Hypertherm Phoenix V9.76.0: instruction

Safety and Compliance Manual

WARNING!

Failure to follow operating instructions could result in personal injury or damage

to equipment.

80669C | Revision 2

Powermax and Hypertherm are trademarks of Hypertherm Inc. and may be registered in the United States and other countries. All other

trademarks are the property of their respective holders.

© 2015 Hypertherm Inc.

Contents

English ................................................................................................................................................................SC-5

Бългapcки / Bulgarian ................................................................................................................................SC-17

󳶰󱆃󱁝󲞷 / Simplified Chinese ..................................................................................................................SC-29

󴁱󵴄󱁝󲞷 / Traditional Chinese .................................................................................................................SC-41

Česky / Czech ...............................................................................................................................................SC-51

Dansk / Danish ..............................................................................................................................................SC-63

Nederlands / Dutch ......................................................................................................................................SC-75

Suomi / Finnish ..............................................................................................................................................SC-87

Français / French ..........................................................................................................................................SC-99

Deutsch / German ......................................................................................................................................SC-111

Ελληνικά / Greek ........................................................................................................................................SC-123

Magyar / Hungarian ....................................................................................................................................SC-135

Italiano / Italian .............................................................................................................................................SC-147

日本語 / Japanese ......................................................................................................................................SC-159

󺺲󸛃󹼊 / Korean ..........................................................................................................................................SC-171

Norsk / Norwegian ......................................................................................................................................SC-183

Polski / Polish ..............................................................................................................................................SC-195

Português / Portuguese ............................................................................................................................SC-207

Romană / Romanian ...................................................................................................................................SC-219

Русский / Russian ......................................................................................................................................SC-231

Srpski / Serbian ...........................................................................................................................................SC-245

Slovenščina / Slovenian ............................................................................................................................SC-257

Español / Spanish .......................................................................................................................................SC-269

Svenska / Swedish .....................................................................................................................................SC-281

Türkçe / Turkish ...........................................................................................................................................SC-293

Safety and Compliance 80669C 3

Contents

4 Safety and Compliance 80669C

WARNING!

Failure to follow operating instructions could result in personal

injury or damage to equipment.

Safety and Compliance Manual

806690 Revision 2 – January 2015

English

Safety

DANGER WARNING CAUTION

RECOGNIZE SAFETY

American National Standards Institute (ANSI) guidelines are used for

INFORMATION

safety signal words and symbols. The signal word DANGER or

WARNING is used with a safety symbol. DANGER identifies the most

The symbols shown in this section are used to identify potential

serious hazards.

hazards. When you see a safety symbol in this manual or on your

• DANGER and WARNING safety labels are located on your machine

machine, understand the potential for personal injury, and follow the

near specific hazards.

related instructions to avoid the hazard.

• DANGER safety messages precede related instructions in the

manual that will result in serious injury or death if not followed

FOLLOW SAFETY

correctly.

INSTRUCTIONS

• WARNING safety messages precede related instructions in this

manual that may result in injury or death if not followed correctly.

Carefully read all safety messages in this manual and safety labels

• CAUTION safety messages precede related instructions in this

on your machine.

manual that may result in minor injury or damage to equipment if not

followed correctly.

• Keep the safety labels on your machine in good condition.

Replace missing or damaged labels immediately.

INSPECT EQUIPMENT BEFORE USING

• Learn how to operate the machine and how to use the controls

properly. Do not let anyone operate it without instruction.

All cutting equipment must be inspected as required to make sure it is in

• Keep your machine in proper working condition. Unauthorized

safe operating condition. When found to be incapable of reliable and

modifications to the machine may affect safety and machine

safe operation, the equipment must be repaired by qualified personnel

service life.

prior to its next use or withdrawn from service.

Safety and Compliance SC-5

English

Safety

RESPONSIBILITY FOR SAFETY

The person or entity responsible for the safety of the workplace must:

• Select contractors who provide trained and qualified personnel, and

• Make sure that operators and their supervisors are trained in the safe

who have awareness of the risks involved, to do cutting.

use of their equipment, the safe use of the process, and emergency

• Tell contractors about flammable materials or hazardous conditions

procedures.

that are specific to the site, or hazardous conditions that they may not

• Make sure that all hazards and safety precautions identified herein

be aware of.

are communicated to and understood by workers before the start of

• Make sure that the quality and quantity of air for ventilation is such

work.

that personnel exposures to hazardous contaminants are below the

• Designate approved cutting areas and establish procedures for safe

allowable limits.

cutting.

• Make sure that ventilation in confined spaces is sufficient to allow

• Be responsible for authorizing cutting operations in areas not

adequate oxygen for life support, to prevent accumulation of

specifically designed or approved for such processes.

asphixiants or flammable explosive mixtures, to prevent

oxygen-enriched atmospheres, and to keep airborne contaminants in

• Make sure that only approved equipment, such as torches and

breathing atmospheres below allowable limits.

personal protective equipment, are used.

A PLASMA ARC CAN DAMAGE FROZEN PIPES

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

STATIC ELECTRICITY CAN DAMAGE PRINTED CIRCUIT BOARDS

Use proper precautions when handling printed circuit boards:

• Store printed circuit boards in anti-static containers.

• Wear a grounded wrist strap when handling printed circuit boards.

GROUNDING SAFETY

Work lead Attach the work lead securely to the workpiece or the

Input power

cutting table with good metal-to-metal contact. Do not connect it to

• Make sure to connect the power cord ground wire to the ground in

the piece that will fall away when the cut is complete.

the disconnect box.

Cutting table Connect the cutting table to an earth ground, in

• If installation of the plasma system involves connecting the power

accordance with appropriate national and local electrical regulations.

cord to the power supply, make sure to connect the power cord

ground wire properly.

• Place the power cord’s ground wire on the stud first, then place any

other ground wires on top of the power cord ground. Tighten the

retaining nut.

• Tighten all electrical connections to avoid excessive heating.

ELECTRICAL HAZARDS

• Only trained and authorized personnel may open this equipment.

• If the equipment must have power when the enclosure is open for

• If the equipment is permanently connected, turn it off, and lock

servicing, arc flash explosion hazards may exist. Follow all local

out/tag out power before the enclosure is opened.

requirements (NFPA 70E in the USA) for safe work practices and for

personal protective equipment when servicing energized equipment.

• If power is supplied to the equipment with a cord, unplug the unit

before the enclosure is opened.

• Prior to operating the equipment after moving, opening, or servicing,

make sure to close the enclosure and make sure that there is proper

• Lockable disconnects or lockable plug covers must be provided by

earth ground continuity to the enclosure.

others.

• Always follow these instructions for disconnecting power before

• Wait 5 minutes after removal of power before entering the enclosure

inspecting or changing torch consumable parts.

to allow stored energy to discharge.

SC-6 Safety and Compliance

English

Safety

ELECTRIC SHOCK CAN KILL

Touching live electrical parts can cause a fatal shock or severe burn.

• Install and ground this equipment according to the instruction

manual and in accordance with national and local regulations.

• Operating the plasma system completes an electrical circuit

between the torch and the workpiece. The workpiece and anything

• Inspect the input power cord frequently for damage or cracking

touching the workpiece are part of the electrical circuit.

of the cover. Replace a damaged power cord immediately.

Bare wiring can kill.

• In machine torch applications, never touch the torch body,

workpiece, or water in a water table when the plasma system is

• Inspect and replace any worn or damaged torch leads.

operating.

• Do not pick up the workpiece, including the waste cutoff, while you

cut. Leave the workpiece in place or on the workbench with the

Electric shock prevention

work lead attached during the cutting process.

All plasma systems use high voltage in the cutting process

• Before checking, cleaning, or changing torch parts, disconnect the

(200 to 400 VDC are common). Take the following

main power or unplug the power supply.

precautions when operating this system:

• Never bypass or shortcut the safety interlocks.

• Wear insulated gloves and boots, and keep your body and clothing

• Before removing any power supply or system enclosure cover,

dry.

disconnect electrical input power. Wait 5 minutes after

• Do not stand, sit, or lie on – or touch – any wet surface when using

disconnecting the main power to allow capacitors to discharge.

the plasma system.

• Never operate the plasma system unless the power supply covers

• Insulate yourself from the work and ground using dry insulating

are in place. Exposed power supply connections present a severe

mats or covers big enough to prevent any physical contact with the

electrical hazard.

work or ground. If you must cut in or near a damp area, use

• When making input connections, attach a proper grounding

extreme caution.

conductor first.

• Provide a disconnect switch close to the power supply with

• Each plasma system is designed to be used only with specific

properly sized fuses. This switch allows the operator to turn off the

torches. Do not substitute other torches, which could overheat and

power supply quickly in an emergency situation.

present a safety hazard.

• When using a water table, make sure that it is correctly connected

to an earth ground.

CUTTING CAN CAUSE FIRE OR EXPLOSION

Fire prevention

WARNING

• Make sure the cutting area is safe before doing any cutting. Keep a

Explosion Hazard

fire extinguisher nearby.

Argon-Hydrogen and Methane

• Remove all flammables within 35 feet (10 m) of the cutting area.

Hydrogen and methane are flammable gases that present an

• Quench hot metal or allow it to cool before handling or before

explosion hazard. Keep flames away from cylinders and hoses that

letting it touch combustible materials.

contain methane or hydrogen mixtures. Keep flames and sparks away

• Never cut containers with potentially flammable materials inside –

from the torch when using methane or argon-hydrogen plasma.

they must be emptied and properly cleaned first.

WARNING

• Ventilate potentially flammable atmospheres before cutting.

Hydrogen Detonation with

• When cutting with oxygen as the plasma gas, an exhaust ventilation

Aluminum Cutting

system is required.

• Do not cut aluminum underwater or with water touching the

underside of the aluminum.

Explosion prevention

• Cutting aluminum underwater or with the water touching the

• Do not use the plasma system if explosive dust or vapors may be

underside of the aluminum can result in an explosive condition that

present.

can detonate during plasma cutting operations.

• Do not cut pressurized cylinders, pipes, or any closed containers.

WARNING

• Do not cut containers that have held combustible materials.

Explosion Hazard

Underwater Cutting with Fuel Gases

• Do not cut underwater with fuel gases containing hydrogen.

• Cutting underwater with fuel gases containing hydrogen can

result in an explosive condition that can detonate during plasma

cutting operations.

Safety and Compliance SC-7

English

Safety

COMPRESSED GAS EQUIPMENT

GAS CYLINDERS CAN

SAFETY

EXPLODE IF DAMAGED

• Never lubricate cylinder valves or regulators with oil or grease.

Gas cylinders contain gas under high pressure. If damaged, a

• Use only correct gas cylinders, regulators, hoses, and fittings

cylinder can explode.

designed for the specific application.

• Handle and use compressed gas cylinders in accordance with

• Maintain all compressed gas equipment and associated parts in

applicable national and local regulations.

good condition.

• Never use a cylinder that is not upright and secured in place.

• Label and color-code all gas hoses to identify the type of gas in

• Keep the protective cap in place over the valve except when the

each hose. Consult applicable national and local regulations.

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.

TOXIC FUMES CAN CAUSE INJURY OR DEATH

The plasma arc by itself is the heat source used for cutting.

The air quality level in any relevant workplace depends on site-specific

Accordingly, although the plasma arc has not been identified as a

variables such as:

source of toxic fumes, the material being cut can be a source of toxic

• Table design (wet, dry, underwater).

fumes or gases that deplete oxygen.

• Material composition, surface finish, and composition of coatings.

The fumes produced vary depending on the metal that is cut. Metals

• Volume of material removed.

that may release toxic fumes include, but are not limited to, stainless

• Duration of cutting or gouging.

steel, carbon steel, zinc (galvanized), and copper.

• Size, air volume, ventilation, and filtration of the workplace.

In some cases, the metal may be coated with a substance that could

• Personal protective equipment.

release toxic fumes. Toxic coatings include, but are not limited to,

• Number of welding and cutting systems in operation.

lead (in some paints), cadmium (in some paints and fillers), and

• Other workplace processes that may produce fumes.

beryllium.

If the workplace must conform to national or local regulations, only

The gases produced by plasma cutting vary based on the material to

monitoring or testing done at the site can determine whether the

be cut and the method of cutting, but may include ozone, oxides of

workplace is above or below allowable levels.

nitrogen, hexavalent chromium, hydrogen, and other substances if

To reduce the risk of exposure to fumes:

such are contained in or released by the material being cut.

• Remove all coatings and solvents from the metal before cutting.

Caution should be taken to minimize exposure to fumes produced by

• Use local exhaust ventilation to remove fumes from the air.

any industrial process. Depending on the chemical composition and

• Do not inhale fumes. Wear an air-supplied respirator when cutting

concentration of the fumes (as well as other factors, such as

any metal coated with, containing, or suspected to contain toxic

ventilation), there may be a risk of physical illness, such as birth

elements.

defects or cancer.

• Make sure that those using welding or cutting equipment, as well as

It is the responsibility of the equipment and site owner to test the air

air-supplied respiration devices, are qualified and trained in the

quality in the cutting area and to make sure that the air quality in the

proper use of such equipment.

workplace meets all local and national standards and regulations.

• Never cut containers with potentially toxic materials inside. Empty

and properly clean the container first.

• Monitor or test the air quality at the site as needed.

• Consult with a local expert to implement a site plan to make sure air

quality is safe.

SC-8 Safety and Compliance

English

Safety

A PLASMA ARC CAN CAUSE INJURY AND BURNS

Instant-on torches

The plasma arc will cut quickly through gloves and skin.

• Keep away from the torch tip.

A plasma arc ignites immediately when the torch switch is activated.

• Do not hold metal near the cutting path.

• Never point the torch toward yourself or others.

ARC RAYS CAN BURN EYES AND SKIN

Minimum protective

Suggested shade

OSHA 29CFR

Europe

Arc current

shade number

number for comfort

1910.133(a)(5)

EN168:2002

(ANSIZ49.1:2012)

(ANSI Z49.1:2012)

Less than 40 A 5 5 8 9

41 A to 60 A 6 6 8 9

61 A to 80 A 8 8 8 9

81 A to 125 A 8 9 8 9

126 A to 150 A 8 9 8 10

151 A to 175 A 8 9 8 11

176 A to 250 A 8 9 8 12

251 A to 300 A 8 9 8 13

301 A to 400 A 9 12 9 13

401 A to 800 A101410N/A

PACEMAKER AND HEARING AID OPERATION

Pacemaker and hearing aid operation can be affected by magnetic

To reduce magnetic field hazards:

fields from high currents.

• Keep both the work lead and the torch lead to one side, away from

your body.

Pacemaker and hearing aid wearers should consult a doctor before

• Route the torch leads as close as possible to the work lead.

going near any plasma arc cutting and gouging operations.

• Do not wrap or drape the torch lead or work lead around your body.

• Keep as far away from the power supply as possible.

Safety and Compliance SC-9

English

Environmental Stewardship

Proper handling and safe use of chemicals

Chemical Regulations in the USA, Europe, and other locations require

that Material Safety Data Sheets (MSDS) be made available for all

chemicals. The list of chemicals is provided by Hypertherm. The MSDS

are for chemicals provided with the product and other chemicals used in

or on the product. MSDS can be downloaded from the Downloads

Library on the Hypertherm web site at https://www.hypertherm.com

.

On the Search screen, insert MSDS in the document title and click on

Search.

In the USA, OSHA does not require Material Safety Data Sheets for

articles such as electrodes, swirl rings, retaining caps, nozzles, shields,

deflectors and other solid parts of the torch.

Hypertherm does not manufacture or provide the materials that are cut

and has no knowledge whether the fumes released from materials that

are cut will pose a physical hazard or health risk. Please consult with your

supplier or other technical advisor if you need guidance concerning the

properties of the material you will cut using a Hypertherm product.

Fumes emission and air quality

Note: The following information on air quality is intended for general

information only and should not be used as a substitute for reviewing and

implementing applicable government regulations or legal standards in

the country where the cutting equipment will be installed and operated.

In the USA, the National Institute for Occupational Safety and Health

(NIOSH) Manual of Analytical Methods (NMAM) is a collection of

methods for sampling and analyzing contaminants in workplace air.

Methods published by others, such as OSHA, MSHA, EPA, ASTM, ISO

or commercial suppliers of sampling and analytical equipment, may have

advantages over NIOSH methods.

For example, ASTM Practice D 4185 is a standard practice for the

collection, dissolution, and determination of trace metals in workplace

atmospheres. The sensitivity, detection limit, and optimum working

concentrations for 23 metals are listed in ASTM D 4185. An industrial

hygienist should be used to determine the optimum sampling protocol,

considering analytical accuracy, cost, and optimum sample number.

Hypertherm uses a third party industrial hygienist to perform and interpret

air quality testing results taken by air sampling equipment positioned at

operator stations in Hypertherm buildings where plasma cutting tables

are installed and operated.

Where applicable, Hypertherm also uses a third party industrial hygienist

to obtain air and water permits.

If you are not fully aware and up to date on all applicable government

regulations and legal standards for the installation site, you should

consult a local expert prior to purchasing, installing, and operating the

equipment.

SC-16 Safety and Compliance

English