Safety considerations for preventive maintenance

Before you start maintenance tasks, make sure to read, understand, and comply with all safety instructions.

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

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

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

ELECTRIC SHOCK CAN KILL

Disconnect electric power before doing installation or maintenance. The line-disconnect switch must STAY in the OFF position until all of the installation or maintenance steps are complete. Refer to the Safety and Compliance Manual (80669C) for more safety information.

Warning

ELECTRIC SHOCK CAN KILL

Voltages at the terminal block and contactors can cause injury or death.

When the line-disconnect switch is in the ON position, there is line voltage at the contactor and the power distribution Printed Circuit Board (PCB). Use extreme caution when you measure the primary power in these areas.

Warning

MACHINE MOTION CAN CAUSE INJURY

The end-use customer and the cutting machine supplier are responsible for providing protection against the hazardous moving parts of this cutting system. Read and follow the instruction manual provided by the cutting machine supplier. 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

INCORRECT SUPPLY-GAS CONNECTIONS CAN CAUSE AN EXPLOSION OR FIRE

An explosion or fire can occur if a supply-gas hose is connected to the wrong port on a gas connect console.

NEVER connect a supply gas to a hose, connection, or fitting that is not designed for that gas type or pressure.

Warning

MISSING CHECK VALVES CAN CAUSE AN EXPLOSION OR FIRE

An explosion or fire can occur if the cutting system is operated without check valves.

Never remove a check valve.

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.

CAUTION

WET FLOOR

If you put too much coolant in the reservoir, the coolant can spill onto the floor. Coolant can cause floors to become slippery.

Be careful not to put too much coolant in the reservoir.

CAUTION

MOVING BLADES CAN CAUSE INJURY

Keep your hands away from moving parts.

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.

Notice

USE THE CORRECT COOLANT

If you use an incorrect coolant, it can cause damage to the cutting system.

Refer to the coolant requirement specifications for your plasma cutting system.

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

INCORRECT HOSES, CONNECTIONS, OR FITTINGS CAN CAUSE DAMAGE AND BAD PERFORMANCE

Noncompliant hoses, hose connections, or hose fittings can crack or leak. Incorrect fittings can cause malfunctions with the internal valves because contaminants can enter the valves through damaged or loose fittings.

All hoses, hose connections, and hose fittings used for supply-gas plumbing must be designed for use with the appropriate gas and pressure rating. NEVER connect a supply gas to a hose, connection, or fitting that is not designed for that gas type or pressure. A replacement hose, connection, or fitting must meet all applicable regulations and codes.

Notice

INCORRECT SUPPLY-GAS FITTINGS CAN CAUSE VALVES TO MALFUNCTION

If you alter or replace the fittings, it can cause the internal valves to malfunction if particulates get inside.

Do not change or replace the supply-gas fittings on the gas connect console.

Notice

INCORRECT SUPPLY-GAS CONNECTIONS CAN CAUSE CUTTING SYSTEM DAMAGE

Incorrect connections can reduce the life of consumables and cause damage to the torch head, torch receptacle, torch leads, and torch connect console.

NEVER connect a supply gas to a hose, connection, or fitting that is not designed for that gas type or pressure.

Notice

INCORRECT SUPPLY-GAS CONNECTIONS CAN CAUSE BAD PERFORMANCE

Cutting system performance can be bad if a supply-gas hose is connected to the wrong port on a gas connect console.

NEVER connect a supply gas to a hose, connection, or fitting that is not designed for that gas type or pressure.

Notice

INCORRECT GAS PRESSURES CAN CAUSE BAD PERFORMANCE

Gas leaks or pressure and flow rates that are outside of recommended ranges can cause problems with system performance, result in bad cut quality, and shorten the life of consumables.

If the quality of the gas is bad or if the pressure setting is incorrect, it can decrease cut quality, cut speed, and cut thickness capabilities.

Make sure the incoming gas pressure aligns with system specifications.

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.

Notice

A LOOSE OR OVERTIGHTENED ELECTRODE CAN CAUSE DAMAGE TO THE TORCH

If you do not correctly install and tighten the electrode, torch damage can occur.

A tool is necessary to correctly install and tighten the torch electrode. Do not use your hands. Hypertherm® recommends tightening the electrode to a torque value of 2.3 N∙m – 2.8 N∙m (20 lbf∙in – 25 lbf∙in).