SAFETY
HYPERTHERM Plasma Systems
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• Never use a cylinder that is not upright and secured
in place.
• Never move or transport a cylinder without its
protective valve cover in place.
• Never use a gas cylinder or its contents for any
purpose other than that for which it is intended.
• Never lubricate cylinder valves with oil or grease.
• Never allow electrical contact between the plasma arc
and a cylinder.
• Never expose cylinders to excessive heat, sparks,
slag or open flame.
• Never use hammers, wrenches or other tools to open
stuck cylinder valves.
Pressure Regulators
• Be certain that all pressure regulators are in proper
working condition.
• Never use a regulator for any gas other than that for
which it is intended.
• Never use a regulator that leaks, creeps excessively
or is physically damaged in any way.
• Never attempt to lubricate a regulator with oil or
grease.
WARNING —
Hydrogen Detonation
with Aluminum Cutting
When cutting aluminum underwater, or with the
water touching the underside of the aluminum,
free hydrogen gas may collect under the
workpiece and detonate during plasma cutting
operations.
Installing an aeration manifold on the floor of the
water table is an effective way to eliminate the
possibility of hydrogen detonation when cutting
aluminum. Refer to the Appendix section of this
manual for instructions on how to fabricate an
aeration manifold.
Hoses
• Label and color-code all gas hoses in order to clearly
identify the type of gas in each hose. Consult
applicable national or local codes.
• Never use the oxygen hose for any gas other than
oxygen.
• Examine hoses at regular intervals for leaks, wear,
loose connections or other hazard.
• Replace hose that is damaged in any way.
Electric Shock Prevention (continued)
• Before changing the torch parts, disconnect the main
power or unplug the power supply. After changing
torch parts and replacing the retaining cap, plug in the
power supply again.
• Never bypass or shortcut the safety interlocks.
• Before removing a power supply cover for
maintenance, disconnect the main power at the wall
disconnect switch or unplug the power supply. To
avoid exposure to severe electrical hazard, wait five
minutes after disconnecting the main power to allow
capacitors to discharge.
• Never operate the plasma system unless the power
supply unit covers are in place. Exposed power
supply connections present a severe electrical
hazard.
Explosion Prevention
WARNING —
Compressed Gas
The plasma system uses compressed gas.
Observe proper precautions when handling and
using compressed gas equipment and cylinders.
• Do not use the plasma system if explosive dust or
vapors may be present.
• Do not cut pressurized cylinders or any closed
container.
WARNING —
Hydrogen Explosion Hazard
If your system uses hydrogen, remember that this
is a flammable gas that presents an explosion
hazard. Keep flames away from cylinders
containing hydrogen mixtures and hoses that
carry hydrogen mixtures. Also, keep flames and
sparks away from the torch when using argon-
hydrogen as the plasma gas.
Compressed Gas Cylinders
Handle and use compressed gas cylinders in accor-
dance with safety standards published by the U.S.
Compressed Gas Association (CGA), American Weld-
ing Society (AWS), Canadian Standards Association
(CSA) or applicable national or local codes.
• Never use a cylinder that leaks or is physically
damaged.
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