Before you begin installation

Before you begin installation, make sure to:

Read, understand, and obey all of the safety instructions that are in this manual, the Safety and Compliance Manual (80669C), the Radio Frequency Warning Manual (80945C), and affixed to the cutting system. Failure to follow safety instructions can result in personal injury or equipment damage.
Get all necessary reference documents. Refer to Document requirements.
Understand and obey the following requirements when planning where to put system components:
Understand and obey all applicable national and local codes and system requirements:

This plasma system can make more than the permitted acoustical noise levels as defined by national and local codes. Always put on correct ear protection when cutting or gouging. Any acoustical noise measurements taken are related to the specific environment in which the system is used. Refer to Noise can damage hearing in the Safety and Compliance Manual (80669C).

In addition, you can find an Acoustical Noise Data Sheet for your system at www.hypertherm.com/docs. In the search box, enter data sheet.

Warning

ELECTRIC SHOCK CAN KILL

If the line-disconnect switch is not in the OFF position you can get a serious electric shock. Electric shock can seriously injure or kill you.

The line-disconnect switch must be in the OFF position before you connect the power cord to the cutting system. It must REMAIN in the OFF position until all installation steps are complete. In the United States, use a "lock out/tag out" procedure until installation is complete. In other countries, follow the appropriate national and local safety procedures. Refer to the Safety and Compliance Manual (80669C) for more safety information.

Warning

ELECTRIC SHOCK CAN KILL

Voltages in the cutting system can cause serious electric shock. Electric shock can seriously injure or kill you.

When the line-disconnect switch is in the ON position, there is line voltage throughout the cutting system. Use extreme caution if you do diagnosis or maintenance tasks when the line-disconnect switch is in the ON position.

Warning

ELECTRIC SHOCK CAN KILL

The plasma power supply contains dangerous electric voltages that can seriously injure or kill you. Even if the plasma power supply is turned OFF, you can still get a serious electric shock if the plasma power supply remains connected to an electric power source.

Use extreme caution if you do diagnosis or maintenance tasks when the plasma power supply remains connected to an electric power source and the outer cover or panels are removed. All work that requires removal of the plasma power supply outer cover or panels must be done by a qualified technician. Refer to the Safety and Compliance Manual (80669C) for more safety information.

Warning

HYDROGEN GAS CAN CAUSE AN EXPLOSION OR FIRE

Hydrogen is a flammable gas that can cause an explosion or fire if it is not removed.

Keep flames away from cylinders and hoses that contain hydrogen. Keep flames and sparks away from the torch when using hydrogen as a plasma gas.

Consult your local safety, fire, and building code requirements for the storage and use of hydrogen.

Hypertherm recommends that you install an exhaust ventilation system to remove the hydrogen-enriched atmosphere that can collect when hydrogen is used as the plasma gas for cutting.

Flashback arrestors are REQUIRED to stop the spread of fire to the supply gases (unless a flashback arrestor is not available for a specific gas or pressure).

As an installer or user, you must supply the exhaust ventilation and flashback arrestors for your cutting system. You can get them from your cutting machine supplier.

Warning

OXYGEN GAS CAN CAUSE A FIRE HAZARD

If you use oxygen as the plasma gas for cutting, it can cause a potential fire hazard due to the oxygen-enriched atmosphere that collects. A fire can occur if oxygen is not removed.

Hypertherm recommends that you install an exhaust ventilation system to remove the oxygen-enriched atmosphere that can collect when oxygen is used as the plasma gas for cutting.

Flashback arrestors are REQUIRED to stop the spread of fire to the supply gases (unless a flashback arrestor is not available for a specific gas or pressure).

As an installer or user, you must supply the exhaust ventilation and flashback arrestors for your cutting system. You can get them from your cutting machine supplier.

Warning

COOLANT CAN BE IRRITATING TO SKIN AND EYES AND HARMFUL OR FATAL IF SWALLOWED

Propylene glycol and benzotriazole are irritating to skin and eyes, and harmful or fatal if swallowed.

When you come into contact, flush skin or eyes with water. If swallowed, seek immediate medical attention.

Notice

AUTOMOTIVE ANTIFREEZE CAN CAUSE DAMAGE TO THE TORCH COOLANT SYSTEM

Antifreeze contains chemicals that can cause damage to the torch coolant system.

Never use automotive antifreeze as an alternative to Hypertherm coolant.

Notice

LOW COOLANT LEVELS CAN DAMAGE THE CUTTING SYSTEM AND COOLANT PUMP

There is a risk of serious damage to the cutting system and to the coolant pump if you operate the cutting system with no coolant or with low coolant. If your coolant pump is damaged, pump replacement can be necessary.

Never operate the cutting system if you get a low coolant level notice.

CAUTION

INCORRECT COOLANT CAN DAMAGE THE CUTTING SYSTEM

Using incorrect coolant can cause damage to the plasma cutting system.

Refer to Coolant requirements.

Notice

PTFE TAPE CAN CAUSE CLOGGED VALVES, REGULATORS, AND TORCHES

Never use PTFE tape on any joint preparation. Use only a liquid or paste thread sealant on male thread ends.

Notice

DIRTY, OILY AIR CAN CAUSE DAMAGE TO THE AIR FILTER BOWL

Some air compressors use synthetic lubricants that contain esters. Esters can cause damage to the polycarbonates in the air filter bowl.

Add more gas filtration if necessary.

Notice

FOR THE BEST CUT QUALITY AND CONSUMABLE LIFE USE THE CORRECT LEAD LENGTHS

Cut quality and the lifespan of consumables will be decreased if you change the lead lengths.

The manufactured lengths of torch and console leads are critical for system performance. Never change the lengths of leads.