertherm S.r.l.Via Torino 220123 Milano, Italia39 02 725 46 312 Tel 39 02 725 46 400 Fax39 02 725 46 314 (Technical Service)

Hypertherm Europe B.V.Vaartveld 94704 SE Roosendaal, Nederland31 165 596907 Tel 31 165 596901 Fax31 165 596908 Tel (Marketing)31 165 596900 Tel (Technical Service)00 800 49 73 7843 Tel (Technical Service)

Hypertherm Japan Ltd.801 Samty Will Building2-40 Miyahara 1-Chome,Yodogawa-ku, Osaka532-0003, Japan81 6 6170 2020 Tel81 6 6170 2015 Fax

HYPERTHERM BRASIL LTDA.Avenida Doutor Renato de

Andrade Maia 350Parque Renato MaiaCEP 07114-000Guarulhos, SP Brasil55 11 6409 2636 Tel55 11 6408 0462 Fax

ELECTROMAGNETIC COMPATIBILITY (EMC)

Hypertherm Plasma Systems i8-06

EMC IntroductionHypertherms CE-marked equipment is built incompliance with standard EN60974-10. The equipmentshould be installed and used in accordance with theinformation below to achieve electromagneticcompatibility.

The limits required by EN60974-10 may not beadequate to completely eliminate interference when theaffected equipment is in close proximity or has a highdegree of sensitivity. In such cases it may be necessaryto use other measures to further reduce interference.

This plasma equipment is designed for use only in anindustrial environment.

Installation and useThe user is responsible for installing and using theplasma equipment according to the manufacturersinstructions. If electromagnetic disturbances aredetected then it shall be the responsibility of the userto resolve the situation with the technical assistance ofthe manufacturer. In some cases this remedial actionmay be as simple as earthing the cutting circuit, seeEarthing of Workpiece. In other cases it could involveconstructing an electromagnetic screen enclosing thepower source and the work complete with associatedinput filters. In all cases electromagnetic disturbancesmust be reduced to the point where they are no longertroublesome.

Assessment of areaBefore installing the equipment the user shall make anassessment of potential electromagnetic problems inthe surrounding area. The following shall be taken intoaccount:

a. Other supply cables, control cables, signalling andtelephone cables; above, below and adjacent to thecutting 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 becarried out.

The size of the surrounding area to be considered willdepend on the structure of the building and otheractivities that are taking place. The surrounding areamay extend beyond the boundaries of the premises.

Methods of reducing emissionsMains supplyCutting equipment must be connected to themains supply according to the manufacturersrecommendations. If interference occurs, it may benecessary to take additional precautions such asfiltering of the mains supply. Consideration should begiven to shielding the supply cable of permanentlyinstalled cutting equipment, in metallic conduit orequivalent. Shielding should be electrically continuousthroughout its length. The shielding should beconnected to the cutting mains supply so that goodelectrical contact is maintained between the conduitand the cutting power source enclosure.

Maintenance of cutting equipmentThe cutting equipment must be routinely maintainedaccording to the manufacturers recommendations.All access and service doors and covers should beclosed and properly fastened when the cuttingequipment is in operation. The cutting equipmentshould not be modified in any way except forthose changes and adjustments covered in themanufacturers instructions. In particular, the sparkgaps of arc striking and stabilizing devices shouldbe adjusted and maintained according to themanufacturers recommendations.

Cutting cablesThe cutting cables should be kept as short as possibleand should be positioned close together, running at orclose to the floor level.

Equipotential bondingBonding of all metallic components in the cuttinginstallation and adjacent to it should be considered.However, metallic components bonded to theworkpiece will increase the risk that the operator could

ELECTROMAGNETIC COMPATIBILITY (EMC)

ii Hypertherm Plasma Systems8-06

receive a shock by touching these metallic componentsand the electrode at the same time. The operatorshould be insulated from all such bonded metalliccomponents.

Earthing of workpieceWhere the workpiece is not bonded to earth forelectrical safety, nor connected to earth because of itssize and position, for example, ships hull or buildingsteelwork, a connection bonding the workpiece to earthmay reduce emissions in some, but not all instances.Care should be taken to prevent the earthing of theworkpiece increasing the risk of injury to users, ordamage to other electrical equipment. Wherenecessary, the connection of the workpiece to earthshould be made by a direct connection to theworkpiece, but in some countries where directconnection is not permitted, the bonding should beachieved by suitable capacitances selected accordingto national regulations.

Note: the cutting circuit may or may not be earthed forsafety reasons. Changing the earthing arrangementsshould only be authorized by a person who iscompetent to assess whether the changes will increasethe risk of injury, for example, by allowing parallelcutting current return paths which may damage theearth circuits of other equipment. Further guidance isgiven in IEC/TS 62081 Arc Welding EquipmentInstallation and Use.

Screening and shieldingSelective screening and shielding of other cablesand equipment in the surrounding area may alleviateproblems of interference. Screening of the entireplasma cutting installation may be considered forspecial applications.

WARRANTY

Hypertherm Plasma Systems iii8-06

WarningGenuine Hypertherm parts are the factory-recommended replacement parts for your Hyperthermsystem. Any damage caused by the use of other thangenuine Hypertherm parts may not be covered by theHypertherm warranty.

WarningYou are responsible for the safe use of the Product.Hypertherm does not and cannot make any guaranteeor warranty regarding the safe use of the Product inyour environment.

GeneralHypertherm, Inc. warrants that its Products shall be freefrom defects in materials and workmanship, ifHypertherm is notified of a defect (i) with respect to thepower supply within a period of two (2) years from thedate of its delivery to you, with the exception ofPowermax Series power supplies, which shall be withina period of three (3) years from the date of delivery toyou, and (ii) with respect to the torch and leads within aperiod of one (1) year from its date of delivery to you.This warranty shall not apply to any Product which hasbeen incorrectly installed, modified, or otherwisedamaged. Hypertherm, at its sole option, shall repair,replace, or adjust, free of charge, any defective Productscovered by this warranty which shall be returned withHypertherms prior authorization (which shall not beunreasonably withheld), properly packed, toHypertherms place of business in Hanover, NewHampshire, or to an authorized Hypertherm repairfacility, all costs, insurance and freight prepaid.Hypertherm shall not be liable for any repairs,replacement, or adjustments of Products covered by thiswarranty, except those made pursuant to this paragraphor with Hypertherms prior written consent. The warrantyabove is exclusive and is in lieu of all otherwarranties, express, implied, statutory, or otherwisewith respect to the Products or as to the resultswhich may be obtained therefrom, and all impliedwarranties or conditions of quality or ofmerchantability or fitness for a particular purpose oragainst infringement. The foregoing shall constitutethe sole and exclusive remedy for any breach byHypertherm of its warranty. Distributors/OEMs mayoffer different or additional warranties, but Distributors/OEMs are not authorized to give any additional warrantyprotection to you or make any representation to youpurporting to be binding upon Hypertherm.

Certification test marksCertified products are identified by one or morecertification test marks from accredited testinglaboratories. The certification test marks are locatedon or near the data plate. Each certification test markmeans that the product and its safety-criticalcomponents conform to the relevant national safetystandards as reviewed by that testing laboratory.Hypertherm places a certification test mark on itsproducts only after that product is manufactured withsafety-critical components that have been authorizedby the accredited testing laboratory.

Once the product has left the Hypertherm factory, thecertification test marks are invalidated if any of thefollowing occurs: The product is significantly modified in a manner that

creates a hazard or non-conformance. 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 thecertification.

CE marking constitutes a manufacturers declaration ofconformity to applicable European directives andstandards. Only those versions of Hypertherm productswith a CE Marking located on or near the data platehave been tested for compliance with the European LowVoltage Directive and the European EMC Directive.EMC filters needed to comply with the European EMCDirective are incorporated within versions of the powersupply with a CE Marking.

Patent indemnityExcept only in cases of products not manufactured byHypertherm or manufactured by a person other thanHypertherm not in strict conformity with Hyperthermsspecifications and in cases of designs, processes,formulae, or combinations not developed or purported tobe developed by Hypertherm, Hypertherm will defend orsettle, at its own expense, any suit or proceedingbrought against you alleging that the use of theHypertherm product, alone and not in combination withany other product not supplied by Hypertherm, infringesany patent of any third party. You shall notify Hyperthermpromptly upon learning of any action or threatened

WARRANTY

iv Hypertherm Plasma Systems8-06

action in connection with any such alleged infringement,and Hypertherms obligation to indemnify shall beconditioned upon Hypertherms sole control of, and theindemnified partys cooperation and assistance in, thedefense of the claim.

Limitation of liabilityIn no event shall Hypertherm be liable to any personor entity for any incidental, consequential, indirect,or punitive damages (including but not limited tolost profits) regardless of whether such liability isbased on breach of contract, tort, strict liability,breach of warranties, failure of essential purpose orotherwise and even if advised of the possibility ofsuch damages.

Liability capIn no event shall Hypertherms liability, whether suchliability is based on breach of contract, tort, strictliability, breach of warranties, failure of essentialpurpose or otherwise, for any claim action suit orproceeding arising out of or relating to the use of theProducts exceed in the aggregate the amount paidfor the Products that gave rise to such claim.

InsuranceAt all times you will have and maintain insurance in suchquantities and types, and with coverage sufficient andappropriate to defend and to hold Hypertherm harmlessin the event of any cause of action arising from the useof the Products.

National and Local codesNational and Local codes governing plumbing andelectrical installation shall take precedent over anyinstructions contained in this manual. In no event shallHypertherm be liable for injury to persons or propertydamage by reason of any code violation or poor workpractices.

Transfer of rightsYou may transfer any remaining rights you may havehereunder only in connection with the sale of all orsubstantially all of your assets or capital stock to asuccessor in interest who agrees to be bound by all ofthe terms and conditions of this Warranty.

Proper disposal of HyperthermproductsHypertherm plasma cutting systems, like all electronicproducts, may contain materials or components, such asprinted circuit boards, that cannot be discarded withordinary waste. It is your responsibility to dispose of anyHypertherm product or component part in anenvironmentally acceptable manner according tonational 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.

In other countries, check national and local laws.

Register your product on-line at:www.hypertherm.com/warranty.htm

TABLE OF CONTENTS

powermax30 Service Manual v

Electromagnetic compatibility ...................................................................................................................................iWarranty ......................................................................................................................................................................ii

Section 1 SAFETYRecognize safety information ...................................................................................................................................1-2Follow safety instructions..........................................................................................................................................1-2Cutting can cause fire or explosion...........................................................................................................................1-2Electric shock can kill................................................................................................................................................1-3Static electricity can damage circuit boards..............................................................................................................1-3Toxic fumes can cause injury or death......................................................................................................................1-4A plasma arc can cause injury and burns .................................................................................................................1-5Arc rays can burn eyes and skin...............................................................................................................................1-5Grounding safety ......................................................................................................................................................1-5Compressed gas equipment safety ..........................................................................................................................1-6Gas cylinders can explode if damaged.....................................................................................................................1-6Noise can damage hearing.......................................................................................................................................1-6Pacemaker and hearing aid operation......................................................................................................................1-6A plasma arc can damage frozen pipes....................................................................................................................1-6Additional safety information.....................................................................................................................................1-6Warning labels ..........................................................................................................................................................1-7

Section 1a SCURITIdentifier les consignes de scurit.........................................................................................................................1a-2Suivre les instructions de scurit ..........................................................................................................................1a-2Le coupage peut provoquer un incendie ou une explosion ....................................................................................1a-2Les chocs lectriques peuvent tre fatals...............................................................................................................1a-3Llectricit statique peut endommager les cartes de circuits imprims .................................................................1a-3Les vapeurs toxiques peuvent provoquer des blessures ou la mort.......................................................................1a-4Larc plasma peut provoquer des blessures ou des brlures .................................................................................1a-5Les rayons de larc peuvent brler les yeux et la peau...........................................................................................1a-5Mise la masse et la terre...................................................................................................................................1a-5Scurit des bouteilles de gaz comprim ...............................................................................................................1a-6Les bouteilles de gaz comprim peuvent exploser en cas de dommages .............................................................1a-6Le bruit peut provoquer des problmes auditifs......................................................................................................1a-6Pacemakers et prothses auditives........................................................................................................................1a-6Un arc plasma peut endommager les tuyaux gels................................................................................................1a-6tiquettes de scurit .............................................................................................................................................1a-7

Section 1b SEGURIDADReconocimiento de informacin de seguridad........................................................................................................1b-2Siga las instrucciones de seguridad .......................................................................................................................1b-2Los cortes pueden provocar incendios o explosiones ............................................................................................1b-2El choque elctrico puede provocar la muerte .......................................................................................................1b-3Electricidad esttica puede daar tablillas de circuito ............................................................................................1b-3Humos txicos pueden causar lesiones o muerte ..................................................................................................1b-4El arco de plasma puede causar lesiones y quemaduras ......................................................................................1b-5Los rayos del arco pueden producir quemaduras en los ojos y en la piel ..............................................................1b-5

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vi powermax30 Service Manual

Seguridad de toma a tierra .....................................................................................................................................1b-5Seguridad de los equipos de gas comprimido........................................................................................................1b-6Los cilindros de gas pueden explotar si estn daados .........................................................................................1b-6El ruido puede deteriorar la audicin ......................................................................................................................1b-6Operacin de marcapasos y de audfonos .............................................................................................................1b-6Un arco plasma puede daar tubos congelados ....................................................................................................1b-6Etiquetas de advertencia ........................................................................................................................................1b-7

Section 2 SPECIFICATIONSPower supply ............................................................................................................................................................2-2

Dimensions and weight ....................................................................................................................................2-2T30v torch ratings .....................................................................................................................................................2-3

Dimensions ......................................................................................................................................................2-3Symbols and markings .............................................................................................................................................2-4

mark ...........................................................................................................................................................2-4CE mark ...........................................................................................................................................................2-4IEC symbols .....................................................................................................................................................2-4

Section 3 MAINTENANCEControls and indicators .............................................................................................................................................3-2

Front controls and LEDs ..................................................................................................................................3-2Rear controls....................................................................................................................................................3-2

Theory of operation...................................................................................................................................................3-3General ............................................................................................................................................................3-3Functional description ......................................................................................................................................3-3Sequence of operation .....................................................................................................................................3-4

Troubleshooting preparation .....................................................................................................................................3-5Test equipment.................................................................................................................................................3-5Troubleshooting procedures and sequence .....................................................................................................3-5External inspection...........................................................................................................................................3-5Internal inspection ............................................................................................................................................3-6

Initial resistance check..............................................................................................................................................3-7Power supply overview .............................................................................................................................................3-8Troubleshooting guide ..............................................................................................................................................3-9Control board LEDs ................................................................................................................................................3-12

Use the Error and Reset LEDs to troubleshoot..............................................................................................3-13System tests ...........................................................................................................................................................3-14

Test 1 voltage input .....................................................................................................................................3-15Test 2 power board voltage checks.............................................................................................................3-16Test 3 VBUS and voltage balance...............................................................................................................3-17Test 4 solenoid valve...................................................................................................................................3-18Test 5 torch stuck open (TSO) ....................................................................................................................3-19Test 6 plasma start ......................................................................................................................................3-20Test 7 torch cap sensor ...............................................................................................................................3-20Test 8 fan.....................................................................................................................................................3-21Test 9 pressure switch.................................................................................................................................3-21

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powermax30 Service Manual vii

Component replacement ........................................................................................................................................3-22Remove an endcap ........................................................................................................................................3-22Replace the torch lead ...................................................................................................................................3-24Replace the work lead....................................................................................................................................3-26Replace the power cord (CSA) ......................................................................................................................3-27Replace the power cord (CE).........................................................................................................................3-28Replace the fan ..............................................................................................................................................3-30Replace the air filter element .........................................................................................................................3-31Replace the air filter/regulator ........................................................................................................................3-32Replace the control board ..............................................................................................................................3-33Replace the power board ...............................................................................................................................3-34Replace the base ...........................................................................................................................................3-37

Section 4 PARTS Power supply parts ...................................................................................................................................................4-2

Exterior.............................................................................................................................................................4-2Interior, power board side.................................................................................................................................4-3Interior, fan side................................................................................................................................................4-4

T30v hand torch parts...............................................................................................................................................4-5Safety-critical parts ...................................................................................................................................................4-6Recommended spare parts ......................................................................................................................................4-7

Section 5 WIRING DIAGRAMSElectrical schematic ..................................................................................................................................................5-3

TABLE OF CONTENTS

viii powermax30 Service Manual

Hypertherm Plasma Systems 1-18-06

Section 1

SAFETY

In this section:

Recognize safety information ...................................................................................................................................1-2Follow safety instructions..........................................................................................................................................1-2Cutting can cause fire or explosion...........................................................................................................................1-2Electric shock can kill................................................................................................................................................1-3Static electricity can damage circuit boards..............................................................................................................1-3Toxic fumes can cause injury or death......................................................................................................................1-4A plasma arc can cause injury and burns .................................................................................................................1-5Arc rays can burn eyes and skin...............................................................................................................................1-5Grounding safety ......................................................................................................................................................1-5Compressed gas equipment safety ..........................................................................................................................1-6Gas cylinders can explode if damaged.....................................................................................................................1-6Noise can damage hearing.......................................................................................................................................1-6Pacemaker and hearing aid operation......................................................................................................................1-6A plasma arc can damage frozen pipes....................................................................................................................1-6Additional safety information.....................................................................................................................................1-6Warning labels ..........................................................................................................................................................1-7

1-2 Hypertherm Plasma Systems11-98

SAFETY

RECOGNIZE SAFETY INFORMATION

The symbols shown in this section are used to identifypotential hazards. When you see a safety symbol in thismanual or on your machine, understand the potentialfor personal injury, and follow the related instructions toavoid the hazard.

FOLLOW SAFETY INSTRUCTIONS

Read carefully all safety messages in this manual andsafety labels on your machine. Keep the safety labels on your machine in good

condition. Replace missing or damaged labelsimmediately.

Learn how to operate the machine and how to use the controls properly. Do not let anyone operate itwithout instruction.

Keep your machine in proper working condition.Unauthorized modifications to the machine mayaffect safety and machine service life.

DANGER WARNING CAUTION

A signal word DANGER or WARNING is used with asafety symbol. DANGER identifies the most serioushazards. 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 injuryor death if not followed correctly.

CAUTION safety messages precede relatedinstructions in this manual that may result indamage 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 andproperly cleaned first.

Ventilate potentially flammable atmospheresbefore cutting.

When cutting with oxygen as the plasma gas, anexhaust 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

WARNINGExplosion Hazard

Argon-Hydrogen and MethaneHydrogen and methane are flammable gases thatpresent an explosion hazard. Keep flames away fromcylinders and hoses that contain methane or hydrogenmixtures. Keep flames and sparks away from the torchwhen using methane or argon-hydrogen plasma.

WARNINGHydrogen Detonation with Aluminum Cutting

When cutting aluminum underwater, or with thewater touching the underside of the aluminum, freehydrogen gas may collect under the workpiece anddetonate during plasma cutting operations.

Install an aeration manifold on the floor of the watertable to eliminate the possibility of hydrogendetonation. Refer to the Appendix section of thismanual for aeration manifold details.


SAFETY

Touching live electrical parts can cause a fatal shockor severe burn. Operating the plasma system completes an

electrical circuit between the torch and theworkpiece. The workpiece and anything touchingthe workpiece are part of the electrical circuit.

Never touch the torch body, workpiece or thewater in a water table when the plasma systemis operating.

Electric shock preventionAll Hypertherm plasma systems use high voltagein the cutting process (200 to 400 VDC arecommon). Take the following precautions whenoperating 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 anyphysical contact with the work or ground. If you mustwork in or near a damp area, use extreme caution.

Provide a disconnect switch close to the powersupply with properly sized fuses. This switch allowsthe operator to turn off the power supply quickly inan emergency situation.

When using a water table, be sure that it is correctlyconnected to earth ground.

ELECTRIC SHOCK CAN KILL

Install and ground this equipment according to theinstruction manual and in accordance with nationaland local codes.

Inspect the input power cord frequently for damageor cracking of the cover. Replace a damaged powercord immediately. Bare wiring can kill.

Inspect and replace any worn or damaged torchleads.

Do not pick up the workpiece, including the wastecutoff, while you cut. Leave the workpiece in placeor on the workbench with the work cable attachedduring the cutting process.

Before checking, cleaning or changing torch parts,disconnect the main power or unplug the powersupply.

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 powerto allow capacitors to discharge.

Never operate the plasma system unless the powersupply covers are in place. Exposed power supplyconnections present a severe electrical hazard.

When making input connections, attach propergrounding conductor first.

Each Hypertherm plasma system is designed to beused only with specific Hypertherm torches. Do notsubstitute other torches which could overheat andpresent a safety hazard.

Use proper precautions when handling printedcircuit boards.

STATIC ELECTRICITY CAN DAMAGE CIRCUIT BOARDS

Store PC boards in anti-static containers. Wear a grounded wrist strap when handling

PC boards.


SAFETY

The plasma arc by itself is the heat source used forcutting. Accordingly, although the plasma arc has notbeen identified as a source of toxic fumes, thematerial being cut can be a source of toxic fumes orgases that deplete oxygen.

Fumes produced vary depending on the metal that iscut. Metals that may release toxic fumes include, butare not limited to, stainless steel, carbon steel, zinc(galvanized), and copper.

In some cases, the metal may be coated with asubstance that could release toxic fumes. Toxiccoatings include, but are not limited to, lead (in somepaints), cadmium (in some paints and fillers), andberyllium.

Gases produced by plasma cutting vary based on thematerial to be cut and the method of cutting, but mayinclude ozone, oxides of nitrogen, hexavalentchromium, hydrogen, and other substances if suchare contained in or released by the material being cut.

Caution should be taken to minimize exposure tofumes produced by any industrial process. Dependingupon the chemical composition and concentration ofthe fumes (as well as other factors, such asventilation), there may be a risk of physical illness,such as birth defects or cancer.

It is the responsibility of the equipment and site ownerto test the air quality in the area where the equipmentis used and to ensure that the air quality in theworkplace meets all local and national standardsand regulations.

TOXIC FUMES CAN CAUSE INJURY OR DEATH

The air quality level in any relevant workplacedepends on site-specific variables such as: Table design (wet, dry, underwater). Material composition, surface finish, and

composition of coatings. Volume of material removed. Duration of cutting or gouging. Size, air volume, ventilation and filtration of the

work area. Personal protective equipment. Number of welding and cutting systems in

operation. Other site processes that may produce fumes.

If the workplace must conform to national or localregulations, only monitoring or testing done at the sitecan determine whether the site is above or belowallowable levels.

To reduce the risk of exposure to fumes: Remove all coatings and solvents from the metal

before cutting. Use local exhaust ventilation to remove fumes from

the air. Do not inhale fumes. Wear an air-supplied

respirator when cutting any metal coated with,containing, or suspected to contain toxic elements.

Assure that those using welding or cuttingequipment, as well as air-supplied respirationdevices, are qualified and trained in the proper useof such equipment.

Never cut containers with potentially toxic materialsinside. Empty and properly clean the container first.

Monitor or test the air quality at the site as needed. Consult with a local expert to implement a site plan

to ensure safe air quality.


SAFETY

Instant-on torchesPlasma arc comes on immediately when the torchswitch is activated.

A PLASMA ARC CAN CAUSE INJURY AND BURNS

The plasma arc will cut quickly through glovesand skin. Keep away from the torch tip. Do not hold metal near the cutting path. Never point the torch toward yourself or others.

Eye protection Plasma arc rays produce intensevisible and invisible (ultraviolet and infrared) rays thatcan 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 appropriatelens shading to protect your eyes from the arcsultraviolet and infrared rays.

Lens shadeArc current AWS (USA) ISO 4850

Up to 100 A No. 8 No. 11100-200 A No. 10 No. 11-12200-400 A No. 12 No. 13Over 400 A No. 14 No. 14

ARC RAYS CAN BURN EYES AND SKIN

Skin protection Wear protective clothing to protectagainst burns caused by ultraviolet light, sparks andhot 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 reducereflection 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.

Work cable Attach the work cable securely to theworkpiece or the work table with good metal-to-metalcontact. Do not connect it to the piece that will fallaway when the cut is complete.

Work table Connect the work table to an earthground, in accordance with appropriate national orlocal 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, besure to connect the power cord ground wireproperly.

Place the power cord's ground wire on the stud first,then place any other ground wires on top of thepower cord ground. Fasten the retaining nut tightly.

Tighten all electrical connections to avoid excessiveheating.


SAFETY

Never lubricate cylinder valves or regulators with oilor grease.

Use only correct gas cylinders, regulators, hosesand fittings designed for the specific application.

Maintain all compressed gas equipment andassociated parts in good condition.

Label and color-code all gas hoses to identify thetype of gas in each hose. Consult applicablenational or local codes.

GAS CYLINDERS CANEXPLODE IF DAMAGEDCOMPRESSED GAS EQUIPMENT SAFETY

Gas cylinders contain gas under high pressure. Ifdamaged, 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.

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

NOISE CAN DAMAGE HEARING

A PLASMA ARC CANDAMAGE FROZEN PIPES

Pacemaker and hearing aid operation can be affectedby magnetic fields from high currents.Pacemaker and hearing aid wearers should consult adoctor before going near any plasma arc cutting andgouging 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 ANDHEARING AID OPERATION

ADDITIONAL SAFETY INFORMATION1. ANSI Standard Z49.1, Safety in Welding and Cutting, American

Welding Society, 550 LeJeune RoadP.O. Box 351020, Miami, FL 33135

2. ANSI Standard Z49.2, Fire Prevention in the Use of Cutting andWelding Processes, American National Standards Institute1430 Broadway, New York, NY 10018

3. ANSI Standard Z87.1, Safe Practices for Occupation andEducational Eye and Face Protection, American NationalStandards Institute, 1430 Broadway, New York, NY 10018

4. AWS F4.1, Recommended Safe Practices for the Preparation forWelding and Cutting of Containers and Piping That Have HeldHazardous Substances, American Welding Society550 LeJeune Road, P.O. Box 351040, Miami, FL 33135

5. AWS F5.2, Recommended Safe Practices for Plasma Arc Cutting, American Welding Society550 LeJeune Road, P.O. Box 351040, Miami, FL 33135

6. CGA Pamphlet P-1, Safe Handling of Compressed Gases inCylinders, Compressed Gas Association1235 Jefferson Davis Highway, Arlington, VA 22202

7. CSA Standard W117.2, Code for Safety in Welding and Cutting,Canadian Standards Association Standard Sales178 Rexdale Boulevard, Rexdale, Ontario M9W 1R3, Canada

8. NFPA Standard 51B, Cutting and Welding Processes, NationalFire Protection Association470 Atlantic Avenue, Boston, MA 02210

9. NFPA Standard 701978, National Electrical Code, National FireProtection Association, 470 Atlantic Avenue, Boston, MA 02210

10. OSHA, Safety and Health Standards, 29FR 1910U.S. Government Printing Office, Washington, D.C. 20402

Prolonged exposure to noise from cutting or gougingcan damage hearing. Use approved ear protection when using plasma

system. Warn others nearby about the noise hazard.


SAFETY

WARNING LABELThis warning label is affixed to some power supplies. It is important that the operator andmaintenance technician understand the intent of these warning symbols as described. Thenumbered 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 awatchperson 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. Protectyourself from electric shock.

3.1 Wear insulating gloves. Do not wear wet ordamaged gloves.

3.2 Insulate yourself from work and ground.

3.3 Disconnect input plug or power before working onmachine.

4. Breathing cutting fumes can be hazardous to yourhealth.

4.1 Keep your head out of the fumes.

4.2 Use forced ventilation or local exhaust to removethe 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 withcorrect shade of filter. Wear complete bodyprotection.

6. Become trained and read the instructions beforeworking on the machine or cutting.

7. Do not remove or paint over (cover) warninglabels.

Read and follow these instructions, employer safetypractices, and material safety data sheets. Refer to ANS Z49.1, Safety in Welding, Cutting and Allied Processes from American Welding Society (http://www.aws.org) and OSHA Safety and Health Standards, 29 CFR 1910 (http://www.osha.gov).

WARNING

1. Cutting sparks can cause explosion or fire.1.1 Do not cut near flammables.1.2 Have a fire extinguisher nearby and ready to use.1.3 Do not use a drum or other closed container as a cutting table.

2. Plasma arc can injure and burn; point the nozzle away from yourself. Arc starts instantly when triggered. 2.1 Turn off power before disassembling torch.2.2 Do not grip the workpiece near the cutting path.2.3 Wear complete body protection.

3. Hazardous voltage. Risk of electric shock or burn.3.1 Wear insulating gloves. Replace gloves when wet or damaged.3.2 Protect from shock by insulating yourself from work and ground.3.3 Disconnect power before servicing. Do not touch live parts.

4. Plasma fumes can be hazardous.4.1 Do not inhale fumes. 4.2 Use forced ventilation or local exhaust to remove the fumes.4.3 Do not operate in closed spaces. Remove fumes with ventilation.

5. Arc rays can burn eyes and injure skin.5.1 Wear correct and appropriate protective equipment to protect head, eyes, ears, hands, and body. Button shirt collar. Protect ears from noise. Use welding helmet with the correct shade of filter.

6. Become trained. Only qualified personnel should operate this equipment. Keep non-qualified personnel and children away.

7. Do not remove, destroy, or cover this label. Replace if it is missing, damaged, or worn (PN 110584 Rev A).

Plasma cutting can be injurious to operator and persons in the work area. Consult manual before operating. Failure to follow all these safety instructions can result in death.

AVERTISSEMENTLe coupage plasma peut tre prjudiciable pour loprateur et les personnes qui se trouvent sur les lieux de travail. Consulter le manuel avant de faire fonctionner. Le non respect des ces instructions de scurit peut entraner la mort.

1. Les tincelles de coupage peuvent provoquer une explosion ou un incendie.1.1 Ne pas couper prs des matires inflammables. 1.2 Un extincteur doit tre proximit et prt tre utilis.1.3 Ne pas utiliser un ft ou un autre contenant ferm comme table de coupage.

2. Larc plasma peut blesser et brler; loigner la buse de soi. Il sallume instantanment quand on lamorce; 2.1 Couper lalimentation avant de dmonter la torche. 2.2 Ne pas saisir la pice couper de la trajectoire de coupage. 2.3 Se protger entirement le corps.

3. Tension dangereuse. Risque de choc lectrique ou de brlure. 3.1 Porter des gants isolants. Remplacer les gants quand ils sont humides ou endommags. 3.2 Se protger contre les chocs en sisolant de la pice et de la terre. 3.3 Couper lalimentation avant lentretien. Ne pas toucher les pices sous tension.

4. Les fumes plasma peuvent tre dangereuses. 4.1 Ne pas inhaler les fumes 4.2 Utiliser une ventilation force ou un extracteur local pour dissiper les fumes. 4.3 Ne pas couper dans des espaces clos. Chasser les fumes par ventilation.

5. Les rayons darc peuvent brler les yeux et blesser la peau. 5.1 Porter un bon quipement de protection pour se protger la tte, les yeux, les oreilles, les mains et le corps. Boutonner le col de la chemise. Protger les oreilles contre le bruit. Utiliser un masque de soudeur avec un filtre de nuance approprie.

6. Suivre une formation. Seul le personnel qualifi a le droit de faire fonctionner cet quipement. Le personnel non qualifi et les enfants doivent se tenir lcart.7. Ne pas enlever, dtruire ni couvrir cette tiquette. La remplacer si elle est absente, endommage ou use (PN 110584 Rev A).


SAFETY

WARNING LABELThis warning label is affixed to some power supplies. It isimportant that the operator and maintenance technicianunderstand the intent of these warning symbols as described.The numbered text corresponds to the numbered boxes onthe label.

1. Cutting sparks can cause explosionor fire.

1.1 Keep flammables away from cutting.

1.2 Keep a fire extinguisher nearby, andhave a watchperson ready to use it.

1.3 Do not cut on any closed containers.

2. The plasma arc can cause injuryand burns.

2.1 Turn off power before disassemblingtorch.

2.2 Do not hold the material near cuttingpath.

2.3 Wear complete body protection.

3. Electric shock from torch or wiringcan kill. Protect yourself from electricshock.

3.1 Wear insulating gloves. Do not wearwet or damaged gloves.

3.2 Insulate yourself from work andground.

3.3 Disconnect input plug or power beforeworking on machine.

4. Breathing cutting fumes can behazardous to your health.

4.1 Keep your head out of the fumes.

4.2 Use forced ventilation or local exhaustto remove the fumes.

4.3 Use ventilating fan to remove thefumes.

5. Arc rays can burn eyes and injure skin.5.1 Wear hat and safety glasses. Use ear

protection and button shirt collar. Usewelding helmet with correct shade offilter. Wear complete body protection.

6. Become trained and read theinstructions before working on themachine or cutting.

7. Do not remove or paint over (cover)warning labels.

Rev. D

8-06Hypertherm Systmes plasma 1a-1

Section 1a

SCURIT

Dans cette section :

Identifier les consignes de scurit.........................................................................................................................1a-2Suivre les instructions de scurit ..........................................................................................................................1a-2Le coupage peut provoquer un incendie ou une explosion ....................................................................................1a-2Les chocs lectriques peuvent tre fatals...............................................................................................................1a-3Llectricit statique peut endommager les cartes de circuits imprims .................................................................1a-3Les vapeurs toxiques peuvent provoquer des blessures ou la mort.......................................................................1a-4Larc plasma peut provoquer des blessures ou des brlures .................................................................................1a-5Les rayons de larc peuvent brler les yeux et la peau...........................................................................................1a-5Mise la masse et la terre...................................................................................................................................1a-5Scurit des bouteilles de gaz comprim ...............................................................................................................1a-6Les bouteilles de gaz comprim peuvent exploser en cas de dommages .............................................................1a-6Le bruit peut provoquer des problmes auditifs......................................................................................................1a-6Pacemakers et prothses auditives........................................................................................................................1a-6Un arc plasma peut endommager les tuyaux gels................................................................................................1a-6tiquettes de scurit .............................................................................................................................................1a-7

11-981a-2 Hypertherm Systmes plasma

SCURIT

IDENTIFIER LES CONSIGNES DE SCURIT

Les symboles indiqus dans cette section sont utiliss pouridentifier les risques ventuels. Si vous trouvez un symbolede scurit, que ce soit dans ce manuel ou sur lquipement,soyez conscient des risques de blessures et suivez lesinstructions correspondantes afin dviter ces risques.

SUIVRE LES INSTRUCTIONS DE SCURIT

Lire attentivement toutes les consignes de scurit dans leprsent manuel et sur les tiquettes de scurit se trouvantsur la machine.

Les tiquettes de scurit doivent rester lisibles. Remplacerimmdiatement les tiquettes manquantes ou abmes.

Apprendre faire fonctionner la machine et utilisercorrectement les commandes. Ne laisser personne utiliserla machine sans connatre son fonctionnement.

Garder la machine en bon tat. Des modifications nonautorises sur la machine peuvent engendrer desproblmes de scurit et raccourcir la dure dutilisationde lquipement.

DANGER AVERTISSEMENT PRCAUTIONLes signaux DANGER ou AVERTISSEMENT sont utilissavec un symbole de scurit, DANGER correspondant auxrisques les plus srieux. Les tiquettes de scurit DANGER et AVERTISSEMENT

sont situes sur la machine pour signaler certainsdangers spcifiques.

Les messages dAVERTISSEMENT prcdent lesinstructions dutilisation expliques dans ce manuel etsignalent les risques de blessures ou de mort au cas oces instructions ne seraient pas suivies correctement.

Les messages de PRCAUTION prcdent lesinstructions dutilisation contenues dans ce manuel etsignalent que le matriel risque dtre endommag si lesinstructions ne sont pas suivies correctement.

Prvention des incendies Avant de commencer, sassurer que la zone de coupage

ne prsente aucun danger. Conserver un extincteur proximit.

loigner toute matire inflammable une distance daumoins 10 m du poste de coupage.

Tremper le mtal chaud ou le laisser refroidir avant de le manipuler ou avant de le mettre en contact avec desmatriaux combustibles.

Ne jamais couper des rcipients pouvant contenir desmatires inflammables avant de les avoir vids etnettoys correctement.

Arer toute atmosphre potentiellement inflammableavant dutiliser un systme plasma.

Lors de lutilisation doxygne comme gaz plasma, unsystme de ventilation par aspiration est ncessaire.

Prvention des explosions Ne pas couper en prsence de poussire ou de vapeurs. Ne pas couper de bouteilles, de tuyaux ou autres

rcipients ferms et pressuriss. Ne pas couper de rcipients contenant des matires

combustibles.

LE COUPAGE PEUT PROVOQUER UN INCENDIEOU UNE EXPLOSION

AVERTISSEMENTRisque dexplosion

argon-hydrogne et mthaneLhydrogne et le mthane sont des gaz inflammables etpotentiellement explosifs. Conserver lcart de touteflamme les bouteilles et tuyaux contenant des mlanges base dhydrogne ou de mthane. Maintenir toute flamme ettincelle lcart de la torche lors de lutilisation dun plasmadargon-hydrogne ou de mthane.

AVERTISSEMENTDtonation de lhydrogne lors du

coupage de laluminium Lors du coupage de laluminium sous leau, ou si leau

touche la partie infrieure de la pice daluminium, delhydrogne libre peut saccumuler sous la pice couperet dtonner lors du coupage plasma.

Installer un collecteur daration au fond de la table eauafin dliminer les risques de dtonation de lhydrogne.Se rfrer lannexe du manuel pour plus derenseignements sur les collecteurs daration.

8-06

Toucher une pice lectrique sous tension peut provoquerun choc lectrique fatal ou des brlures graves. La mise en fonctionnement du systme plasma ferme un

circuit lectrique entre la torche et la pice couper. Lapice couper et tout autre lment en contact avec cettepice font partie du circuit lectrique.

Ne jamais toucher le corps de la torche, la pice couperou leau de la table eau pendant le fonctionnement dusystme plasma.

Prvention des chocs lectriquesTous les systmes plasma Hypertherm utilisent des hautestensions pour le coupage (souvent de 200 400 V). On doit prendre les prcautions suivantes quand on utilise lesystme plasma : Porter des bottes et des gants isolants et garder le corps

et les vtements au sec. Ne pas se tenir, sasseoir ou se coucher sur une surface

mouille, ni la toucher quand on utilise le systme plasma. Sisoler de la surface de travail et du sol en utilisant des

tapis isolants secs ou des couvertures assez grandespour viter tout contact physique avec le travail ou le sol.Sil savre ncessaire de travailler dans ou prs dunendroit humide, procder avec une extrme prudence.

Installer un sectionneur avec fusibles appropris, proximit de la source de courant. Ce dispositif permet loprateur darrter rapidement la source de courant encas durgence.

En cas dutilisation dune table eau, sassurer que cettedernire est correctement mise la terre.

LES CHOCS LECTRIQUES PEUVENT TRE FATALS

Installer et mettre la terre lquipement selon lesinstructions du prsent manuel et conformment auxcodes lectriques locaux et nationaux.

Inspecter frquemment le cordon dalimentation primairepour sassurer quil nest ni endommag, ni fendu.Remplacer immdiatement un cordon endommag. Un cble dnud peut tuer.

Inspecter et remplacer les cbles de la torche qui sontuss ou endommags.

Ne pas saisir la pice couper ni les chutes lors ducoupage. Laisser la pice couper en place ou sur latable de travail, le cble de retour connect lors ducoupage.

Avant de vrifier, de nettoyer ou de remplacer les picesde la torche, couper lalimentation ou dbrancher la prisede courant.

Ne jamais contourner ou court-circuiter les verrouillagesde scurit.

Avant denlever le capot du systme ou de la source decourant, couper lalimentation lectrique. Attendre ensuite5 minutes pour que les condensateurs se dchargent.

Ne jamais faire fonctionner le systme plasma sans queles capots de la source de courant ne soient en place.Les raccords exposs de la source de courant sontextrmement dangereux.

Lors de linstallation des connexions, attacher tout dabordla prise de terre approprie.

Chaque systme plasma Hypertherm est conu pour treutilis uniquement avec des torches Hyperthermspcifiques. Ne pas utiliser des torches inappropries quipourraient surchauffer et prsenter des risques pour lascurit.

On doit prendre les prcautions qui simposentquand on manipule les circuits imprims.

LLECTRICIT STATIQUE PEUT ENDOMMAGER LES CARTES DE CIRCUITS IMPRIMS

On doit ranger les cartes de circuits imprims dansdes contenants antistatiques.

On doit porter un bracelet antistatique quand onmanipule les cartes de circuits imprims.

Hypertherm Systmes plasma 1a-3

SCURIT


SCURIT

Larc plasma est lui-mme la source de chaleurutilise pour le coupage. Par consquent, bien quelarc plasma nait pas t reconnu comme une sourcede vapeurs toxiques, le matriau coup peut tre unesource de vapeurs ou de gaz toxiques qui puisentloxygne.

Les vapeurs produites varient selon le mtal coup.Les mtaux qui peuvent dgager des vapeurstoxiques comprennent, entre autres, lacierinoxydable, lacier au carbone, le zinc (galvanis) et lecuivre.

Dans certains cas, le mtal peut tre revtu dunesubstance susceptible de dgager des vapeurstoxiques. Les revtements toxiques comprennententre autres, le plomb (dans certaines peintures), lecadmium (dans certaines peintures et enduits) et lebryllium.

Les gaz produits par le coupage plasma varient selonle matriau couper et la mthode de coupage, maisils peuvent comprendre lozone, les oxydes dazote, lechrome hexavalent, lhydrogne et autres substancesprsentes dans le matriau coup ou en manent.

On doit prendre les prcautions qui simposent pourrduire au minimum lexposition aux vapeursproduites par tout processus industriel. Selon lacomposition chimique et la concentration des vapeurs(ainsi que dautres facteurs comme la ventilation), ilpeut y avoir un risque de maladie physique, commedes malformations ou le cancer.

Il incombe au propritaire du matriel et du site devrifier la qualit de lair dans le secteur o lon utilisele matriel et de sassurer que la qualit de lair surles lieux de travail rpond aux normes etrglementation locales et nationales.

LES VAPEURS TOXIQUES PEUVENT PROVOQUER DES BLESSURES OU LA MORT

Le niveau de qualit de lair dans tout lieu de travaildpend des variables propres au site comme : Type de table (humide, sche, sous leau). Composition du matriau, fini de la surface et

composition des revtements. Volume de matriau enlev. Dure du coupage ou du gougeage. Dimensions, volume dair, ventilation et filtration de

la zone de travail. quipement de protection individuelle. Nombre de systmes de soudage et de coupage en

fonctionnement. Autres procds du site qui peuvent produire des

vapeurs.

Si les lieux de travail doivent tre conformes auxrglements nationaux ou locaux, seuls les contrlesou les essais effectus au site peuvent dterminer sicelui-ci se situe au-dessus ou au-dessous desniveaux admissibles.

Pour rduire le risque dexposition aux vapeurs : liminer tout revtement et solvant du mtal avant

le coupage. Utiliser la ventilation dextraction locale pour

liminer les vapeurs de lair. Ne pas inhaler les vapeurs. Porter un respirateur

adduction dair quand on coupe des mtaux revtusdlments toxiques ou qui en contiennent ou sontsusceptibles den contenir.

Sassurer que les personnes qui utilisent unmatriel de soudage ou de coupage ainsi que lesdispositifs de respiration par adduction dair sontqualifis et ont reu la formation sur la bonneutilisation dun tel matriel.

Ne jamais couper les contenants dans lesquels ilpeut y avoir des matriaux toxiques. En premierlieu, vider et nettoyer correctement le contenant.

Contrler ou prouver la qualit de lair au siteselon les besoins.

Consulter un expert local pour mettre en uvre unplan du site afin dassurer une qualit de lair sre.

5-02

Torches allumage instantanLarc plasma sallume immdiatement aprs que la torchesoit mise en marche.

LARC PLASMA PEUT PROVOQUER DES BLESSURES OU DES BRLURES

Larc plasma coupe facilement les gants et la peau. Rester loign de lextrmit de la torche. Ne pas tenir de mtal prs de la trajectoire de coupe. Ne jamais pointer la torche vers soi ou dautres

personnes.

Protection des yeux Les rayons de larc plasma produisentde puissants rayons visibles ou invisibles (ultraviolets etinfrarouges) qui peuvent brler les yeux et la peau. Utiliser des lunettes de scurit conformment aux codes

locaux ou nationaux en vigueur. Porter des lunettes de protection (lunettes ou masque muni

dcrans latraux et encore masque de soudure) avec desverres teints appropris pour protger les yeux des rayonsultraviolets et infrarouges de larc.

Puissance des verres teintsCourant de larc AWS (.-U.) ISO 4850Jusqu 100 A No 8 No 11100-200 A No 10 No 11-12200-400 A No 12 No 13Plus de 400 A No 14 No 14

LES RAYONS DE LARC PEUVENT BRLER LES YEUX ET LA PEAU

Protection de la peau Porter des vtements de scuritpour se protger contre les brlures que peuvent causer lesrayons ultraviolets, les tincelles et le mtal brlant : Gants crispin, chaussures et casque de scurit. Vtements ignifuges couvrant toutes les parties exposes

du corps. Pantalon sans revers pour viter que des tincelles ou

des scories puissent sy loger. Avant le coupage, retirer de ses poches tout objet

combustible comme les briquets au butane ou lesallumettes.

Zone de coupage Prparer la zone de coupage afin derduire la rverbration et la transmission de la lumireultraviolette : Peindre les murs et autres surfaces de couleur sombre

pour rduire la rflexion de la lumire. Utiliser des crans et autres dispositifs de protection afin

de protger les autres personnes de la lumire et de larverbration.

Prvenir les autres personnes de ne pas regarder larc.Utiliser des affiches ou des panneaux.

Cble de retour Bien fixer le cble de retour (ou demasse) la pice couper ou la table de travail de faon assurer un bon contact mtal-mtal. Ne pas fixer le cblede retour la partie de la pice qui doit se dtacher.

Table de travail Raccorder la table de travail la terre,conformment aux codes de scurit locaux ou nationauxappropris.

MISE LA MASSE ET LA TERRE Alimentation Sassurer que le fil de terre du cordon dalimentation est

connect la terre dans le coffret du sectionneur. Sil est ncessaire de brancher le cordon dalimentation

la source de courant lors de linstallation du systme,sassurer que le fil de terre est correctement branch.

Placer tout dabord le fil de terre du cordon dalimentationsur le plot de mise la terre puis placer les autres fils deterre par-dessus. Bien serrer lcrou de retenue.

Sassurer que toutes les connexions sont bien serrespour viter la surchauffe.


SCURIT


SCURIT

Ne jamais lubrifier les robinets des bouteilles ou lesrgulateurs avec de lhuile ou de la graisse.

Utiliser uniquement les bouteilles, rgulateurs, tuyaux etaccessoires appropris et conus pour chaque applicationspcifique.

Entretenir lquipement et les pices dquipement gazcomprim afin de les garder en bon tat.

tiqueter et coder avec des couleurs tous les tuyaux degaz afin didentifier le type de gaz contenu dans chaquetuyau. Se rfrer aux codes locaux ou nationaux envigueur.

LES BOUTEILLES DE GAZCOMPRIM PEUVENT EXPLOSEREN CAS DE DOMMAGES

SCURIT DES BOUTEILLES DE GAZ COMPRIM

Les bouteilles de gaz contiennent du gaz haute pression.Si une bouteille est endommage, elle peut exploser. Manipuler et utiliser les bouteilles de gaz comprim

conformment aux codes locaux ou nationaux. Ne jamais utiliser une bouteille qui nest pas place la

verticale et bien assujettie. Le capuchon de protection doit tre plac sur le robinet

sauf si la bouteille est en cours dutilisation ou connectepour utilisation.

viter tout prix le contact lectrique entre larc plasma etune bouteille.

Ne jamais exposer des bouteilles une chaleurexcessive, aux tincelles, aux scories ou aux flammesnues.

Ne jamais utiliser des marteaux, des cls ou dautresoutils pour dbloquer le robinet des bouteilles.

Les tuyaux gels peuvent tre endommags ou clater sil'on essaie de les dgeler avec une torche plasma.

LE BRUIT PEUT PROVOQUER DESPROBLMES AUDITIFS

UN ARC PLASMAPEUT ENDOMMAGER LESTUYAUX GELS

Les champs magntiques produits par les courants hautetension peuvent affecter le fonctionnement des prothsesauditives et des pacemakers. Les personnes portant cetype dappareil doivent consulter un mdecin avant desapprocher dun lieu o seffectue le coupage ou legougeage plasma.Pour rduire les risques associs aux champs magntiques : Garder loin de soi et du mme ct du corps le cble de

retour et le faisceau de la torche. Faire passer le faisceau de la torche le plus prs possible

du cble de retour. Ne pas senrouler le faisceau de la torche ou le cble de

retour autour du corps. Se tenir le plus loin possible de la source de courant.

PACEMAKERS ET PROTHSES AUDITIVES

Une exposition prolonge au bruit du coupage ou dugougeage peut provoquer des problmes auditifs. Utiliser un casque de protection homologu lors de

lutilisation du systme plasma. Prvenir les personnes aux alentours des risques

encourus en cas dexposition au bruit.

8-99

tiquette de scuritCette tiquette est affiche sur la source de courant. Il est important que lutilisateur etle technicien de maintenance comprennent la signification des symboles de scurit.


SCURIT

Read and follow these instructions, employer safetypractices, and material safety data sheets. Refer to ANS Z49.1, Safety in Welding, Cutting and Allied Processes from American Welding Society (http://www.aws.org) and OSHA Safety and Health Standards, 29 CFR 1910 (http://www.osha.gov).

WARNING

1. Cutting sparks can cause explosion or fire.1.1 Do not cut near flammables.1.2 Have a fire extinguisher nearby and ready to use.1.3 Do not use a drum or other closed container as a cutting table.

2. Plasma arc can injure and burn; point the nozzle away from yourself. Arc starts instantly when triggered. 2.1 Turn off power before disassembling torch.2.2 Do not grip the workpiece near the cutting path.2.3 Wear complete body protection.

3. Hazardous voltage. Risk of electric shock or burn.3.1 Wear insulating gloves. Replace gloves when wet or damaged.3.2 Protect from shock by insulating yourself from work and ground.3.3 Disconnect power before servicing. Do not touch live parts.

4. Plasma fumes can be hazardous.4.1 Do not inhale fumes. 4.2 Use forced ventilation or local exhaust to remove the fumes.4.3 Do not operate in closed spaces. Remove fumes with ventilation.

5. Arc rays can burn eyes and injure skin.5.1 Wear correct and appropriate protective equipment to protect head, eyes, ears, hands, and body. Button shirt collar. Protect ears from noise. Use welding helmet with the correct shade of filter.

6. Become trained. Only qualified personnel should operate this equipment. Keep non-qualified personnel and children away.

7. Do not remove, destroy, or cover this label. Replace if it is missing, damaged, or worn (PN 110584 Rev A).

Plasma cutting can be injurious to operator and persons in the work area. Consult manual before operating. Failure to follow all these safety instructions can result in death.

AVERTISSEMENTLe coupage plasma peut tre prjudiciable pour loprateur et les personnes qui se trouvent sur les lieux de travail. Consulter le manuel avant de faire fonctionner. Le non respect des ces instructions de scurit peut entraner la mort.

1. Les tincelles de coupage peuvent provoquer une explosion ou un incendie.1.1 Ne pas couper prs des matires inflammables. 1.2 Un extincteur doit tre proximit et prt tre utilis.1.3 Ne pas utiliser un ft ou un autre contenant ferm comme table de coupage.

2. Larc plasma peut blesser et brler; loigner la buse de soi. Il sallume instantanment quand on lamorce; 2.1 Couper lalimentation avant de dmonter la torche. 2.2 Ne pas saisir la pice couper de la trajectoire de coupage. 2.3 Se protger entirement le corps.

3. Tension dangereuse. Risque de choc lectrique ou de brlure. 3.1 Porter des gants isolants. Remplacer les gants quand ils sont humides ou endommags. 3.2 Se protger contre les chocs en sisolant de la pice et de la terre. 3.3 Couper lalimentation avant lentretien. Ne pas toucher les pices sous tension.

4. Les fumes plasma peuvent tre dangereuses. 4.1 Ne pas inhaler les fumes 4.2 Utiliser une ventilation force ou un extracteur local pour dissiper les fumes. 4.3 Ne pas couper dans des espaces clos. Chasser les fumes par ventilation.

5. Les rayons darc peuvent brler les yeux et blesser la peau. 5.1 Porter un bon quipement de protection pour se protger la tte, les yeux, les oreilles, les mains et le corps. Boutonner le col de la chemise. Protger les oreilles contre le bruit. Utiliser un masque de soudeur avec un filtre de nuance approprie.

6. Suivre une formation. Seul le personnel qualifi a le droit de faire fonctionner cet quipement. Le personnel non qualifi et les enfants doivent se tenir lcart.7. Ne pas enlever, dtruire ni couvrir cette tiquette. La remplacer si elle est absente, endommage ou use (PN 110584 Rev A).

1. Les tincelles produites par le coupage peuventprovoquer une explosion ou un incendie.

1.1 Pendant le coupage, loigner toute matireinflammable.

1.2 Conserver un extincteur proximit et sassurer quunepersonne soit prte lutiliser.

1.3 Ne jamais couper de rcipients ferms.2. Larc plasma peut provoquer des blessures et des

brlures.2.1 Couper lalimentation avant de dmonter la torche.2.2 Ne pas tenir la surface couper prs de la trajectoire de

coupe.2.3 Porter des vtements de protection couvrant tout le

corps.3. Un choc lectrique caus par la torche ou les cbles

peut tre fatal. Se protger contre les risques de chocslectriques.

3.1 Porter des gants isolants. Ne pas porter de gantsmouills ou abms.

3.2 Sisoler de la surface de travail et du sol.

3.3 Dbrancher la prise ou la source de courant avant demanipuler lquipement.

4. Linhalation des vapeurs produites par le coupage peuttre dangereuse pour la sant.

4.1 Garder le visage lcart des vapeurs.4.2 Utiliser un systme de ventilation par aspiration ou

dchappement localis pour dissiper les vapeurs.4.3 Utiliser un ventilateur pour dissiper les vapeurs.5. Les rayons de larc peuvent brler les yeux et provoquer

des lsions de la peau.5.1 Porter un casque et des lunettes de scurit. Se

protger les oreilles et porter une chemise dont le colpeut tre dboutonn. Porter un casque de souduredont la protection filtrante est suffisante. Porter desvtements protecteurs couvrant la totalit du corps.

6. Se former la technique du coupage et lire lesinstructions avant de manipuler lquipement ou deprocder au coupage.

7. Ne pas retirer ou peindre (recouvrir) les tiquettes descurit.


SCURIT

tiquette de scuritCette tiquette est affiche sur la source de courant. Il est importantque lutilisateur et le technicien de maintenance comprennent lasignification des symboles de scurit. Les numros de la listecorrespondent aux numros des images.

1. Les tincelles produites par le coupagepeuvent provoquer une explosion ou unincendie.

1.1 Pendant le coupage, loigner toute matireinflammable.

1.2 Conserver un extincteur proximit etsassurer quune personne soit prte lutiliser.

1.3 Ne jamais couper de rcipients ferms.2. Larc plasma peut provoquer des blessures

et des brlures.2.1 Couper lalimentation avant de dmonter la

torche.2.2 Ne pas tenir la surface couper prs de la

trajectoire de coupe.2.3 Porter des vtements de protection

couvrant tout le corps.3. Un choc lectrique caus par la torche ou

les cbles peut tre fatal. Se protgercontre les risques de chocs lectriques.

3.1 Porter des gants isolants. Ne pas porter degants mouills ou abms.

3.2 Sisoler de la surface de travail et du sol.3.3 Dbrancher la prise ou la source de

courant avant de manipuler lquipement.4. Linhalation des vapeurs produites par le

coupage peut tre dangereuse pour lasant.

4.1 Garder le visage lcart des vapeurs.4.2 Utiliser un systme de ventilation par

aspiration ou dchappement localis pourdissiper les vapeurs.

4.3 Utiliser un ventilateur pour dissiper lesvapeurs.

5. Les rayons de larc peuvent brler les yeuxet provoquer des lsions de la peau.

5.1 Porter un casque et des lunettes descurit. Se protger les oreilles et porterune chemise dont le col peut tredboutonn. Porter un casque de souduredont la protection filtrante est suffisante.Porter des vtements protecteurs couvrantla totalit du corps.

6. Se former la technique du coupage et lireles instructions avant de manipulerlquipement ou de procder au coupage.

7. Ne pas retirer ou peindre (recouvrir) lestiquettes de scurit.

Rev. D

8-06Hypertherm Sistemas plasma 1b-1

Seccon 1b

SEGURIDAD

En esta seccin:

Reconocimiento de informacin de seguridad........................................................................................................1b-2Siga las instrucciones de seguridad .......................................................................................................................1b-2Los cortes pueden provocar incendios o explosiones ............................................................................................1b-2El choque elctrico puede provocar la muerte .......................................................................................................1b-3Electricidad esttica puede daar tablillas de circuito ............................................................................................1b-3Humos txicos pueden causar lesiones o muerte ..................................................................................................1b-4El arco de plasma puede causar lesiones y quemaduras ......................................................................................1b-5Los rayos del arco pueden producir quemaduras en los ojos y en la piel ..............................................................1b-5Seguridad de toma a tierra .....................................................................................................................................1b-5Seguridad de los equipos de gas comprimido........................................................................................................1b-6Los cilindros de gas pueden explotar si estn daados .........................................................................................1b-6El ruido puede deteriorar la audicin ......................................................................................................................1b-6Operacin de marcapasos y de audfonos .............................................................................................................1b-6Un arco plasma puede daar tubos congelados ....................................................................................................1b-6Etiquetas de advertencia ........................................................................................................................................1b-7

11-98

SEGURIDAD

1b-2 Hypertherm Sistemas plasma

RECONOCIMIENTO DEINFORMACIN DE SEGURIDAD

Los smbolos que se muestran en esta seccin se utilizanpara identificar los posibles peligros. Cuando vea un smbolode seguridad en este manual o en su mquina, recuerde queexiste la posibilidad de que se produzcan lesiones personalesy siga las instrucciones correspondientes para evitar elpeligro.

SIGA LAS INSTRUCCIONES DESEGURIDAD

Lea atentamente todos los mensajes de seguridad de estemanual y las etiquetas de seguridad en su mquina. Mantenga las etiquetas de seguridad de su mquina en

buen estado. Reemplace las etiquetas que se pierdan o sedaen inmediatamente.

Aprenda a utilizar la mquina y a utilizar los controles de lamanera correcta. No permita que sea utilizada por alguienque no conozca su funcionamiento.

Mantenga su mquina en buenas condiciones defuncionamiento. La realizacin de modificaciones noautorizadas a la mquina puede comprometer laseguridad y la vida til de la mquina.

PELIGRO ADVERTENCIA PRECAUCINLas palabras PELIGRO y ADVERTENCIA se utilizanconjuntamente con un smbolo de seguridad. La palabraPELIGRO se utiliza para identificar los mayores peligros. Encontrar etiquetas de seguridad con las inscripciones

PELIGRO y ADVERTENCIA en su mquina, junto apeligros especficos.

En este manual, la palabra ADVERTENCIA va seguida deinstrucciones que, si no se siguen correctamente, puedenprovocar lesiones e inclusive la muerte.

En este manual, la palabra PRECAUCIN va seguida deinstrucciones que, si no se siguen correctamente, puedenprovocar daos en el equipo.

Prevencin ante el fuego Asegrese de que el rea sea segura antes de proceder

a cortar. Tenga a mano un extinguidor de incendios. Retire todos los materiales inflamables, colocndolos a

por lo menos 10 metros del rea de corte. Remoje los metales calientes o permita que se enfren

antes de que entren en contacto con materialescombustibles.

Nunca corte depsitos que contengan materialesinflamables primero es necesario vaciarlos y limpiarlosdebidamente.

Antes de realizar cortes en atmsferas potencialmenteinflamables, asegrese de ventilar bien.

Al realizar cortes utilizando oxgeno como gas plasma, serequiere tener un sistema de ventilacin de escape.

Prevencin ante explosiones No corte en atmsferas que contengan polvo o vapores

explosivos. No corte depsitos o tubos a presin ni cualquier depsito

cerrado. No corte depsitos que hayan contenido materiales

combustibles.

LOS CORTES PUEDEN PROVOCAR INCENDIOS O EXPLOSIONES

ADVERTENCIAPeligro de explosin

Argn-Hidrgeno y metanoEl hidrgeno y el metano son gases inflamables quesuponen un peligro de explosin. Mantenga el fuego lejos delos cilindros y las mangueras que contengan mezclas dehidrgeno o metano. Mantenga la llama y las chispas lejosde la antorcha al utilizar metano o argn-hidrgeno comoplasma.

ADVERTENCIADetonacin de hidrgeno con

el corte de aluminio Al cortar aluminio bajo agua o con agua en contacto con el

lado inferior del aluminio, puede acumularse gashidrgeno bajo la pieza a cortar y detonar durante laoperacin de corte por plasma.

Instale un mltiple de aireacin en el fondo de la mesa deagua para eliminar la posibilidad de la detonacin delhidrgeno. Consulte la seccin del apndice de estemanual para conocer detalles acerca del mltiple deaireacin.

8-06

El contacto directo con piezas elctricas conectadas puedeprovocar un electrochoque fatal o quemaduras graves. Al hacer funcionar el sistema de plasma, se completa un

circuito elctrico entre la antorcha y la pieza a cortar.La pieza a cortar es una parte del circuito elctrico,como tambin cualquier cosa que se encuentre encontacto con ella.

Nunca toque el cuerpo de la antorcha, la pieza a cortar oel agua en una mesa de agua cuando el sistema deplasma se encuentre en funcionamiento.

Prevencin ante el electrochoqueTodos los sistemas por plasma de Hypertherm usan altovoltaje en el proceso de corte (son comunes los voltajes CDde 200 a 400). Tome las siguientes precauciones cuando seutiliza el equipo de plasma: Use guantes y botas aislantes y mantenga el cuerpo y la

ropa secos. No se siente, se pare o se ponga sobre cualquier super-

ficie hmeda cuando est trabajando con el equipo. Aslese elctricamente de la pieza a cortar y de la tierra

utilizando alfombrillas o cubiertas de aislamiento secas losuficientemente grandes como para impedir todo contactofsico con la pieza a cortar o con la tierra. Si su nicaopcin es trabajar en una rea hmeda o cerca de ella,sea muy cauteloso.

Instale un interruptor de corriente adecuado en cuanto afusibles, en una pared cercana a la fuente de energa.Este interruptor permitir al operador desconectarrpidamente la

pmx30 sm 805170r2.pdf

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