Plasma Arc

Cutting & Gouging System

Operator Manual
804480 Revision 3

AMPS

60
40

30
80

100

AC V

50
60 PSI
70
80

4.0
5.0
6.0
BAR

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+
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 Operator Manual

(P/N 804480)

Revision 3 – September 2009

Hypertherm, Inc.
Hanover, NH USA
www.hypertherm.com

© Copyright 2009 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.
Hypertherm, Inc. Hypertherm Europe B.V.
Etna Road, P.O. Box 5010 Vaartveld 9
Hanover, NH 03755 USA 4704 SE
603-643-3441 Tel (Main Office) Roosendaal, Nederland
603-643-5352 Fax (All Departments) 31 165 596907 Tel
[email protected] (Main Office Email) 31 165 596901 Fax
800-643-9878 Tel (Technical Service) 31 165 596908 Tel (Marketing)
[email protected] (Technical Service Email) 31 165 596900 Tel (Technical Service)
800-737-2978 Tel (Customer Service) 00 800 4973 7843 Tel (Technical Service)
[email protected] (Customer Service Email)
Hypertherm Japan Ltd.
Hypertherm Automation 801 Samty Will Building
5 Technology Drive, Suite 300 2-40 Miyahara 1-Chome,
West Lebanon, NH 03784 USA Yodogawa-ku, Osaka
603-298-7970 Tel 532-0003, Japan
603-298-7977 Fax 81 6 6170 2020 Tel
81 6 6170 2015 Fax
Hypertherm Plasmatechnik GmbH
Technologiepark Hanau Hypertherm Brasil Ltda.
Rodenbacher Chaussee 6 Avenida Doutor Renato de
D-63457 Hanau-Wolfgang, Deutschland Andrade Maia 350
49 6181 58 2100 Tel Parque Renato Maia
49 6181 58 2134 Fax CEP 07114-000
49 6181 58 2123 (Technical Service) Guarulhos, SP Brasil
55 11 2409 2636 Tel
Hypertherm (S) Pte Ltd. 55 11 2408 0462 Fax
82 Genting Lane
Media Centre Hypertherm México, S.A. de C.V.
Annexe Block #A01-01 Avenida Toluca No. 444, Anexo 1,
Singapore 349567, Republic of Singapore Colonia Olivar de los Padres
65 6841 2489 Tel Delegación Álvaro Obregón
65 6841 2490 Fax México, D.F. C.P. 01780
65 6841 2489 (Technical Service) 52 55 5681 8109 Tel
52 55 5683 2127 Fax
Hypertherm (Shanghai) Trading Co., Ltd.
Unit A, 5th Floor, Careri Building
432 West Huai Hai Road
Shanghai, 200052
PR China
86-21 5258 3330/1 Tel
86-21 5258 3332 Fax

7/1/09
 ELECTROMAGNETIC COMPATIBILITY (EMC)

EMC Introduction b. Radio and television transmitters and

receivers.
Hypertherm’s CE-marked equipment is built in
compliance with standard EN60974-10. The c. Computer and other control equipment.
equipment should be installed and used in d. Safety critical equipment, for example
accordance with the information below to guarding of industrial equipment.
achieve electromagnetic compatibility.
e. Health of the people around, for example the
use of pacemakers and hearing aids.
The limits required by EN60974-10 may not
be adequate to completely eliminate interfer- f. Equipment used for calibration or
ence when the affected equipment is in close measurement.
proximity or has a high degree of sensitivity. g. Immunity of other equipment in the
In such cases it may be necessary to use other environment. User shall ensure that other
measures to further reduce interference. equipment being used in the environment is
compatible. This may require additional
This cutting equipment is designed for use protection measures.
only in an industrial environment.
h. Time of day that cutting or other activities
are to be carried out.
Installation and use
The user is responsible for installing and The size of the surrounding area to be con-
using the plasma equipment according to the sidered will depend on the structure of the
manufacturer’s instructions. If electromagnetic building and other activities that are taking
disturbances are detected then it shall be the place. The surrounding area may extend
responsibility of the user to resolve the beyond the boundaries of the premises.
situation with the technical assistance of the
manufacturer. In some cases this remedial Methods of reducing
action may be as simple as earthing the
cutting circuit, see Earthing of Workpiece.
emissions
In other cases it could involve constructing an Mains supply
electromagnetic screen enclosing the power
source and the work complete with associated Cutting equipment must be connected to the
input filters. In all cases electromagnetic mains supply according to the manufacturer’s
disturbances must be reduced to the point recommendations. If interference occurs, it may
where they are no longer troublesome. be necessary to take additional precautions
such as filtering of the mains supply.
Consideration should be given to shielding the
Assessment of area supply cable of permanently installed cutting
Before installing the equipment the user shall equipment, in metallic conduit or equivalent.
make an assessment of potential electro- Shielding should be electrically continuous
magnetic problems in the surrounding area. throughout its length. The shielding should
The following shall be taken into account: be connected to the cutting mains supply so
that good electrical contact is maintained
a. Other supply cables, control cables, between the conduit and the cutting power
signalling and telephone cables; above, source enclosure.
below and adjacent to the cutting equipment.

Hypertherm i
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ELECTROMAGNETIC COMPATIBILITY (EMC)

Maintenance of cutting equipment workpiece to earth should be made by a direct

connection to the workpiece, but in some
The cutting equipment must be routinely countries where direct connection is not
maintained according to the manufacturer’s permitted, the bonding should be achieved by
recommendations. All access and service doors suitable capacitances selected according to
and covers should be closed and properly national regulations.
fastened when the cutting equipment is in
operation. The cutting equipment should not be Note: the cutting circuit may or may not be
modified in any way except for those changes earthed for safety reasons. Changing the
and adjustments covered in the manufacturer’s earthing arrangements should only be
instructions. In particular, the spark gaps of arc authorized by a person who is competent to
striking and stabilizing devices should be assess whether the changes will increase the
adjusted and maintained according to the risk of injury, for example, by allowing parallel
manufacturer’s recommendations. cutting current return paths which may damage
the earth circuits of other equipment. Further
Cutting cables guidance is given in IEC/ TS 62081 Arc
Welding Equipment Installation and Use.
The cutting cables should be kept as short
as possible and should be positioned close
together, running at or close to the floor level. Screening and shielding
Selective screening and shielding of other
Equipotential bonding cables and equipment in the surrounding area
may alleviate problems of interference.
Bonding of all metallic components in the
Screening of the entire plasma cutting
cutting installation and adjacent to it should be
installation may be considered for special
considered. However, metallic components
applications.
bonded to the workpiece will increase the risk
that the operator could receive a shock by
touching these metallic components and the
electrode (nozzle for laser heads) at the same
time. The operator should be insulated from all
such bonded metallic components.

Earthing of workpiece
Where the workpiece is not bonded to earth
for electrical safety, nor connected to earth
because of its size and position, for example,
ship’s hull or building steelwork, a connection
bonding the workpiece to earth may reduce
emissions in some, but not all instances.
Care should be taken to prevent the earthing
of the workpiece increasing the risk of injury to
users, or damage to other electrical equipment.
Where necessary, the connection of the

ii Hypertherm
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 WARRANTY

Attention costs, insurance and freight prepaid.

Hypertherm shall not be liable for any repairs,
Genuine Hypertherm parts are the factory-
replacement, or adjustments of Products
recommended replacement parts for your
Hypertherm system. Any damage caused by the covered by this warranty, except those made
use of other than genuine Hypertherm parts may pursuant to this paragraph or with Hypertherm’s
not be covered by the Hypertherm warranty. prior written consent. The warranty above is
exclusive and is in lieu of all other
You are responsible for the safe use of the warranties, express, implied, statutory, or
Product. Hypertherm does not and cannot make otherwise with respect to the Products or
any guarantee or warranty regarding the safe as to the results which may be obtained
use of the Product in your environment. therefrom, and all implied warranties or
conditions of quality or of merchantability
General or fitness for a particular purpose or
Hypertherm, Inc. warrants that its Products shall against infringement. The foregoing shall
be free from defects in materials and workman- constitute the sole and exclusive remedy
ship, if Hypertherm is notified of a defect (i) with for any breach by Hypertherm of its
respect to the power supply within a period of warranty. Distributors/OEMs may offer different
two (2) years from the date of its delivery to you, or additional warranties, but Distributors/OEMs
with the exception of Powermax brand power are not authorized to give any additional
supplies, which shall be within a period of three warranty protection to you or make any
(3) years from the date of delivery to you, and representation to you purporting to be binding
(ii) with respect to the torch and leads within a upon Hypertherm.
period of one (1) year from its date of delivery to
you, and with respect to torch lifter assemblies Certification test marks
within a period of one (1) year from its date of Certified products are identified by one or more
delivery to you, and with respect to laser heads certification test marks from accredited testing
within a period of one (1) year from its date of laboratories. The certification test marks are
delivery to you. This warranty shall not apply to located on or near the data plate. Each
any Powermax brand power supplies that have certification test mark means that the product
been used with phase converters. In addition, and its safety-critical components conform to
Hypertherm does not warranty systems that the relevant national safety standards as
have been damaged as a result of poor power reviewed by that testing laboratory. Hypertherm
quality, whether from phase converters or places a certification test mark on its products
incoming line power. This warranty shall not only after that product is manufactured with
apply to any Product which has been incorrectly safety-critical components that have been
installed, modified, or otherwise damaged. authorized by the accredited testing laboratory.
Hypertherm, at its sole option, shall repair, Once the product has left the Hypertherm
replace, or adjust, free of charge, any defective factory, the certification test marks are
Products covered by this warranty which shall invalidated if any of the following occurs:
be returned with Hypertherm’s prior • The product is significantly modified
authorization (which shall not be unreasonably in a manner that creates a hazard or
withheld), properly packed, to Hypertherm’s non-conformance.
place of business in Hanover, New Hampshire, • Safety-critical components are replaced with
or to an authorized Hypertherm repair facility, all unauthorized spare parts.

Hypertherm iii
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WARRANTY

• Any unauthorized assembly or accessory that It is important that the product and its
uses or generates a hazardous voltage is certification test mark be suitable for the end-
added. use installation site. When Hypertherm
• There is any tampering with a safety circuit or products are shipped to one country for export
other feature that is designed into the product to another country, the product must be
as part of the certification. configured and certified properly for the end-
use site.
CE marking constitutes a manufacturer’s
declaration of conformity to applicable European
directives and standards. Only those versions of
Higher-level systems
Hypertherm products with a CE Marking located When a system integrator adds additional
on or near the data plate have been tested for equipment; such as cutting tables, motor drives,
compliance with the European Low Voltage motion controllers or robots; to a Hypertherm
Directive and the European EMC Directive. plasma cutting system, the combined system
EMC filters needed to comply with the European may be considered a higher-level system. A
EMC Directive are incorporated within versions higher-level system with hazardous moving parts
of the power supply with a CE Marking. may constitute industrial machinery or robotic
equipment, in which case the OEM or end-use
customer may be subject to additional
Differences in National Standards
regulations and standards than those relevant to
Differences in standards include, but are not the plasma cutting system as manufactured by
limited to: Hypertherm.
• Voltages It is the responsibility of the end-use customer
• Plug and cord ratings and the OEM to perform a risk assessment for
• Language requirements the higher-level system and to provide
• Electromagnetic compatibility requirements protection against hazardous moving parts.
Unless the higher-level system is certified when
These differences in national standards may the OEM incorporates Hypertherm products
make it impossible or impractical for all into it, the installation also may be subject to
certification test marks to be placed on the approval by local authorities. Seek advice from
same version of a product. For example, the legal counsel and local regulatory experts if
CSA versions of Hypertherm’s products do not uncertain about compliance.
comply with European EMC requirements and
they do not have a CE marking on the data External interconnecting cables between
plate. component parts of the higher level system
must be suitable for contaminants and
Countries that require CE marking or have movement as required by the final end-use
compulsory EMC regulations must use CE installation site. When the external inter-
versions of Hypertherm products with the CE connecting cables are subject to oil, dust, or
marking on the data plate. These include: water contaminants, hard usage ratings may be
• Australia required. When external interconnecting cables
• New Zealand are subject to continuous movement, constant
flexing ratings may be required. It is the
• Countries in the European Union responsibility of the end-use customer or the
• Russia OEM to ensure the cables are suitable for the
application. Since there are differences in the

iv Hypertherm
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 WARRANTY

ratings and costs that can be required by use of the Products exceed in the aggregate
local regulations for higher-level systems, the amount paid for the Products that gave
it is necessary to verify that any external rise to such claim.
interconnecting cables are suitable for the
end-use installation site. Insurance
At all times you will have and maintain insurance
Patent indemnity in such quantities and types, and with coverage
Except only in cases of products not sufficient and appropriate to defend and to hold
manufactured by Hypertherm or manufactured Hypertherm harmless in the event of any cause
by a person other than Hypertherm not in strict of action arising from the use of the Products.
conformity with Hypertherm’s specifications and
in cases of designs, processes, formulae, or National and Local codes
combinations not developed or purported to be National and Local codes governing plumbing
developed by Hypertherm, Hypertherm will and electrical installation shall take precedent
defend or settle, at its own expense, any suit or over any instructions contained in this manual.
proceeding brought against you alleging that the In no event shall Hypertherm be liable for injury
use of the Hypertherm product, alone and not in to persons or property damage by reason of
combination with any other product not supplied any code violation or poor work practices.
by Hypertherm, infringes any patent of any third
party. You shall notify Hypertherm promptly upon Transfer of rights
learning of any action or threatened action in You may transfer any remaining rights you may
connection with any such alleged infringement, have hereunder only in connection with the sale
and Hypertherm’s obligation to indemnify shall of all or substantially all of your assets or capital
be conditioned upon Hypertherm’s sole control stock to a successor in interest who agrees to
of, and the indemnified party’s cooperation and be bound by all of the terms and conditions of
assistance in, the defense of the claim. this Warranty.
Limitation of liability Proper disposal of
In no event shall Hypertherm be liable to Hypertherm products
any person or entity for any incidental,
consequential, indirect, or punitive damages Hypertherm plasma cutting systems, like all
(including but not limited to lost profits) electronic products, may contain materials or
regardless of whether such liability is based components, such as printed circuit boards, that
on breach of contract, tort, strict liability, cannot be discarded with ordinary waste. It is
breach of warranties, failure of essential your responsibility to dispose of any Hypertherm
purpose or otherwise and even if advised product or component part in an environmentally
of the possibility of such damages. acceptable manner according to national and
local codes.
Liability cap • In the United States, check all federal, state,
In no event shall Hypertherm’s liability, and local laws.
whether such liability is based on breach
• In the European Union, check the EU
of contract, tort, strict liability, breach of
directives, national, and local laws. For more
warranties, failure of essential purpose or
information, visit www.hypertherm.com/weee.
otherwise, for any claim action suit or
proceeding arising out of or relating to the • In other countries, check national and local
laws.

Hypertherm v
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WARRANTY

vi Hypertherm
 TABLE OF CONTENTS

Electromagnetic compatibility................................................................................................................................i
Warranty....................................................................................................................................................................iii

Section 1 Safety
Recognize safety information ...........................................................................................................................1-2
Follow safety instructions..................................................................................................................................1-2
Cutting can cause fire or explosion ................................................................................................................1-2
Electric shock can kill.........................................................................................................................................1-3
Static electricity can damage circuit boards ................................................................................................1-3
Toxic fumes can cause injury or death............................................................................................................1-4
A plasma arc can cause injury and burns......................................................................................................1-5
Arc rays can burn eyes and skin......................................................................................................................1-5
Grounding safety.................................................................................................................................................1-6
Compressed gas equipment safety................................................................................................................1-6
Gas cylinders can explode if damaged..........................................................................................................1-6
Noise can damage hearing ...............................................................................................................................1-7
Pacemaker and hearing aid operation............................................................................................................1-7
A plasma arc can damage frozen pipes.........................................................................................................1-7
Additional safety information ............................................................................................................................1-8
Warning labels .....................................................................................................................................................1-9
Dust collection information.............................................................................................................................1-11

Section 1a Sécurité
Identifier les consignes de sécurité ..............................................................................................................1a-2
Suivre les instructions de sécurité ................................................................................................................1a-2
Le coupage peut provoquer un incendie ou une explosion ....................................................................1a-2
Les chocs électriques peuvent être fatals ..................................................................................................1a-3
L’électricité statique peut endommager les cartes de circuits imprimés .............................................1a-3
Les vapeurs toxiques peuvent provoquer des blessures ou la mort .....................................................1a-4
L’arc plasma peut provoquer des blessures ou des brûlures .................................................................1a-5
Les rayons de l’arc peuvent brûler les yeux et la peau.............................................................................1a-5
Mise à la masse et à la terre...........................................................................................................................1a-6
Sécurité des bouteilles de gaz comprimé...................................................................................................1a-6
Les bouteilles de gaz comprimé peuvent exploser en cas de dommages ..........................................1a-6
Le bruit peut provoquer des problèmes auditifs ........................................................................................1a-7
Pacemakers et prothèses auditives ..............................................................................................................1a-7
Un arc plasma peut endommager les tuyaux gelés...................................................................................1a-7
Symboles et marquage....................................................................................................................................1a-8
Étiquette de sécurité ........................................................................................................................................1a-9
Information sur le dépoussiérage ...............................................................................................................1a-11

Section 1b Seguridad
Reconocimiento de información de seguridad ..........................................................................................1b-2
Siga las instrucciones de seguridad ............................................................................................................1b-2
Los cortes pueden provocar incendios o explosiones ............................................................................1b-2

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TABLE OF CONTENTS

El choque eléctrico puede provocar la muerte..........................................................................................1b-3

Electricidad estática puede dañar tablillas de circuito ............................................................................1b-3
Humos tóxicos pueden causar lesiones o muerte....................................................................................1b-4
El arco de plasma puede causar lesiones y quemaduras.......................................................................1b-5
Los rayos del arco pueden producir quemaduras en los ojos y en la piel ..........................................1b-5
Seguridad de toma a tierra.............................................................................................................................1b-6
Seguridad de los equipos de gas comprimido..........................................................................................1b-6
Los cilindros de gas pueden explotar si están dañados .........................................................................1b-6
El ruido puede deteriorar la audición ...........................................................................................................1b-7
Operación de marcapasos y de audífonos.................................................................................................1b-7
Un arco plasma puede dañar tubos congelados ......................................................................................1b-7
Símbolos y marcas ...........................................................................................................................................1b-8
Etiquetas de advertencia ................................................................................................................................1b-9
Información sobre la colección de polvo seco........................................................................................1b-11

Section 2 Specifications
Power supply ......................................................................................................................................................2-2
Duty cycle...................................................................................................................................................2-3
Dimensions and weight...........................................................................................................................2-3
T100 torches ......................................................................................................................................................2-4
Torch dimensions......................................................................................................................................2-5
Symbols and markings.......................................................................................................................................2-6
S mark........................................................................................................................................................2-6
CE mark ......................................................................................................................................................2-6
IEC symbols used ....................................................................................................................................2-6

Section 3 Setup
Upon receipt.........................................................................................................................................................3-2
Claims ....................................................................................................................................................................3-2
Contents of box ...................................................................................................................................................3-2
Lifting the power supply ....................................................................................................................................3-3
Locating power supply.......................................................................................................................................3-4
Power connection ...............................................................................................................................................3-4
Engine drives .............................................................................................................................................3-5
Grounding ............................................................................................................................................................3-6
Power cords .........................................................................................................................................................3-6
Three-phase power cord – plug installation..................................................................................................3-7
Power cord installation ............................................................................................................................3-7
Plug installation .........................................................................................................................................3-7
Torch installation..................................................................................................................................................3-8
Plasma gas supply ..........................................................................................................................................3-10
Additional gas filtration .........................................................................................................................3-10
Gas supply installation ....................................................................................................................................3-11
T100M-2 torch alignment ...............................................................................................................................3-11

viii powermax1650 Operator Manual

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 TABLE OF CONTENTS

ON/OFF pendant connection .......................................................................................................................3-12

Machine interface connection .............................................................................................................3-12
Arc voltage...............................................................................................................................................3-13
Changing XFER (start machine motion) from dry contact closure to voltage signal.............3-15

Section 4 Operation
Controls and indicators .....................................................................................................................................4-2
Indicator LEDs...........................................................................................................................................4-2
Install the consumables .....................................................................................................................................4-3
T100 consumable configurations....................................................................................................................4-4
Shielded......................................................................................................................................................4-4
Unshielded .................................................................................................................................................4-4
FineCut........................................................................................................................................................4-4
Gouging ......................................................................................................................................................4-5
T100M-2 consumable configurations ............................................................................................................4-5
Shielded......................................................................................................................................................4-5
FineCut........................................................................................................................................................4-6
Ohmic sensing retaining cap .................................................................................................................4-6
Unshielded .................................................................................................................................................4-6
Set the mode switch...........................................................................................................................................4-7
Turn ON the power .............................................................................................................................................4-7
Check the indicator lights..................................................................................................................................4-7
Adjust the gas pressure and current setting ................................................................................................4-8
Hand torch operation .........................................................................................................................................4-9
Safety trigger operation ..........................................................................................................................4-9
Attach the work clamp ..........................................................................................................................4-10
Start a cut from the edge of the workpiece .....................................................................................4-10
Hand torch cutting technique..............................................................................................................4-11
Piercing ....................................................................................................................................................4-12
Gouging ...................................................................................................................................................4-13
Cut charts...........................................................................................................................................................4-14

Section 5 Maintenance and parts

Routine maintenance..........................................................................................................................................5-2
Inspect the consumables........................................................................................................................5-3
Filter element replacement .....................................................................................................................5-4
Controls and indicators .....................................................................................................................................5-5
Basic troubleshooting ........................................................................................................................................5-6
System circuit diagram ......................................................................................................................................5-9
Technical questions..........................................................................................................................................5-10
Parts.....................................................................................................................................................................5-10
Torch parts ...............................................................................................................................................5-10
Power supply parts ................................................................................................................................5-11
Accessories.............................................................................................................................................5-11

powermax1650 Operator Manual ix

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TABLE OF CONTENTS

x powermax1650 Operator Manual

0
 Section 1

SAFETY

In this section:

Recognize safety information ...........................................................................................................................1-2

Follow safety instructions..................................................................................................................................1-2
Cutting can cause fire or explosion ................................................................................................................1-2
Electric shock can kill.........................................................................................................................................1-3
Static electricity can damage circuit boards ................................................................................................1-3
Toxic fumes can cause injury or death............................................................................................................1-4
A plasma arc can cause injury and burns......................................................................................................1-5
Arc rays can burn eyes and skin......................................................................................................................1-5
Grounding safety.................................................................................................................................................1-6
Compressed gas equipment safety................................................................................................................1-6
Gas cylinders can explode if damaged..........................................................................................................1-6
Noise can damage hearing ...............................................................................................................................1-7
Pacemaker and hearing aid operation............................................................................................................1-7
A plasma arc can damage frozen pipes.........................................................................................................1-7
Additional safety information.............................................................................................................................1-7
Symbols and markings.......................................................................................................................................1-8
Warning labels .....................................................................................................................................................1-9
Dry dust collection information......................................................................................................................1-11

Hypertherm 1-1
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SAFETY

RECOGNIZE SAFETY INFORMATION DANGER WARNING CAUTION

The symbols shown in this section are used to
identify potential hazards. When you see a Hypertherm uses American National Standards
safety symbol in this manual or on your machine, Institute guidelines for safety signal words and
understand the potential for personal injury, and follow symbols. A signal word DANGER or WARNING is
the related instructions to avoid the hazard. used with a safety symbol. DANGER identifies the
most serious hazards.
FOLLOW SAFETY • DANGER and WARNING safety labels are
INSTRUCTIONS located on your machine near specific hazards.
Read carefully all safety messages in this • DANGER safety messages precede related
manual and safety labels on your machine. instructions in the manual that will result in serious
• Keep the safety labels on your machine in good injury or death if not followed correctly.
condition. Replace missing or damaged labels • WARNING safety messages precede related
immediately. instructions in this manual that may result in injury
• Learn how to operate the machine and how to use or death if not followed correctly.
the controls properly. Do not let anyone operate it • CAUTION safety messages precede related
without instruction. instructions in this manual that may result in
• Keep your machine in proper working condition. minor injury or damage to equipment if not
Unauthorized modifications to the machine may followed correctly.
affect safety and machine service life.

CUTTING CAN CAUSE FIRE OR EXPLOSION

Fire Prevention WARNING

• Be sure the area is safe before doing any cutting. Explosion Hazard
Keep a fire extinguisher nearby. Argon-Hydrogen and Methane
• Remove all flammables within 35 feet (10 m) of Hydrogen and methane are flammable gases that
the cutting area. present an explosion hazard. Keep flames away from
• Quench hot metal or allow it to cool before cylinders and hoses that contain methane or hydrogen
handling or before letting it touch combustible mixtures. Keep flames and sparks away from the torch
materials.
when using methane or argon-hydrogen plasma.
• Never cut containers with potentially flammable
materials inside – they must be emptied and
properly cleaned first.
WARNING
• Ventilate potentially flammable atmospheres
Hydrogen Detonation with
before cutting.
Aluminum Cutting
• When cutting with oxygen as the plasma gas,
an exhaust ventilation system is required. • When cutting aluminum underwater, or with the
water touching the underside of the aluminum,
Explosion Prevention free hydrogen gas may collect under the workpiece
• Do not use the plasma system if explosive dust and detonate during plasma cutting operations.
or vapors may be present. • Install an aeration manifold on the floor of the water
• Do not cut pressurized cylinders, pipes, or any
table to eliminate the possibility of hydrogen
closed container.
• Do not cut containers that have held combustible detonation. Refer to the Appendix section of this
materials. manual for aeration manifold details.

1-2 Hypertherm
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 SAFETY

ELECTRIC SHOCK CAN KILL

Touching live electrical parts can cause a fatal shock • Install and ground this equipment according to the
or severe burn. instruction manual and in accordance with national
• Operating the plasma system completes an and local codes.
electrical circuit between the torch and the • Inspect the input power cord frequently for damage
workpiece. The workpiece and anything touching or cracking of the cover. Replace a damaged
the workpiece are part of the electrical circuit. power cord immediately. Bare wiring can kill.
• Never touch the torch body, workpiece or the • Inspect and replace any worn or damaged torch
water in a water table when the plasma system leads.
is operating. • Do not pick up the workpiece, including the waste
cutoff, while you cut. Leave the workpiece in place
Electric Shock Prevention or on the workbench with the work cable attached
All Hypertherm plasma systems use high during the cutting process.
voltage in the cutting process (200 to 400 VDC • Before checking, cleaning or changing torch parts,
are common). Take the following precautions disconnect the main power or unplug the power
when operating this system: supply.
• Wear insulated gloves and boots, and keep your • Never bypass or shortcut the safety interlocks.
body and clothing dry. • Before removing any power supply or system
• Do not stand, sit or lie on – or touch – any wet enclosure cover, disconnect electrical input power.
surface when using the plasma system. Wait 5 minutes after disconnecting the main power
• Insulate yourself from work and ground using dry to allow capacitors to discharge.
insulating mats or covers big enough to prevent • Never operate the plasma system unless the power
any physical contact with the work or ground. supply covers are in place. Exposed power supply
If you must work in or near a damp area, use connections present a severe electrical hazard.
extreme caution. • When making input connections, attach proper
• Provide a disconnect switch close to the power grounding conductor first.
supply with properly sized fuses. This switch allows • Each Hypertherm plasma system is designed to be
the operator to turn off the power supply quickly in used only with specific Hypertherm torches. Do not
an emergency situation. substitute other torches which could overheat and
• When using a water table, be sure that it is present a safety hazard.
correctly connected to earth ground.

STATIC ELECTRICITY CAN DAMAGE CIRCUIT BOARDS

Use proper precautions when handling printed • Store PC boards in anti-static containers.
circuit boards.
• Wear a grounded wrist strap when handling
PC boards.

Hypertherm 1-3
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SAFETY

TOXIC FUMES CAN CAUSE INJURY OR DEATH

The plasma arc by itself is the heat source used for • Duration of cutting or gouging.
cutting. Accordingly, although the plasma arc has • Size, air volume, ventilation and filtration of the
not been identified as a source of toxic fumes, the work area.
material being cut can be a source of toxic fumes
or gases that deplete oxygen. • Personal protective equipment.
• Number of welding and cutting systems
Fumes produced vary depending on the metal that
in operation.
is cut. Metals that may release toxic fumes include,
but are not limited to, stainless steel, carbon steel, • Other site processes that may produce fumes.
zinc (galvanized), and copper.
If the workplace must conform to national or local
In some cases, the metal may be coated with a regulations, only monitoring or testing done at the
substance that could release toxic fumes. Toxic site can determine whether the site is above or
coatings include, but are not limited to, lead (in below allowable levels.
some paints), cadmium (in some paints and fillers),
and beryllium. To reduce the risk of exposure to fumes:

Gases produced by plasma cutting vary based on • Remove all coatings and solvents from the metal
the material to be cut and the method of cutting, before cutting.
but may include ozone, oxides of nitrogen, • Use local exhaust ventilation to remove fumes
hexavalent chromium, hydrogen, and other from the air.
substances if such are contained in or released • Do not inhale fumes. Wear an air-supplied
by the material being cut. respirator when cutting any metal coated with,
Caution should be taken to minimize exposure containing, or suspected to contain toxic
to fumes produced by any industrial process. elements.
Depending upon the chemical composition and • Assure that those using welding or cutting
concentration of the fumes (as well as other factors, equipment, as well as air-supplied respiration
such as ventilation), there may be a risk of physical devices, are qualified and trained in the proper
illness, such as birth defects or cancer. use of such equipment.
It is the responsibility of the equipment and site • Never cut containers with potentially toxic
owner to test the air quality in the area where the materials inside. Empty and properly clean the
equipment is used and to ensure that the air quality container first.
in the workplace meets all local and national • Monitor or test the air quality at the site as
standards and regulations. needed.
The air quality level in any relevant workplace • Consult with a local expert to implement a site
depends on site-specific variables such as: plan to ensure safe air quality.
• Table design (wet, dry, underwater).
• Material composition, surface finish, and
composition of coatings.
• Volume of material removed.

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 SAFETY

A PLASMA ARC CAN CAUSE INJURY AND BURNS

Instant-On Torches The plasma arc will cut quickly through gloves
Plasma arc comes on immediately when the torch and skin.
switch is activated. • Keep away from the torch tip.
• Do not hold metal near the cutting path.
• Never point the torch toward yourself or others.

ARC RAYS CAN BURN EYES AND SKIN

Eye Protection Plasma arc rays produce intense visible and invisible (ultraviolet and infrared) rays that can
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 appropriate
lens shading to protect your eyes from the arc’s ultraviolet and infrared rays.
Skin Protection Wear protective clothing to protect against burns caused by ultraviolet light, sparks and
hot 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 reduce reflection 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.
Minimum protective Suggested shade
Arc current OSHA 29CFR Europe
shade number number for comfort
(amps) 1910.133(a)(5) EN168:2002
(ANSI Z49.1:2005) (ANSI Z49.1:2005)
Less than 40 A 5 5 8 9
41 to 60 A 6 6 8 9
61 to 80 A 8 8 8 9
81 to 125 A 8 9 8 9
126 to 150 A 8 9 8 10
151 to 175 A 8 9 8 11
176 to 250 A 8 9 8 12
251 to 300 A 8 9 8 13
301 to 400 A 9 12 9 13
401 to 800 A 10 14 10

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SAFETY

GROUNDING SAFETY

Work Cable Attach the work cable securely to the Input Power
workpiece or the work table with good metal-to-metal • Be sure to connect the power cord ground wire
contact. Do not connect it to the piece that will fall to the ground in the disconnect box.
away when the cut is complete.
• If installation of the plasma system involves
Work Table Connect the work table to an earth connecting the power cord to the power supply,
ground, in accordance with appropriate national or be sure to connect the power cord ground wire
local electrical codes. 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. Fasten the retaining
nut tightly.
• Tighten all electrical connections to avoid
excessive heating.

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.
• Use only correct gas cylinders, regulators, hoses If damaged, a cylinder can explode.
and fittings designed for the specific application.
• Handle and use compressed gas cylinders in
• Maintain all compressed gas equipment and accordance with applicable national or local
associated parts in good condition. codes.
• Label and color-code all gas hoses to identify • Never use a cylinder that is not upright and
the type of gas in each hose. Consult applicable secured in place.
national or local codes.
• 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.

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 SAFETY

NOISE CAN DAMAGE PACEMAKER AND

HEARING HEARING AID OPERATION
Pacemaker and hearing aid operation can be
Prolonged exposure to noise from cutting or affected by magnetic fields from high currents.
gouging can damage hearing.
Pacemaker and hearing aid wearers should
• Use approved ear protection when using consult a doctor before going near any plasma arc
plasma system. cutting and gouging operations.
• Warn others nearby about the noise hazard.
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
A PLASMA ARC the work cable.
CAN DAMAGE
• Do not wrap or drape the torch lead or work
FROZEN PIPES
cable around your body.
Frozen pipes may be damaged or can burst if you • Keep as far away from the power supply
attempt to thaw them with a plasma torch. as possible.

ADDITIONAL SAFETY INFORMATION 7. CSA Standard W117.2, Code for Safety in Welding
and Cutting, Canadian Standards Association
1. ANSI Standard Z49.1, Safety in Welding and Cutting,
Standard Sales, 178 Rexdale Boulevard, Rexdale,
American Welding Society, 550 LeJeune Road, P.O. Box
Ontario M9W 1R3, Canada
351020, Miami, FL 33135
8. NFPA Standard 51B, Cutting and Welding
2. ANSI Standard Z49.2, Fire Prevention in the Use of
Processes, National Fire Protection Association,
Cutting and Welding Processes, American National
470 Atlantic Avenue, Boston, MA 02210
Standards Institute, 1430 Broadway, New York, NY
10018 9. NFPA Standard 70–1978, National Electrical Code,
National Fire Protection Association, 470 Atlantic
3. ANSI Standard Z87.1, Safe Practices for Occupation
Avenue, Boston, MA 02210
and Educational Eye and Face Protection, American
National Standards Institute, 1430 Broadway, New York, 10. OSHA, Safety and Health Standards, 29FR 1910
NY 10018 U.S. Government Printing Office, Washington, D.C.
20402
4. AWS F4.1, Recommended Safe Practices for the
Preparation for Welding and Cutting of Containers and 11. AWS Safety and Health Fact Sheets, American
Piping That Have Held Hazardous Substances, Welding Society 550 LeJeune Road, P.O. Box
American Welding Society, 550 LeJeune Road, P.O. Box 351040, Miami, FL 33135
351040, Miami, FL 33135 www.aws.org/technical/facts/
5. AWS F5.2, Recommended Safe Practices for Plasma
Arc Cutting, American Welding Society, 550 LeJeune
Road, P.O. Box 351040, Miami, FL 33135
6. CGA Pamphlet P-1, Safe Handling of Compressed
Gases in Cylinders, Compressed Gas Association,
1235 Jefferson Davis Highway, Arlington, VA 22202

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SAFETY

SYMBOLS AND MARKINGS

Your Hypertherm product may have one or more of the following markings on or near the data plate. Due to
differences and conflicts in national regulations, not all marks are applied to every version of a product.

S mark symbol
The S mark symbol indicates that the power supply and torch are suitable for operations carried out
in environments with increased hazard of electrical shock per IEC 60974-1.

CSA mark
Hypertherm products with a CSA mark meet the United States and Canadian regulations for
product safety. The products were evaluated, tested, and certified by CSA-International. Alternatively
the product may have a mark by one of the other Nationally Recognized Testing Laboratories (NRTL)
accredited in both the United States and Canada, such as Underwriters Laboratories, Incorporated
(UL) or TÜV.

CE marking
The CE marking signifies the manufacturer’s declaration of conformity to applicable European
directives and standards. Only those versions of Hypertherm products with a CE marking located on
or near the data plate have been tested for compliance with the European Low Voltage Directive and
the European Electromagnetic Compatibility (EMC) Directive. EMC filters needed to comply with the
European EMC Directive are incorporated within versions of the product with a CE marking.

GOST-R mark
CE versions of Hypertherm products that include a GOST-R mark of conformity meet the product
safety and EMC requirements for export to the Russian Federation.

c-Tick mark
CE versions of Hypertherm products with a c-Tick mark comply with the EMC regulations required
for sale in Australia and New Zealand.

CCC mark
The China Compulsory Certification (CCC) mark indicates that the product has been tested and
found compliant with product safety regulations required for sale in China.

1-8 Hypertherm
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 SAFETY

WARNING LABEL
This warning label is affixed to some power supplies. It is important that the operator
and maintenance technician understand the intent of these warning symbols as
described. The numbered text corresponds to the numbered boxes on the label.

Read and follow these instructions, employer safety

practices, and material safety data sheets. Refer to WARNING AVERTISSEMENT
ANS Z49.1, “Safety in Welding, Cutting and Allied
Processes” from American Welding Society Plasma cutting can be injurious to operator and persons Le coupage plasma peut être préjudiciable pour l’opérateur et les personnes qui se
(http://www.aws.org) and OSHA Safety and Health in the work area. Consult manual before operating. Failure trouvent sur les lieux de travail. Consulter le manuel avant de faire fonctionner. Le
Standards, 29 CFR 1910 (http://www.osha.gov). to follow all these safety instructions can result in death. non respect des ces instructions de sécurité peut entraîner la mort.

1. Cutting sparks can cause explosion or fire. 1. Les étincelles de coupage peuvent provoquer une explosion
1.1 Do not cut near flammables. ou un incendie.
1.2 Have a fire extinguisher nearby and ready to use. 1.1 Ne pas couper près des matières inflammables.
1.3 Do not use a drum or other closed container as a cutting table. 1.2 Un extincteur doit être à proximité et prêt à être utilisé.
1.3 Ne pas utiliser un fût ou un autre contenant fermé comme table de coupage.
2. Plasma arc can injure and burn; point the nozzle away 2. L’arc plasma peut blesser et brûler; éloigner la buse de soi.
from yourself. Arc starts instantly when triggered. Il s’allume instantanément quand on l’amorce;
2.1 Turn off power before disassembling torch. 2.1 Couper l’alimentation avant de démonter la torche.
2.2 Do not grip the workpiece near the cutting path. 2.2 Ne pas saisir la pièce à couper de la trajectoire de coupage.
2.3 Wear complete body protection. 2.3 Se protéger entièrement le corps.

3. Hazardous voltage. Risk of electric shock or burn. 3. Tension dangereuse. Risque de choc électrique ou de brûlure.
3.1 Wear insulating gloves. Replace gloves when wet or damaged. 3.1 Porter des gants isolants. Remplacer les gants quand ils sont humides ou
3.2 Protect from shock by insulating yourself from work and ground. endommagés.
3.3 Disconnect power before servicing. Do not touch live parts. 3.2 Se protéger contre les chocs en s’isolant de la pièce et de la terre.
3.3 Couper l’alimentation avant l’entretien. Ne pas toucher les pièces sous tension.

4. Plasma fumes can be hazardous. 4. Les fumées plasma peuvent être dangereuses.
4.1 Do not inhale fumes. 4.1 Ne pas inhaler les fumées
4.2 Use forced ventilation or local exhaust to remove the fumes. 4.2 Utiliser une ventilation forcée ou un extracteur local pour dissiper les fumées.
4.3 Do not operate in closed spaces. Remove fumes with ventilation. 4.3 Ne pas couper dans des espaces clos. Chasser les fumées par ventilation.

5. Arc rays can burn eyes and injure skin. 5. Les rayons d’arc peuvent brûler les yeux et blesser la peau.
5.1 Wear correct and appropriate protective equipment to protect 5.1 Porter un bon équipement de protection pour se protéger la tête, les yeux, les
head, eyes, ears, hands, and body. Button shirt collar. Protect ears oreilles, les mains et le corps. Boutonner le col de la chemise. Protéger les oreilles
from noise. Use welding helmet with the correct shade of filter. contre le bruit. Utiliser un masque de soudeur avec un filtre de nuance appropriée.

6. Become trained. Only qualified personnel should operate this 6. Suivre une formation. Seul le personnel qualifié a le droit de faire
equipment. Use torches specified in the manual. Keep non-qualified fonctionner cet équipement. Utiliser exclusivement les torches indiquées dans le
personnel and children away. manual. Le personnel non qualifié et les enfants doivent se tenir à l’écart.
7. Do not remove, destroy, or cover this label. 7. Ne pas enlever, détruire ni couvrir cette étiquette.
Replace if it is missing, damaged, or worn (PN 110584 Rev C). La remplacer si elle est absente, endommagée ou usée (PN 110584 Rev C).

1. Cutting sparks can cause explosion or fire. 4. Plasma fumes can be hazardous.
1.1 Do not cut near flammables. 4.1 Do not inhale fumes.
1.2 Have a fire extinguisher nearby and ready to use. 4.2 Use forced ventilation or local exhaust to remove
1.3 Do not use a drum or other closed container as the fumes.
a cutting table. 4.3 Do not operate in closed spaces. Remove fumes
2. Plasma arc can injure and burn; point the nozzle with ventilation.
away from yourself. Arc starts instantly when 5. Arc rays can burn eyes and injure skin.
triggered. 5.1 Wear correct and appropriate protective
2.1 Turn off power before disassembling torch. equipment to protect head, eyes, ears, hands,
2.2 Do not grip the workpiece near the cutting path. and body. Button shirt collar. Protect ears from
noise. Use welding helmet with the correct
2.3 Wear complete body protection.
shade of filter.
3. Hazardous voltage. Risk of electric shock or
6. Become trained. Only qualified personnel should
burn.
operate this equipment. Use torches specified in
3.1 Wear insulating gloves. Replace gloves when the manual. Keep non-qualified personnel and
wet or damaged. children away.
3.2 Protect from shock by insulating yourself from 7. Do not remove, destroy, or cover this label.
work and ground. Replace if it is missing, damaged, or worn.
3.3 Disconnect power before servicing. Do not
touch live parts.

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SAFETY

WARNING LABEL 1. Cutting sparks can cause explosion

or fire.
This warning label is affixed to some power supplies. It is
important that the operator and maintenance technician 1.1 Do not cut near flammables.
understand the intent of these warning symbols as described. 1.2 Have a fire extinguisher nearby and
The numbered text corresponds to the numbered boxes on ready to use.
the label. 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.
110647 Rev. A 6. Become trained. Only qualified
www.hypertherm.com/weee personnel should operate this
equipment. Use torches specified in
the manual. Keep non-qualified
personnel and children away.
7. Do not remove, destroy, or cover
this label. Replace if it is missing,
damaged, or worn.

1-10 Hypertherm
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 SAFETY

DRY DUST COLLECTION INFORMATION

At some sites, dry dust can represent a potential explosion hazard.

The U.S. National Fire Protection Association’s 2007 edition of NFPA standard 68, “Explosion Protection by
Deflagration Venting,” provides requirements for the design, location, installation, maintenance, and use of
devices and systems to vent combustion gases and pressures after any deflagration event. Consult with the
manufacturer or installer of any dry dust collection system for applicable requirements before you install a new
dry dust collection system or make significant changes in the process or materials used with an existing dry
dust collection system.

Consult your local “Authority Having Jurisdiction” (AHJ) to determine whether any edition of NFPA 68 has
been “adopted by reference” in your local building codes.

Refer to NFPA68 for definitions and explanations of regulatory terms such as deflagration, AHJ, adopted by
reference, the Kst value, deflagration index, and other terms.

Note 1 – Hypertherm’s interpretation of these new requirements is that unless a site-specific evaluation has
been completed to determine that all dust generated is not combustible, the 2007 edition of NFPA 68
requires the use of explosion vents designed to the worst-case Kst value (see annex F) that could be
generated from dust so that the explosion vent size and type can be designed. NFPA 68 does not specifically
identify plasma cutting or other thermal cutting processes as requiring deflagration venting systems, but it
does apply these new requirements to all dry dust collection systems.

Note 2 – Users of Hypertherm manuals should consult and comply with all applicable federal, state, and local
laws and regulations. Hypertherm does not, by the publication of any Hypertherm manual, intend to urge
action that is not in compliance with all applicable regulations and standards, and this manual may never be
construed as doing so.

Hypertherm 1-11
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SAFETY

1-12 Hypertherm
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 Section 1a

SÉCURITÉ

Dans cette section :

Identifier les consignes de sécurité ..............................................................................................................1a-2

Suivre les instructions de sécurité ................................................................................................................1a-2
Le coupage peut provoquer un incendie ou une explosion ....................................................................1a-2
Les chocs électriques peuvent être fatals ..................................................................................................1a-3
L’électricité statique peut endommager les cartes de circuits imprimés .............................................1a-3
Les vapeurs toxiques peuvent provoquer des blessures ou la mort .....................................................1a-4
L’arc plasma peut provoquer des blessures ou des brûlures .................................................................1a-5
Les rayons de l’arc peuvent brûler les yeux et la peau.............................................................................1a-5
Mise à la masse et à la terre...........................................................................................................................1a-6
Sécurité des bouteilles de gaz comprimé...................................................................................................1a-6
Les bouteilles de gaz comprimé peuvent exploser en cas de dommages ..........................................1a-6
Le bruit peut provoquer des problèmes auditifs ........................................................................................1a-7
Pacemakers et prothèses auditives ..............................................................................................................1a-7
Un arc plasma peut endommager les tuyaux gelés...................................................................................1a-7
Symboles et marquage....................................................................................................................................1a-8
Étiquettes de sécurité......................................................................................................................................1a-9
Information sur le dépoussiérage ...............................................................................................................1a-11

Hypertherm 1a-1
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SÉCURITÉ

IDENTIFIER LES CONSIGNES DANGER AVERTISSEMENT ATTENTION

DE SÉCURITÉ Hypertherm adopte les lignes directrices de l’American
Les symboles indiqués dans cette section sont utilisés National Standards Institute relativement aux termes, aux
pour identifier les risques éventuels. Si vous trouvez un symbole symboles et à la signalisation de sécurité. Les signaux
de sécurité, que ce soit dans ce manuel ou sur l’équipement, DANGER ou AVERTISSEMENT sont utilisés avec un symbole
soyez conscient des risques de blessures et suivez les de sécurité, DANGER correspondant aux risques les plus
instructions correspondantes afin d’éviter ces risques. sérieux.
• Les étiquettes de sécurité DANGER et AVERTISSEMENT
SUIVRE LES INSTRUCTIONS sont situées sur la machine pour signaler certains dangers
DE SÉCURITÉ spécifiques.
Lire attentivement toutes les consignes de sécurité • Les messages de sécurité DANGER précèdent les
dans le présent manuel et sur les étiquettes de sécurité se directives associées dans le manuel qui, si elles ne sont pas
trouvant sur la machine. suivies scrupuleusement, entraînent des blessures graves
• Les étiquettes de sécurité doivent rester lisibles. Remplacer voire mortelles.
immédiatement les étiquettes manquantes ou abîmées. • Les messages d’AVERTISSEMENT précèdent les
• Apprendre à faire fonctionner la machine et à utiliser instructions d’utilisation expliquées dans ce manuel et
correctement les commandes. Ne laisser personne utiliser signalent les risques de blessures ou de mort au cas où ces
la machine sans connaître son fonctionnement. instructions ne seraient pas suivies correctement.
• Garder la machine en bon état. Des modifications non • Les messages de sécurité ATTENTION précèdent les
autorisées sur la machine peuvent engendrer des problèmes directives associées dans le manuel qui, si elles ne sont pas
de sécurité et raccourcir la durée d’utilisation de l’équipement. suivies scrupuleusement, peuvent entraîner des blessures
secondaires ou endommager l’équipement.

LE COUPAGE PEUT PROVOQUER

UN INCENDIE OU UNE EXPLOSION
Prévention des incendies AVERTISSEMENT
• Avant de commencer, s’assurer que la zone de coupage Risque d’explosion
ne présente aucun danger. Conserver un extincteur argon-hydrogène et méthane
à proximité.
L’hydrogène et le méthane sont des gaz inflammables
• Éloigner toute matière inflammable à une distance
et potentiellement explosifs. Conserver à l’écart de toute
d’au moins 10 m du poste de coupage.
flamme les bouteilles et tuyaux contenant des mélanges
• Tremper le métal chaud ou le laisser refroidir avant
à base d’hydrogène ou de méthane. Maintenir toute
de le manipuler ou avant de le mettre en contact avec
flamme et étincelle à l’écart de la torche lors de l’utilisation
des matériaux combustibles.
d’un plasma d’argon-hydrogène ou de méthane.
• Ne jamais couper des récipients pouvant contenir
des matières inflammables avant de les avoir vidés
AVERTISSEMENT
et nettoyés correctement.
Détonation de l’hydrogène lors du
• Aérer toute atmosphère potentiellement inflammable
coupage de l’aluminium
avant d’utiliser un système plasma.
• Lors de l’utilisation d’oxygène comme gaz plasma, un • Lors du coupage de l’aluminium sous l’eau, ou si l’eau
système de ventilation par aspiration est nécessaire. touche la partie inférieure de la pièce d’aluminium, de
l’hydrogène libre peut s’accumuler sous la pièce à couper
Prévention des explosions
et détonner lors du coupage plasma.
• Ne pas couper en présence de poussière ou de vapeurs.
• Ne pas couper de bouteilles, de tuyaux ou autres • Installer un collecteur d’aération au fond de la table à eau
récipients fermés et pressurisés. afin d’éliminer les risques de détonation de l’hydrogène.
• Ne pas couper de récipients contenant des matières Se référer à l’annexe du manuel pour plus de
combustibles. renseignements sur les collecteurs d’aération.

1a-2 Hypertherm
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 SÉCURITÉ

LES CHOCS ÉLECTRIQUES PEUVENT ÊTRE FATALS

Toucher une pièce électrique sous tension peut provoquer • Installer et mettre à la terre l’équipement selon les
un choc électrique fatal ou des brûlures graves. instructions du présent manuel et conformément aux
• La mise en fonctionnement du système plasma ferme codes électriques locaux et nationaux.
un circuit électrique entre la torche et la pièce à couper. • Inspecter fréquemment le cordon d’alimentation primaire
La pièce à couper et tout autre élément en contact avec pour s’assurer qu’il n’est ni endommagé, ni fendu.
cette pièce font partie du circuit électrique. Remplacer immédiatement un cordon endommagé.
Un câble dénudé peut tuer.
• Ne jamais toucher le corps de la torche, la pièce à couper
ou l’eau de la table à eau pendant le fonctionnement du • Inspecter et remplacer les câbles de la torche qui sont
système plasma. usés ou endommagés.
• Ne pas saisir la pièce à couper ni les chutes lors du
coupage. Laisser la pièce à couper en place ou sur la
Prévention des chocs électriques table de travail, le câble de retour connecté lors du
Tous les systèmes plasma Hypertherm utilisent des hautes coupage.
tensions pour le coupage (souvent de 200 à 400 V). On • Avant de vérifier, de nettoyer ou de remplacer les pièces
doit prendre les précautions suivantes quand on utilise le de la torche, couper l’alimentation ou débrancher la prise
système plasma : de courant.
• Porter des bottes et des gants isolants et garder le corps • Ne jamais contourner ou court-circuiter les verrouillages
et les vêtements au sec. de sécurité.
• Ne pas se tenir, s’asseoir ou se coucher sur une surface • Avant d’enlever le capot du système ou de la source de
mouillée, ni la toucher quand on utilise le système plasma. courant, couper l’alimentation électrique. Attendre ensuite
5 minutes pour que les condensateurs se déchargent.
• S’isoler de la surface de travail et du sol en utilisant des
• Ne jamais faire fonctionner le système plasma sans que
tapis isolants secs ou des couvertures assez grandes
les capots de la source de courant ne soient en place.
pour éviter tout contact physique avec le travail ou le sol.
Les raccords exposés de la source de courant sont
S’il s’avère nécessaire de travailler dans ou près d’un
extrêmement dangereux.
endroit humide, procéder avec une extrême prudence.
• Lors de l’installation des connexions, attacher tout
• Installer un sectionneur avec fusibles appropriés, à d’abord la prise de terre appropriée.
proximité de la source de courant. Ce dispositif permet à
• Chaque système plasma Hypertherm est conçu pour
l’opérateur d’arrêter rapidement la source de courant en
être utilisé uniquement avec des torches Hypertherm
cas d’urgence.
spécifiques. Ne pas utiliser des torches inappropriées
• En cas d’utilisation d’une table à eau, s’assurer que cette qui pourraient surchauffer et présenter des risques pour
dernière est correctement mise à la terre. la sécurité.

L’ÉLECTRICITÉ STATIQUE PEUT ENDOMMAGER

LES CARTES DE CIRCUITS IMPRIMÉS

On doit prendre les précautions qui s’imposent quand on • On doit ranger les cartes de circuits imprimés dans des
manipule les circuits imprimés. contenants antistatiques.
• On doit porter un bracelet antistatique quand on
manipule les cartes de circuits imprimés.

Hypertherm 1a-3
11/08
SÉCURITÉ

LES VAPEURS TOXIQUES PEUVENT PROVOQUER

DES BLESSURES OU LA MORT

L’arc plasma est lui-même la source de chaleur utilisée Le niveau de qualité de l’air dans tout lieu de travail
pour le coupage. Par conséquent, bien que l’arc plasma dépend des variables propres au site comme :
n’ait pas été reconnu comme une source de vapeurs • Type de table (humide, sèche, sous l’eau).
toxiques, le matériau coupé peut être une source de
• Composition du matériau, fini de la surface
vapeurs ou de gaz toxiques qui épuisent l’oxygène.
et composition des revêtements.
• Volume de matériau enlevé.
Les vapeurs produites varient selon le métal coupé.
• Durée du coupage ou du gougeage.
Les métaux qui peuvent dégager des vapeurs toxiques
comprennent, entre autres, l’acier inoxydable, l’acier au • Dimensions, volume d’air, ventilation et filtration
carbone, le zinc (galvanisé) et le cuivre. de la zone de travail.
• Équipement de protection individuelle.
Dans certains cas, le métal peut être revêtu d’une • Nombre de systèmes de soudage et de coupage
substance susceptible de dégager des vapeurs toxiques. en fonctionnement.
Les revêtements toxiques comprennent entre autres, • Autres procédés du site qui peuvent produire
le plomb (dans certaines peintures), le cadmium (dans des vapeurs.
certaines peintures et enduits) et le béryllium.
Si les lieux de travail doivent être conformes aux
règlements nationaux ou locaux, seuls les contrôles ou les
Les gaz produits par le coupage plasma varient selon essais effectués au site peuvent déterminer si celui-ci se
le matériau à couper et la méthode de coupage, mais situe au-dessus ou au-dessous des niveaux admissibles.
ils peuvent comprendre l’ozone, les oxydes d’azote,
le chrome hexavalent, l’hydrogène et autres substances Pour réduire le risque d’exposition aux vapeurs :
présentes dans le matériau coupé ou en émanent. • Éliminer tout revêtement et solvant du métal avant
le coupage.
On doit prendre les précautions qui s’imposent pour • Utiliser la ventilation d’extraction locale pour éliminer
réduire au minimum l’exposition aux vapeurs produites par les vapeurs de l’air.
tout processus industriel. Selon la composition chimique • Ne pas inhaler les vapeurs. Porter un respirateur
et la concentration des vapeurs (ainsi que d’autres à adduction d’air quand on coupe des métaux revêtus
facteurs comme la ventilation), il peut y avoir un risque de d’éléments toxiques ou qui en contiennent ou sont
maladie physique, comme des malformations ou le cancer. susceptibles d’en contenir.
• S’assurer que les personnes qui utilisent un matériel
Il incombe au propriétaire du matériel et du site de vérifier de soudage ou de coupage ainsi que les dispositifs de
la qualité de l’air dans le secteur où l’on utilise le matériel respiration par adduction d’air sont qualifiés et ont reçu
et de s’assurer que la qualité de l’air sur les lieux de travail la formation sur la bonne utilisation d’un tel matériel.
répond aux normes et réglementation locales et nationales. • Ne jamais couper les contenants dans lesquels il peut
y avoir des matériaux toxiques. En premier lieu, vider et
nettoyer correctement le contenant.
• Contrôler ou éprouver la qualité de l’air au site selon
les besoins.
• Consulter un expert local pour mettre en œuvre un plan
du site afin d’assurer une qualité de l’air sûre.

1a-4 Hypertherm
11/08
 SÉCURITÉ

L’ARC PLASMA PEUT PROVOQUER DES BLESSURES OU DES BRÛLURES

Torches à allumage instantané L’arc plasma coupe facilement les gants et la peau.
L’arc plasma s’allume immédiatement après que la torche • Rester éloigné de l’extrémité de la torche.
soit mise en marche. • Ne pas tenir de métal près de la trajectoire de coupe.
• Ne jamais pointer la torche vers soi ou d’autres
personnes.

LES RAYONS DE L’ARC PEUVENT BRÛLER LES YEUX ET LA PEAU

Protection des yeux Les rayons de l’arc plasma produisent de puissants rayons visibles ou invisibles (ultraviolets et
infrarouges) qui peuvent brûler les yeux et la peau.
• Utiliser des lunettes de sécurité conformément aux codes locaux ou nationaux en vigueur.
• Porter des lunettes de protection (lunettes ou masque muni d’écrans latéraux et encore masque de soudure) avec des
verres teintés appropriés pour protéger les yeux des rayons ultraviolets et infrarouges de l’arc.
Protection de la peau Porter des vêtements de sécurité pour se protéger contre les brûlures que peuvent causer les
rayons ultraviolets, les étincelles et le métal brûlant :
• Gants à crispin, chaussures et casque de sécurité.
• Vêtements ignifuges couvrant toutes les parties exposées du corps.
• Pantalon sans revers pour éviter que des étincelles ou des scories puissent s’y loger.
• Avant le coupage, retirer de ses poches tout objet combustible comme les briquets au butane ou les allumettes.
Zone de coupage Préparer la zone de coupage afin de réduire la réverbération et la transmission de la lumière
ultraviolette :
• Peindre les murs et autres surfaces de couleur sombre pour réduire la réflexion de la lumière.
• Utiliser des écrans et autres dispositifs de protection afin de protéger les autres personnes de la lumière et de
la réverbération.
• Prévenir les autres personnes de ne pas regarder l’arc. Utiliser des affiches ou des panneaux.

Indice de protection Indice de protection

Courant de l’arc suggéré pour assurer OSHA 29CFR Europe
minimum
(A) le confort 1910.133(a)(5) EN168:2002
(ANSI Z49.1:2005) (ANSI Z49.1:2005)
Moins de 40 A 5 5 8 9
41 à 60 A 6 6 8 9
61 à 80 A 8 8 8 9
81 à 125 A 8 9 8 9
126 à 150 A 8 9 8 10
151 à 175 A 8 9 8 11
176 à 250 A 8 9 8 12
251 à 300 A 8 9 8 13
301 à 400 A 9 12 9 13
401 à 800 A 10 14 10

Hypertherm 1a-5
11/08
SÉCURITÉ

MISE À LA MASSE ET À LA TERRE

Câble de retour Bien fixer le câble de retour (ou de Alimentation

masse) à la pièce à couper ou à la table de travail de façon • S’assurer que le fil de terre du cordon d’alimentation est
à assurer un bon contact métal-métal. Ne pas fixer le câble connecté à la terre dans le coffret du sectionneur.
de retour à la partie de la pièce qui doit se détacher.
• S’il est nécessaire de brancher le cordon d’alimentation
à la source de courant lors de l’installation du système,
Table de travail Raccorder la table de travail à la terre,
s’assurer que le fil de terre est correctement branché.
conformément aux codes de sécurité locaux ou nationaux
appropriés. • Placer tout d’abord le fil de terre du cordon
d’alimentation sur le plot de mise à la terre puis placer
les autres fils de terre par-dessus. Bien serrer l’écrou
de retenue.
• S’assurer que toutes les connexions sont bien serrées
pour éviter la surchauffe.

SÉCURITÉ DES BOUTEILLES LES BOUTEILLES DE

DE GAZ COMPRIMÉ GAZ COMPRIMÉ
• Ne jamais lubrifier les robinets des bouteilles ou les PEUVENT EXPLOSER
régulateurs avec de l’huile ou de la graisse. EN CAS DE DOMMAGES
• Utiliser uniquement les bouteilles, régulateurs, tuyaux Les bouteilles de gaz contiennent du gaz à haute
et accessoires appropriés et conçus pour chaque pression. Si une bouteille est endommagée, elle peut
application spécifique. exploser.
• Entretenir l’équipement et les pièces d’équipement • Manipuler et utiliser les bouteilles de gaz comprimé
à gaz comprimé afin de les garder en bon état. conformément aux codes locaux ou nationaux.
• Étiqueter et coder avec des couleurs tous les tuyaux • Ne jamais utiliser une bouteille qui n’est pas placée
de gaz afin d’identifier le type de gaz contenu dans à la verticale et bien assujettie.
chaque tuyau. Se référer aux codes locaux ou nationaux • Le capuchon de protection doit être placé sur le robinet
en vigueur. sauf si la bouteille est en cours d’utilisation ou
connectée pour utilisation.
• Éviter à tout prix le contact électrique entre l’arc plasma
et une bouteille.
• Ne jamais exposer des bouteilles à une chaleur
excessive, aux étincelles, aux scories ou aux flammes
nues.
• Ne jamais utiliser des marteaux, des clés ou d’autres
outils pour débloquer le robinet des bouteilles.

1a-6 Hypertherm
11/08
 SÉCURITÉ

LE BRUIT PEUT PROVOQUER PACEMAKERS ET

DES PROBLÈMES AUDITIFS PROTHÈSES AUDITIVES

Les champs magnétiques produits par les courants

Une exposition prolongée au bruit du coupage ou du à haute tension peuvent affecter le fonctionnement
gougeage peut provoquer des problèmes auditifs. des prothèses auditives et des pacemakers.
• Utiliser un casque de protection homologué lors de
l’utilisation du système plasma. Les personnes portant ce type d’appareil doivent
consulter un médecin avant de s’approcher d’un lieu
• Prévenir les personnes aux alentours des risques où s’effectue le coupage ou le gougeage plasma.
encourus en cas d’exposition au bruit.
Pour réduire les risques associés aux champs
magnétiques :
• Garder loin de soi et du même côté du corps le câble
de retour et le faisceau de la torche.
UN ARC PLASMA PEUT
• Faire passer le faisceau de la torche le plus près
ENDOMMAGER LES possible du câble de retour.
TUYAUX GELÉS • Ne pas s’enrouler le faisceau de la torche ou le câble
de retour autour du corps.
Les tuyaux gelés peuvent être endommagés ou éclater
si l'on essaie de les dégeler avec une torche plasma. • Se tenir le plus loin possible de la source de courant.

Hypertherm 1a-7
11/08
SÉCURITÉ

SYMBOLES ET MARQUAGE
Votre produit Hypertherm peut comporter une ou plusieurs des marques suivantes sur sa plaque signalétique ou à
proximité. En raison des différends et des conflits relatifs aux règlements nationaux, toutes les marques ne sont pas
appliquées à chaque version d’un produit.

Symbole marque S
Le symbole de marque S indique que la source de courant et la torche conviennent pour les travaux effectués
dans les milieux à risque accru de choc électrique selon l’IEC 60974-1.

Marque CSA
Les produits Hypertherm comportant la marque CSA répondent aux règlements des États-Unis et du Canada
relatifs à la sécurité du produit. Les produits sont évalués, mis à l’essai et certifiés par la CSA-International.
En outre, le produit peut porter une marque d’un des laboratoires d’essai reconnus sur le plan national (NRTL)
accrédité aux États-Unis et au Canada comme les Underwriters Laboratories, Incorporated (UL) ou TÜV.

Marque CE
La marque CE signifie la déclaration de conformité du fabricant aux directives et normes européennes
applicables. Seules les versions des produits Hypertherm portant la marque CE placée sur la plaque
signalétique ou à proximité ont été mises à l’essai de conformité à la directive européenne sur la basse
tension et la compatibilité électromagnétique européenne (CEM). Les filtres CEM qui doivent se conformer
à la directive CEM européenne sont intégrés aux versions du produit portant la marque CE.

Marque GOST-R
Les versions CE des produits Hypertherm qui portent la marque de conformité GOST-R répondent aux
exigences de sécurité du produit et de CEM en vue de l’exportation à la Fédération russe.

Marque c-Tick
Les versions CE des produits Hypertherm portant la marque c-Tick sont conformes aux règlements CEM
prescrits pour la vente en Australie et en Nouvelle-Zélande.

Marque CCC
La marque de certification obligatoire en Chine (CCC) indique que le produit a été mis à l’essai et déclaré
conforme aux règlements de sécurité du produit prescrits pour la vente en Chine.

1a-8 Hypertherm
11/08
 SÉCURITÉ

ÉTIQUETTE DE SÉCURITÉ
Cette étiquette est affichée sur la source de courant. Il est important que l’utilisateur et
le technicien de maintenance comprennent la signification des symboles de sécurité.
Les numéros de la liste correspondent aux numéros des images.

Read and follow these instructions, employer safety

practices, and material safety data sheets. Refer to WARNING AVERTISSEMENT
ANS Z49.1, “Safety in Welding, Cutting and Allied
Processes” from American Welding Society Plasma cutting can be injurious to operator and persons Le coupage plasma peut être préjudiciable pour l’opérateur et les personnes qui se
(http://www.aws.org) and OSHA Safety and Health in the work area. Consult manual before operating. Failure trouvent sur les lieux de travail. Consulter le manuel avant de faire fonctionner. Le
Standards, 29 CFR 1910 (http://www.osha.gov). to follow all these safety instructions can result in death. non respect des ces instructions de sécurité peut entraîner la mort.

1. Cutting sparks can cause explosion or fire. 1. Les étincelles de coupage peuvent provoquer une explosion
1.1 Do not cut near flammables. ou un incendie.
1.2 Have a fire extinguisher nearby and ready to use. 1.1 Ne pas couper près des matières inflammables.
1.3 Do not use a drum or other closed container as a cutting table. 1.2 Un extincteur doit être à proximité et prêt à être utilisé.
1.3 Ne pas utiliser un fût ou un autre contenant fermé comme table de coupage.
2. Plasma arc can injure and burn; point the nozzle away 2. L’arc plasma peut blesser et brûler; éloigner la buse de soi.
from yourself. Arc starts instantly when triggered. Il s’allume instantanément quand on l’amorce;
2.1 Turn off power before disassembling torch. 2.1 Couper l’alimentation avant de démonter la torche.
2.2 Do not grip the workpiece near the cutting path. 2.2 Ne pas saisir la pièce à couper de la trajectoire de coupage.
2.3 Wear complete body protection. 2.3 Se protéger entièrement le corps.

3. Hazardous voltage. Risk of electric shock or burn. 3. Tension dangereuse. Risque de choc électrique ou de brûlure.
3.1 Wear insulating gloves. Replace gloves when wet or damaged. 3.1 Porter des gants isolants. Remplacer les gants quand ils sont humides ou
3.2 Protect from shock by insulating yourself from work and ground. endommagés.
3.3 Disconnect power before servicing. Do not touch live parts. 3.2 Se protéger contre les chocs en s’isolant de la pièce et de la terre.
3.3 Couper l’alimentation avant l’entretien. Ne pas toucher les pièces sous tension.

4. Plasma fumes can be hazardous. 4. Les fumées plasma peuvent être dangereuses.
4.1 Do not inhale fumes. 4.1 Ne pas inhaler les fumées
4.2 Use forced ventilation or local exhaust to remove the fumes. 4.2 Utiliser une ventilation forcée ou un extracteur local pour dissiper les fumées.
4.3 Do not operate in closed spaces. Remove fumes with ventilation. 4.3 Ne pas couper dans des espaces clos. Chasser les fumées par ventilation.

5. Arc rays can burn eyes and injure skin. 5. Les rayons d’arc peuvent brûler les yeux et blesser la peau.
5.1 Wear correct and appropriate protective equipment to protect 5.1 Porter un bon équipement de protection pour se protéger la tête, les yeux, les
head, eyes, ears, hands, and body. Button shirt collar. Protect ears oreilles, les mains et le corps. Boutonner le col de la chemise. Protéger les oreilles
from noise. Use welding helmet with the correct shade of filter. contre le bruit. Utiliser un masque de soudeur avec un filtre de nuance appropriée.

6. Become trained. Only qualified personnel should operate this 6. Suivre une formation. Seul le personnel qualifié a le droit de faire
equipment. Use torches specified in the manual. Keep non-qualified fonctionner cet équipement. Utiliser exclusivement les torches indiquées dans le
personnel and children away. manual. Le personnel non qualifié et les enfants doivent se tenir à l’écart.
7. Do not remove, destroy, or cover this label. 7. Ne pas enlever, détruire ni couvrir cette étiquette.
Replace if it is missing, damaged, or worn (PN 110584 Rev C). La remplacer si elle est absente, endommagée ou usée (PN 110584 Rev C).

1. Les étincelles de coupage peuvent provoquer une 4. Les fumées du plasma peuvent être dangereuses.
explosion ou un incendie. 4.1 Ne pas inhaler les fumées.
1.1 Ne pas couper près des matières inflammables. 4.2 Utiliser une ventilation forcée ou par aspiration
1.2 Un extincteur doit se trouver sur les lieux et prêt à la source pour éliminer les fumées.
à être utilisé. 4.3 Ne pas utiliser dans des espaces clos. Chasser
1.3 Ne pas utiliser un fût ou un autre contenant fermé les fumées avec la ventilation.
comme table de coupe. 5. Les rayons d’arc peuvent brûler les yeux et blesser
2. L’arc plasma peut blesser et brûler ; ne jamais pointer la peau.
la buse vers soi. L’arc s’amorce instantanément quand 5.1 Porter un bon équipement de protection pour se
on appuie sur la gâchette. protéger la tête, les yeux, les oreilles, les mains et le
2.1 Couper l’alimentation avant de démonter la torche. corps. Boutonner le col de la chemise. Se protéger les
2.2 Ne pas saisir la pièce près de la trajectoire de coupage. oreilles contre le bruit. Utiliser le masque de soudage
avec le filtre ayant le bon indice de protection.
2.3 Se protéger entièrement le corps.
6. S’entraîner. Seul le personnel qualifié doit faire
3. Tension dangereuse. Risque de choc électrique
fonctionner cet équipement. Utiliser les torches
ou de brûlure.
prescrites dans le manuel. Tenir le personnel non
3.1 Porter des gants isolants. Remplacer les gants s’ils qualifié et les enfants à l’écart.
sont humides ou endommagés.
7. Ne pas enlever, détruire ou couvrir cette étiquette.
3.2 Se protéger contre les chocs en s’isolant de la pièce La remplacer si elle est manquante, endommagée
et de la terre. ou usée.
3.3 Couper l’alimentation avant d’entretenir. Ne pas
toucher les pièces sous tension.

Hypertherm 1a-9
11/08
SÉCURITÉ

ÉTIQUETTE DE SÉCURITÉ 1. Les étincelles de coupage peuvent

provoquer une explosion ou un incendie.
Cette étiquette est affichée sur la source de courant. Il est important que
1.1 Ne pas couper près des matières
l’utilisateur et le technicien de maintenance comprennent la signification
inflammables.
des symboles de sécurité. Les numéros de la liste correspondent aux
1.2 Un extincteur doit se trouver sur les lieux
numéros des images.
et prêt à être utilisé.
1.3 Ne pas utiliser un fût ou un autre contenant
fermé comme table de coupe.
2. L’arc plasma peut blesser et brûler ;
ne jamais pointer la buse vers soi. L’arc
s’amorce instantanément quand on appuie
sur la gâchette.
2.1 Couper l’alimentation avant de démonter
la torche.
2.2 Ne pas saisir la pièce près de la trajectoire
de coupage.
2.3 Se protéger entièrement le corps.
3. Tension dangereuse. Risque de choc
électrique ou de brûlure.
3.1 Porter des gants isolants. Remplacer les
gants s’ils sont humides ou endommagés.
3.2 Se protéger contre les chocs en s’isolant
de la pièce et de la terre.
3.3 Couper l’alimentation avant d’entretenir.
Ne pas toucher les pièces sous tension.
4. Les fumées du plasma peuvent être
dangereuses.
4.1 Ne pas inhaler les fumées.
4.2 Utiliser une ventilation forcée ou par
aspiration à la source pour éliminer les
fumées.
4.3 Ne pas utiliser dans des espaces clos.
Chasser les fumées avec la ventilation.
5. Les rayons d’arc peuvent brûler les yeux
et blesser la peau.
5.1 Porter un bon équipement de protection
pour se protéger la tête, les yeux, les
oreilles, les mains et le corps. Boutonner le
col de la chemise. Se protéger les oreilles
contre le bruit. Utiliser le masque de
soudage avec le filtre ayant le bon indice
www.hypertherm.com/weee
110647 Rev. A
de protection.
6. S’entraîner. Seul le personnel qualifié doit
faire fonctionner cet équipement. Utiliser
les torches prescrites dans le manuel.
Tenir le personnel non qualifié et les
enfants à l’écart.
7. Ne pas enlever, détruire ou couvrir cette
étiquette. La remplacer si elle est
manquante, endommagée ou usée.

1a-10 Hypertherm
11/08
 SÉCURITÉ

INFORMATION SUR LE DÉPOUSSIÉRAGE

À certains endroits, la poussière peut représenter un risque d’explosion potentiel. À certains endroits, la poussière peut
représenter un risque d’explosion potentiel.

La norme NFPA 68 de la National Fire Protection Association des É.-U. (édition 2007) « Explosion Protection by
Deflagration Venting » établit les exigences relatives à la conception, à l’emplacement, à l’installation, à l’entretien et
à l’utilisation de dispositifs et de systèmes pour évacuer à l’air libre les gaz de combustion et les pressions après une
éventuelle déflagration. Communiquer avec le fabricant ou avec l’installateur pour tout système de dépoussiérage afin de
connaître les exigences applicables avant d’installer un tel système neuf ou d’apporter des modifications importantes aux
procédés ou aux matériaux utilisés à un système de dépoussiérage existant.

Consultez l’autorité compétente locale pour déterminer si une édition de la NFPA 68 a été adoptée par référence dans vos
codes du bâtiment locaux.

Voir le document NFPA68 pour obtenir des définitions et des explications des termes réglementaires tels que
« déflagration, autorité compétente, adopté par référence, valeur du pire cas, indice de déflagration » et autres termes.

Note 1 – L’interprétation d’Hypertherm de ces nouvelles exigences est que, sauf évaluation particulière du site, pour
déterminer que toute la poussière produite n’est pas combustible, l’édition 2007 de la NFPA 68 exige l’utilisation d’évents
d’explosion conçus pour la valeur du pire des cas (voir annexe F) qui pourrait provenir de la poussière de sorte que l’on
puisse concevoir la dimension et le type d’évent d’explosion. La NFPA 68 ne stipule pas particulièrement le procédé de
coupage plasma particulier ou autres procédés de coupage thermique comme le prescrivent ces nouveaux règlements
à tous les systèmes de dépoussiérage.

Note 2 – Les utilisateurs des manuels d’Hypertherm doivent consulter tous les règlements et lois fédéraux et locaux
applicables et s’y conformer. Hypertherm n’a pas l’intention, en publiant un manuel d’Hypertherm, de demander des
mesures qui ne sont pas conformes aux règlements et normes applicables et ce manuel ne peut jamais être interprété
dans ce sens.

Hypertherm 1a-11
11/08
SÉCURITÉ

1a-12 Hypertherm
11/08
 Seccíon 1b

SEGURIDAD

En esta sección:

Reconocimiento de información de seguridad ..........................................................................................1b-2

Siga las instrucciones de seguridad ............................................................................................................1b-2
Los cortes pueden provocar incendios o explosiones ............................................................................1b-2
El choque eléctrico puede provocar la muerte..........................................................................................1b-3
Electricidad estática puede dañar tablillas de circuito ............................................................................1b-3
Humos tóxicos pueden causar lesiones o muerte....................................................................................1b-4
El arco de plasma puede causar lesiones y quemaduras.......................................................................1b-5
Los rayos del arco pueden producir quemaduras en los ojos y en la piel ..........................................1b-5
Seguridad de toma a tierra.............................................................................................................................1b-6
Seguridad de los equipos de gas comprimido..........................................................................................1b-6
Los cilindros de gas pueden explotar si están dañados .........................................................................1b-6
El ruido puede deteriorar la audición ...........................................................................................................1b-7
Operación de marcapasos y de audífonos.................................................................................................1b-7
Un arco plasma puede dañar tubos congelados ......................................................................................1b-7
Símbolos y marcas ...........................................................................................................................................1b-8
Etiquetas de advertencia ................................................................................................................................1b-9
Información sobre la colección de polvo seco........................................................................................1b-11

Hypertherm 1b-1
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SEGURIDAD

RECONOCIMIENTO DE PELIGRO ADVERTENCIA PRECAUCIÓN

INFORMACIÓN DE SEGURIDAD Hypertherm usa las directivas del Instituto Americano de
Los símbolos que se muestran en esta sección se Normas Nacionales (American National Standards Institute)
utilizan para identificar los posibles peligros. Cuando vea para las palabras y símbolos que señalan seguridad. Las
un símbolo de seguridad en este manual o en su máquina, palabras PELIGRO y ADVERTENCIA se utilizan
recuerde que existe la posibilidad de que se produzcan conjuntamente con un símbolo de seguridad. La palabra
lesiones personales y siga las instrucciones correspondientes PELIGRO se utiliza para identificar los mayores peligros.
para evitar el peligro.
• Encontrará etiquetas de seguridad con las inscripciones
SIGA LAS INSTRUCCIONES PELIGRO y ADVERTENCIA en su máquina, junto a peligros
DE SEGURIDAD específicos.
Lea atentamente todos los mensajes de seguridad • Los mensajes de seguridad de PELIGRO preceden
de este manual y las etiquetas de seguridad en su máquina. instrucciones relacionadas en el manual que resultarán en
• Mantenga las etiquetas de seguridad de su máquina en lesión grave o muerte si no se las sigue correctamente.
buen estado. Reemplace las etiquetas que se pierdan • En este manual, la palabra ADVERTENCIA va seguida de
o se dañen inmediatamente. instrucciones que, si no se siguen correctamente, pueden
• Aprenda a utilizar la máquina y a utilizar los controles de la provocar lesiones e inclusive la muerte.
manera correcta. No permita que sea utilizada por alguien
que no conozca su funcionamiento. • Los mensajes de seguridad de CUIDADO o PRECAUCIÓN
• Mantenga su máquina en buenas condiciones de preceden mensajes relacionados con instrucciones en el
funcionamiento. La realización de modificaciones no manual que puede resultar en lesiones menores, o daño
autorizadas a la máquina puede comprometer la seguridad a equipo, si no se siguen correctamente.
y la vida útil de la máquina.

LOS CORTES PUEDEN PROVOCAR INCENDIOS

O EXPLOSIONES
Prevención ante el fuego ADVERTENCIA
• Asegúrese de que el área sea segura antes de proceder Peligro de explosión
a cortar. Tenga a mano un extinguidor de incendios. Argón-Hidrógeno y metano
• Retire todos los materiales inflamables, colocándolos
a por lo menos 10 metros del área de corte. El hidrógeno y el metano son gases inflamables que
• Remoje los metales calientes o permita que se enfríen suponen un peligro de explosión. Mantenga el fuego lejos
antes de que entren en contacto con materiales de los cilindros y las mangueras que contengan mezclas
combustibles. de hidrógeno o metano. Mantenga la llama y las chispas
• Nunca corte depósitos que contengan materiales lejos de la antorcha al utilizar metano o argón-hidrógeno
inflamables – primero es necesario vaciarlos y limpiarlos como plasma.
debidamente. ADVERTENCIA
• Antes de realizar cortes en atmósferas potencialmente Detonación de hidrógeno con
inflamables, asegúrese de ventilar bien. el corte de aluminio
• Al realizar cortes utilizando oxígeno como gas plasma, • Al cortar aluminio bajo agua o con agua en contacto con
se requiere tener un sistema de ventilación de escape. el lado inferior del aluminio, puede acumularse gas
Prevención ante explosiones hidrógeno bajo la pieza a cortar y detonar durante la
• No corte en atmósferas que contengan polvo o vapores operación de corte por plasma.
explosivos. • Instale un múltiple de aireación en el fondo de la mesa
• No corte depósitos o tubos a presión ni cualquier de agua para eliminar la posibilidad de la detonación
depósito cerrado. del hidrógeno. Consulte la sección del apéndice de
• No corte depósitos que hayan contenido materiales este manual para conocer detalles acerca del múltiple
combustibles. de aireación.

1b-2 Hypertherm
11/08
 SEGURIDAD

EL CHOQUE ELÉCTRICO PUEDE PROVOCAR LA MUERTE

El contacto directo con piezas eléctricas conectadas puede • Instale este equipo y conéctelo a tierra según el manual
provocar un electrochoque fatal o quemaduras graves. de instrucciones y de conformidad con los códigos
• Al hacer funcionar el sistema de plasma, se completa un locales y nacionales.
circuito eléctrico entre la antorcha y la pieza a cortar. La • Inspeccione el cordón de alimentación primaria con
pieza a cortar es una parte del circuito eléctrico, como frecuencia para asegurarse de que no esté dañado
también cualquier cosa que se encuentre en contacto ni agrietado. Si el cordón de alimentación primaria está
con ella. dañado, reemplácelo inmediatamente. Un cable
• Nunca toque el cuerpo de la antorcha, la pieza a cortar pelado puede provocar la muerte.
o el agua en una mesa de agua cuando el sistema de • Inspeccione las mangueras de la antorcha y
plasma se encuentre en funcionamiento. reemplácelas cuando se encuentren dañadas.
• No toque la pieza ni los recortes cuando se está
Prevención ante el electrochoque cortando. Deje la pieza en su lugar o sobre la mesa
Todos los sistemas por plasma de Hypertherm usan alto de trabajo con el cable de trabajo conectado en
voltaje en el proceso de corte (son comunes los voltajes todo momento.
CD de 200 a 400). Tome las siguientes precauciones
• Antes de inspeccionar, limpiar o cambiar las piezas de la
cuando se utiliza el equipo de plasma:
antorcha, desconecte la potencia primaria o desenchufe
• Use guantes y botas aislantes y mantenga el cuerpo la fuente de energía.
y la ropa secos.
• Nunca evite o descuide los bloqueos de seguridad.
• No se siente, se pare o se ponga sobre cualquier
• Antes de retirar la cubierta de una fuente de energía
superficie húmeda cuando esté trabajando con el equipo.
o del gabinete de un sistema, desconecte la potencia
• Aíslese eléctricamente de la pieza a cortar y de la tierra primaria de entrada. Espere 5 minutos después de
utilizando alfombrillas o cubiertas de aislamiento secas desconectar la potencia primaria para permitir la
lo suficientemente grandes como para impedir todo descarga de los condensadores.
contacto físico con la pieza a cortar o con la tierra. Si su
• Nunca opere el sistema de plasma sin que las tapas de
única opción es trabajar en una área húmeda o cerca de
la fuente de energía estén en su lugar. Las conexiones
ella, sea muy cauteloso.
expuestas de la fuente de energía presentan un serio
• Instale un interruptor de corriente adecuado en cuanto riesgo eléctrico.
a fusibles, en una pared cercana a la fuente de energía.
• Al hacer conexiones de entrada, conecte el conductor
Este interruptor permitirá al operador desconectar
de conexión a tierra en primer lugar.
rápidamente la fuente de energía en caso de emergencia.
• Cada sistema de plasma Hypertherm está diseñado para
• Al utilizar una mesa de agua, asegúrese de que ésta se
ser utilizado sólo con antorchas Hypertherm específicas.
encuentre correctamente conectada a la toma a tierra.
No utilice antorchas diferentes, que podrían recalentarse
y ser peligrosas.

ELECTRICIDAD ESTÁTICA PUEDE DAÑAR TABLILLAS DE CIRCUITO

Use precauciones adecuadas cuando maneje tablillas • Almacene las tablillas PC en recipientes antiestáticos.
impresas de circuito • Use la defensa de muñeca conectada a tierra cuando
maneje tablillas PC.

Hypertherm 1b-3
11/08
SEGURIDAD

HUMOS TÓXICOS PUEDEN CAUSAR LESIONES O MUERTE

El arco plasma es por si solo la fuente de calor que se El nivel de la calidad del aire en cualquier lugar de trabajo
usa para cortar. Según esto, aunque el arco de plasma relevante depende en variables específicas al sitio tales
no ha sido identificado como la fuente de humo tóxico, como:
el material que se corta puede ser la fuente de humo • Diseño de mesa (mojada, seca, bajo agua).
o gases tóxicos que vacían el oxígeno.
• La composición del material, el acabado de la
superficie, y la composición de los recubrimientos.
El humo producido varía según el metal que está • Volumen que se quita del material.
cortándose. Metales que pueden liberar humo tóxico
• La duración del corte o ranura.
incluyen, pero no están limitados a, acero inoxidable,
acero al carbón, cinc (galvanizado), y cobre. • Tamaño, volumen del aire, ventilación y filtración del
lugar de trabajo.
• Equipo de protección personal.
En algunos casos, el metal puede estar recubierto con
una sustancia que podría liberar humos tóxicos. Los • Número de sistemas de soldar y cortar en la operación.
recubrimientos tóxicos incluyen, pero no están limitados • Otros procesos del lugar que pueden producir humo.
a, plomo (en algunas pinturas), cadmio (en algunas
pinturas y rellenos), y berilio. Si el lugar de trabajo debe cumplir reglamentos
nacionales o locales, solamente el monitoreo o las
pruebas que se hacen en el lugar pueden determinar si
Los gases producidos por el corte por plasma varían el sitio está encima o debajo de los niveles permitidos.
basándose en el material a cortarse y el método de
cortar, pero pueden incluir ozono, óxidos de nitrógeno, Para reducir el riesgo de exposición a humo:
cromo hexavalente, hidrógeno, y otras substancias, si • Quite todos los recubrimientos y solventes del metal
están contenidas dentro o liberadas por el material que antes de cortar.
se corta.
• Use ventilación extractora local para quitar humo
del aire.
Se debe tener cuidado de minimizar la exposición del • No inhale el humo. Use un respirador con fuente propia
humo producido por cualquier proceso industrial. Según de aire cuando corte cualquier metal recubierto con,
la composición química y la concentración del humo (al o sospechado de contener, elementos tóxicos.
igual que otros factores, tales como ventilación), puede
• Garantice que aquéllos usando equipo de soldar
haber el riesgo de enfermedad física, tal como defectos
o cortar, al igual que aparatos de respiración con aire
de natividad o cáncer.
propio de aire, estén capacitados y entrenados en el
uso apropiado de tal equipo.
Es la responsabilidad del dueño del equipo y instalación • Nunca corte recipientes con materiales potencialmente
el comprobar la calidad de aire en el lugar donde se está tóxicos adentro. Primero, vacíe y limpie el recipiente
usando el equipo para garantizar que la calidad del aire adecuadamente.
en el lugar de trabajo cumpla con todas las normas y
• Monitoree o compruebe la calidad del aire en el sitio
reglamentos locales y nacionales.
como fuera necesario.
• Consulte con un experto local para realizar un plan
al sitio para garantizar la calidad de aire seguro.

1b-4 Hypertherm
11/08
 SEGURIDAD

EL ARCO DE PLASMA PUEDE CAUSAR LESIONES Y QUEMADURAS

Antorchas de encendido instantáneo El arco de plasma puede cortar a través de guantes y

El arco de plasma se enciende inmediatamente después de la piel con rapidez.
de activarse el interruptor de la antorcha. • Manténgase alejado de la punta de la antorcha.
• No sostenga el metal junto al trayecto de corte.
• Nunca apunte la antorcha hacia Ud. mismo o hacia
otras personas.

LOS RAYOS DEL ARCO PUEDEN PRODUCIR QUEMADURAS EN LOS

OJOS Y EN LA PIEL
Protección para los ojos Los rayos del arco de plasma producen rayos intensos visibles e invisibles (ultravioleta
e infrarrojo) que pueden quemar los ojos y la piel.
• Utilice protección para los ojos de conformidad con los códigos locales o nacionales aplicables.
• Colóquese protectores para los ojos (gafas o anteojos protectores con protectores laterales, y bien un casco de
soldar) con lentes con sombreado adecuado para proteger sus ojos de los rayos ultravioleta e infrarrojos del arco.
Protección para la piel Vista ropa de protección para proteger la piel contra quemaduras causadas por la radiación
ultravioleta de alta intensidad, por las chispas y por el metal caliente:
• Guantes largos, zapatos de seguridad y gorro.
• Roipa de combustión retardada y que cubra todas las partes expuestas.
• Pantalones sin dobladillos para impedir que recojan chispas y escorias.
• Retire todo material combustible de los bolsillos, como encendedores a butano e inclusive cerillas, antes de
comenzar a cortar.
Área de corte Prepare el área de corte para reducir la reflexión y la transmisión de la luz ultravioleta:
• Pinte las paredes y demás superficies con colores oscuros para reducir la reflexión.
• Utilice pantallas o barreras protectoras para proteger a los demás de los destellos.
• Advierta a los demás que no debe mirarse el arco. Utilice carteles o letreros.
El número de matiz El número de matiz
Corriente de sugerido para OSHA 29CFR Europa
protector mínimo
arco (amps.) comodidad 1910.133(a)(5) EN168:2002
(ANSI Z49.1:2005) (ANSI Z49.1:2005)
Menos de 40 A 5 5 8 9
41 a 60 A 6 6 8 9
61 a 80 A 8 8 8 9
81 a 125 A 8 9 8 9
126 a 150 A 8 9 8 10
151 a 175 A 8 9 8 11
176 a 250 A 8 9 8 12
251 a 300 A 8 9 8 13
301 a 400 A 9 12 9 13
401 a 800 A 10 14 10

Hypertherm 1b-5
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SEGURIDAD

SEGURIDAD DE TOMA A TIERRA

Cable de trabajo La pinza del cable de trabajo debe Potencia primaria de entrada
estar bien sujetada a la pieza y hacer un buen contacto • Asegúrese de que el alambre de toma a tierra del
de metal a metal con ella o bien con la mesa de trabajo. cordón de alimentación está conectado al terminal
No conecte el cable con la parte que va a quedar de tierra en la caja del interruptor de corriente.
separada por el corte. • Si la instalación del sistema de plasma supone
la conexión del cordón de alimentación primaria
Mesa de trabajo Conecte la mesa de trabajo a una a la fuente de energía, asegúrese de conectar
buena toma de tierra, de conformidad con los códigos correctamente el alambre de toma a tierra del cordón
eléctricos nacionales o locales apropiados. de alimentación primaria.
• Coloque en primer lugar el alambre de toma a tierra
del cordón de alimentación primaria en el espárrago
luego coloque cualquier otro alambre de tierra sobre
el conductor de tierra del cable. Ajuste firmemente
la tuerca de retención.
• Asegúrese de que todas las conexiones eléctricas
están firmemente realizadas para evitar
sobrecalentamientos.

SEGURIDAD DE LOS EQUIPOS DE GAS LOS CILINDROS DE GAS

COMPRIMIDO PUEDEN EXPLOTAR SI
ESTÁN DAÑADOS
• Nunca lubrique reguladores o válvulas de cilindros con
aceite o grasa. Los cilindros de gas contienen gas bajo alta presión.
• Utilice solamente cilindros, reguladores, mangueras y Un cilindro dañado puede explotar.
conectores de gas correctos que hayan sido diseñados • Manipule y utilice los cilindros de gas comprimido de
para la aplicación específica. acuerdo con los códigos locales o nacionales aplicables.
• Mantenga todo el equipo de gas comprimido y las • No use nunca un cilindro que no esté de pie y bien
piezas relacionadas en buen estado. sujeto.
• Coloque etiquetas y códigos de color en todas las • Mantenga la tapa de protección en su lugar encima
mangueras de gas para identificar el tipo de gas que de la válvula, excepto cuando el cilindro se encuentre
conduce cada una. Consulte los códigos locales en uso o conectado para ser utilizado.
o nacionales aplicables. • No permita nunca el contacto eléctrico entre el arco
de plasma y un cilindro.
• No exponga nunca los cilindros a calor excesivo,
chispas, escorias o llamas.
• No emplee nunca martillos, llaves u otro tipo de
herramientas para abrir de golpe la válvula del cilindro.

1b-6 Hypertherm
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 SEGURIDAD

EL RUIDO PUEDE OPERACIÓN DE

DETERIORAR LA AUDICIÓN MARCAPASOS Y DE
AUDÍFONOS
La exposición prolongada al ruido propio de las
operaciones de corte y ranurado puede dañar la Los campos magnéticos producidos por las elevadas
audición. corrientes pueden afectar la operación de marcapasos
y de audífonos.
• Utilice un método de protección de los oídos
aprobado al utilizar el sistema de plasma. Las personas que lleven marcapasos y audífonos
deberán consultar a un médico antes de acercarse
• Advierta a las demás personas que se encuentren en
a sitios donde se realizan operaciones de corte
las cercanías acerca del peligro que supone el ruido
y ranurado por plasma.
excesivo.
Para reducir los peligros de los campos magnéticos:
• Mantenga el cable de trabajo y la manguera de la
antorcha a un lado, lejos del cuerpo.
UN ARCO PLASMA • Dirija la manguera antorcha lo más cerca posible
PUEDE DAÑAR TUBOS del cable de trabajo.
CONGELADOS • No envuelva el cable de trabajo ni la manguera de
la antorcha en su cuerpo.
Se puede hacer daño a los tubos congelados, o se los
puede reventar, si uno trata de descongelarlos con una • Manténgase tan lejos de la fuente de energía como
antorcha por plasma. sea posible.

Hypertherm 1b-7
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SÍMBOLOS Y MARCAS
Su producto de Hypertherm puede tener una o más de las marcas que siguen en, o cerca de la placa de datos. Debido
a diferencias y conflictos en reglamentos nacionales, no todas las marcas se aplican a toda versión del producto.

Símbolo de marca S
El símbolo de marca S indica que la fuente de energía y antorcha son aptas para operaciones que se llevan
a cabo en entornos con peligro aumentado de choque o descarga eléctrica según IEC 60974-1.

Marca CSA
Los productos de Hypertherm con la marca CSA cumplen con los reglamentos de Estados Unidos y
Canadá para la seguridad del producto. Estos productos fueron evaluados, comprobados, y certificados por
CSA-Internacional. Alternativamente, el producto puede tener la marca según uno de los otros Laboratorios de
Prueba Reconocidos nacionalmente (NRTL siglas en inglés) acreditados en ambos Estados Unidos y Canadá,
tales como Underwriters Laboratories, Incorporated (UL) ó TÜV.

Marcas CE
Las marcas CE significan una declaración del fabricante de conformidad a las directivas y estándares aplicables
Europeos. Sólo aquellas versiones del producto Hypertherm con la marca CE ubicada en o cerca de la placa
de datos han sido comprobadas para cumplir con la Directiva Europea de Voltaje Bajo, la Compatibilidad
Electromagnético Europea (EMC). Los filtros EMC que necesitan cumplir con la Directiva Europea EMC están
incorporados dentro de las versiones del producto con la marca CE.

Marca GOST-R
Las versiones de los productos Hypertherm CE que incluye la marca de conformidad GOST-R cumplen con
la seguridad del productos y los requisitos EMC para exportarse a la Federación Rusa.

Marca c-Tick
Las versiones CE de los productos Hypertherm con la marca c-Tick cumple con los reglamentos EMC
requeridos para venta en Australia y Nueva Zelandia.

Marca CCC
La marca de Certificación Obligatoria China (CCC en inglés) indica que el producto ha sido comprobado y se
lo ha encontrado que cumple con los reglamentos de seguridad del producto requeridos para venta en China.

1b-8 Hypertherm
11/08
 SEGURIDAD

ETIQUETA DE ADVERTENCIA
Esta etiqueta de advertencia se encuentra adherida a la fuente de energía. Es importante que el
operador y el técnico de mantenimiento comprendan el sentido de estos símbolos de advertencia
según se describen. El texto numerado corresponde a los cuadros numerados de la etiqueta.

Read and follow these instructions, employer safety

practices, and material safety data sheets. Refer to WARNING AVERTISSEMENT
ANS Z49.1, “Safety in Welding, Cutting and Allied
Processes” from American Welding Society Plasma cutting can be injurious to operator and persons Le coupage plasma peut être préjudiciable pour l’opérateur et les personnes qui se
(http://www.aws.org) and OSHA Safety and Health in the work area. Consult manual before operating. Failure trouvent sur les lieux de travail. Consulter le manuel avant de faire fonctionner. Le
Standards, 29 CFR 1910 (http://www.osha.gov). to follow all these safety instructions can result in death. non respect des ces instructions de sécurité peut entraîner la mort.

1. Cutting sparks can cause explosion or fire. 1. Les étincelles de coupage peuvent provoquer une explosion
1.1 Do not cut near flammables. ou un incendie.
1.2 Have a fire extinguisher nearby and ready to use. 1.1 Ne pas couper près des matières inflammables.
1.3 Do not use a drum or other closed container as a cutting table. 1.2 Un extincteur doit être à proximité et prêt à être utilisé.
1.3 Ne pas utiliser un fût ou un autre contenant fermé comme table de coupage.
2. Plasma arc can injure and burn; point the nozzle away 2. L’arc plasma peut blesser et brûler; éloigner la buse de soi.
from yourself. Arc starts instantly when triggered. Il s’allume instantanément quand on l’amorce;
2.1 Turn off power before disassembling torch. 2.1 Couper l’alimentation avant de démonter la torche.
2.2 Do not grip the workpiece near the cutting path. 2.2 Ne pas saisir la pièce à couper de la trajectoire de coupage.
2.3 Wear complete body protection. 2.3 Se protéger entièrement le corps.

3. Hazardous voltage. Risk of electric shock or burn. 3. Tension dangereuse. Risque de choc électrique ou de brûlure.
3.1 Wear insulating gloves. Replace gloves when wet or damaged. 3.1 Porter des gants isolants. Remplacer les gants quand ils sont humides ou
3.2 Protect from shock by insulating yourself from work and ground. endommagés.
3.3 Disconnect power before servicing. Do not touch live parts. 3.2 Se protéger contre les chocs en s’isolant de la pièce et de la terre.
3.3 Couper l’alimentation avant l’entretien. Ne pas toucher les pièces sous tension.

4. Plasma fumes can be hazardous. 4. Les fumées plasma peuvent être dangereuses.
4.1 Do not inhale fumes. 4.1 Ne pas inhaler les fumées
4.2 Use forced ventilation or local exhaust to remove the fumes. 4.2 Utiliser une ventilation forcée ou un extracteur local pour dissiper les fumées.
4.3 Do not operate in closed spaces. Remove fumes with ventilation. 4.3 Ne pas couper dans des espaces clos. Chasser les fumées par ventilation.

5. Arc rays can burn eyes and injure skin. 5. Les rayons d’arc peuvent brûler les yeux et blesser la peau.
5.1 Wear correct and appropriate protective equipment to protect 5.1 Porter un bon équipement de protection pour se protéger la tête, les yeux, les
head, eyes, ears, hands, and body. Button shirt collar. Protect ears oreilles, les mains et le corps. Boutonner le col de la chemise. Protéger les oreilles
from noise. Use welding helmet with the correct shade of filter. contre le bruit. Utiliser un masque de soudeur avec un filtre de nuance appropriée.

6. Become trained. Only qualified personnel should operate this 6. Suivre une formation. Seul le personnel qualifié a le droit de faire
equipment. Use torches specified in the manual. Keep non-qualified fonctionner cet équipement. Utiliser exclusivement les torches indiquées dans le
personnel and children away. manual. Le personnel non qualifié et les enfants doivent se tenir à l’écart.
7. Do not remove, destroy, or cover this label. 7. Ne pas enlever, détruire ni couvrir cette étiquette.
Replace if it is missing, damaged, or worn (PN 110584 Rev C). La remplacer si elle est absente, endommagée ou usée (PN 110584 Rev C).

1. Las chispas producidas por el corte pueden causar 3.3 Antes de trabajar en una máquina, desconecte
explosiones o incendios. el enchufe de entrada o la potencia primaria.
1.1 Mantenga los materiales inflamables lejos del lugar 4. La inhalación de los humos provenientes del área
de corte. de corte puede ser nociva para la salud.
1.2 Tenga a mano un extinguidor de incendios y asegúrese 4.1 Mantenga la cabeza fuera de los gases tóxicos.
de que alguien esté preparado para utilizarlo.
4.2 Utilice ventilación forzada o un sistema local de escape
1.3 No corte depósitos cerrados. para eliminar los humos.
2. El arco de plasma puede causar quemaduras y lesiones. 4.3 Utilice un ventilador para eliminar los humos.
2.1 Apague la fuente de energía antes de desarmar 5. Los rayos del arco pueden producir quemaduras en los
la antorcha. ojos y en la piel.
2.2 No sostenga el material junto al trayecto de corte. 5.1 Utilice un sombrero y gafas de seguridad. Utilice
protección para los oídos y abróchese el botón del
2.3 Proteja su cuerpo completamente.
cuello de la camisa. Utilice un casco de soldar con
3. Los electrochoques provocados por la antorcha el filtro de sombreado adecuado. Proteja su cuerpo
o el cableado pueden ser fatales. Protéjase del completamente.
electrochoque.
6. Antes de trabajar en la máquina o de proceder a cortar,
3.1 Colóquese guantes aislantes. No utilice guantes capacítese y lea las instrucciones completamente.
dañados o mojados.
7. No retire las etiquetas de advertencia ni las cubra con
3.2 Aíslese de la pieza de trabajo y de la tierra. pintura.

Hypertherm 1b-9
11/08
SEGURIDAD

ETIQUETA DE ADVERTENCIA 1. Las chispas producidas por el corte

Esta etiqueta de advertencia se encuentra adherida a la fuente de pueden causar explosiones o incendios.
energía. Es importante que el operador y el técnico de mantenimiento 1.1 Mantenga los materiales inflamables
comprendan el sentido de estos símbolos de advertencia según se lejos del lugar de corte.
describen. El texto numerado corresponde a los cuadros numerados 1.2 Tenga a mano un extinguidor de
de la etiqueta. incendios y asegúrese de que alguien
esté preparado para utilizarlo.
1.3 No corte depósitos cerrados.
2. El arco de plasma puede causar
quemaduras y lesiones.
2.1 Apague la fuente de energía antes
de desarmar la antorcha.
2.2 No sostenga el material junto al trayecto
de corte.
2.3 Proteja su cuerpo completamente.
3. Los electrochoques provocados por
la antorcha o el cableado pueden ser
fatales. Protéjase del electrochoque.
3.1 Colóquese guantes aislantes. No utilice
guantes dañados o mojados.
3.2 Aíslese de la pieza de trabajo y de la tierra.
3.3 Antes de trabajar en una máquina,
desconecte el enchufe de entrada
o la potencia primaria.
4. La inhalación de los humos provenientes
del área de corte puede ser nociva para
la salud.
4.1 Mantenga la cabeza fuera de los gases
tóxicos.
4.2 Utilice ventilación forzada o un sistema
local de escape para eliminar los humos.
4.3 Utilice un ventilador para eliminar los
humos.
5. Los rayos del arco pueden producir
quemaduras en los ojos y en la piel.
5.1 Utilice un sombrero y gafas de
seguridad. Utilice protección para los
oídos y abróchese el botón del cuello
110647 Rev. A
de la camisa. Utilice un casco de soldar
www.hypertherm.com/weee con el filtro de sombreado adecuado.
Proteja su cuerpo completamente.
6. Antes de trabajar en la máquina
o de proceder a cortar, capacítese
y lea las instrucciones completamente.
7. No retire las etiquetas de advertencia
ni las cubra con pintura.

1b-10 Hypertherm
11/08
 SEGURIDAD

INFORMACIÓN SOBRE LA COLECCIÓN DE POLVO SECO

En algunos sitios, el polvo seco puede representar un peligro potencial de explosión.

La edición del 2007 de “U.S. National Fire Protection Association” iniciales en inglés NFPA (La Asociación Americana
Nacional de Protección Contra Incendios) del estándar 68 “Protección de Explosión por medio de Respiradero de
Deflagración” proporciona requisitos para el diseño, ubicación, instalación, mantenimiento, y uso de aparatos y sistemas
para dar salida a gases de combustión y presiones después de todo evento de deflagración. Consulte con el fabricante
o instalador de cualquier sistema de colección de polvo seco para los requisitos aplicables antes de que instale un
sistema nuevo de colección de polvo seco, o haga cambios significativos en el proceso o materiales que se usen con
un sistema existente de colección de polvo seco.

Consulte su “Autoridad que Tenga Jurisdicción” (iniciales en inglés AHJ) local para determinar si cualquier edición
de la NFPA 68 ha sido “adoptada por referencia” en los códigos de construcción locales.

Remítase a la NFPA 68 para definiciones y explicaciones de los términos reguladores como “deflagración, AHJ, adoptada
por referencia, el valor Kst, índice de deflagración” y otros términos.

Nota 1 – La interpretación de Hypertherm de estos nuevos requisitos es que, a no ser que se haya completado una
evaluación específica del sitio para determinar que todo polvo generado no es combustible, la edición del 2007 de
la NFPA 68 requiere el uso de respiraderos de explosión diseñados para el peor caso del valor Kst (vea anexo F) que
pudiera ser generado por el polvo, de manera que el tamaño y tipo del respiradero de explosión pueda diseñarse.
La NFPA 68 no identifica específicamente corte por plasma u otros procesos de cortes termales como si requirieran
sistemas de respiraderos de deflagración, pero en realidad aplica estos nuevos requisitos a todos los sistemas de
colección de polvos secos.

Nota 2 – Los usuarios de los manuales de Hypertherm deberían consultar y cumplir con todas las leyes y reglamentos
federales, estatales y locales aplicables. Hypertherm, al publicar todo manual de Hypertherm, no intenta urgir acción
que no esté en cumplimiento con todos los reglamentos y normas, y este manual nunca debe interpretarse como
si lo hiciera así.

Hypertherm 1b-11
11/08
SEGURIDAD

1b-12 Hypertherm
11/08
 Section 2

SPECIFICATIONS

In this section:

Power supply ......................................................................................................................................................2-2

Duty cycle ..................................................................................................................................................2-3
Dimensions and weight ..........................................................................................................................2-3
T100 torches ......................................................................................................................................................2-4
Torch dimensions................................................................................................................................................2-5
T100 hand torch ......................................................................................................................................2-5
T100M-2 machine torch.........................................................................................................................2-5
Symbols and markings......................................................................................................................................2-6
S mark .......................................................................................................................................................2-6
CE mark .....................................................................................................................................................2-6
IEC symbols..............................................................................................................................................2-6

powermax1650 Operator Manual 2-1

3
SPECIFICATIONS

Power supply
Rated open circuit voltage (U0) 300 VDC
Output characteristic* Drooping
*Defined as a plot of output voltage
versus output current
Rated output current (I2) 30A – 100A
Hypertherm Standard Rated Output 160 VDC
Voltage (U2)
Duty cycle (X*) at 104°F (40°C) at U1 – Volts AC rms X
rated conditions (U1, I1, U2, I2) 200-208 VAC 3PH 60%
230-240 VAC 3PH 70%
*X = Ton/Tbase, 380-415 VAC 3PH 80%
Ton = time, minutes 480 VAC 3PH 80%
Tbase = 10 minutes 600 VAC 3PH 80%
Operating temperature 14o to 104o F (-10o to 40o C)
Rated AC phases (PH) and line frequency (Hz) PH Hz
Standard and CE Model 3 50-60
Rated input voltage (U1), rated input U1 – Volts AC rms I1-Amps rms I1eff
current (I1) and I1eff* at rated output 200-208 VAC 3PH 53 41
U2 and I2 – cutting only. 230-240 VAC 3PH 46 38
380-415 VAC 3PH 27 24
*I1eff = (I1) X used to determine 480 VAC 3PH 22 20
rating of power cord. 600 VAC 3PH 21 19
U1 – Volts AC rms Harmonic power factor Displacement
power factor
Power factor 200-208 VAC 3PH 0.94 0.98
230-240 VAC 3PH 0.94 0.98
380-415 VAC 3PH 0.94 0.99
480 VAC 3PH 0.94 0.99
600 VAC 3PH 0.78 0.99
Rsce – Short Circuit Ratio—CE model only U1 – Volts AC rms, 3PH Rsce
400 VAC 191
230 VAC 142
This equipment conforms to IEC 61000-3-12,
provided that Rsce min = 191 at 400VAC 3PH and
142 at 230 VAC 3PH.
IP code—Degree of protection IP23CS*
provided by enclosure IP – “International Protection”
2 – No ingress foreign objects >=12.5mm (0.5 in)
3 – No harmful ingress spraying water
C – AC line circuits protected against ingress of
tool >=2.5 mm dia. x 100 mm long
(0.1 inch x 4.0 inch)
S – fan stationary during water test

*WARNING: DO NOT OPERATE IN THE RAIN

Toppling, tilting (with or without wheel kit) Up to 15o incline.
Gas type Air Nitrogen
Gas quality Clean, moisture-free, oil-free
Gas inlet pressure and flow 90 psig (6.1 bar) 550 scfh/9.2 scfm (260 l/min)

2-2 powermax1650 Operator Manual

0
 SPECIFICATIONS

Duty cycle

Duty cycle is the percentage of time, during a 10 minute period, that the power supply can cut
continuously. The diagram below depicts an 80% duty cycle.

8 minutes cutting 2 minutes resting

Dimensions and weight

16.8 in
(427 mm)
26.4 in
(671 mm)

128 lb
(58.06 kg)

AMPS

60
40

30
80

100

25.8 in
(655 mm)
AC V

50
60 PSI
70
80

4.0
5.0
6.0
BAR

Weight of power supply

without torch
_
+

powermax1650 Operator Manual 2-3

0
SPECIFICATIONS

T100 torches

Handheld cutting capacity at 100 amps

Recommended capacity 1-1/4 inch (32 mm) at 19 ipm (482 mm per min)

Maximum capacity 1-1/2 inch (38 mm) at 10 ipm (250 mm per min)

Severance capacity 1-3/4 inch (45 mm) at low speed

Mechanized cutting capacity at 100 amps

Recommended pierce capacity up to 1/2 inch (13 mm)

Maximum pierce capacity 3/4 inch (19 mm)
Severance with an edge start 1-3/4 inch (45 mm) at low speed

Gouging capability

Metal removal rate on mild steel 24 pounds (10.8 kg) / hour

Weight

7.2 pounds (3.3 kg) with 25 ft (7.5 m) lead

T100 13.9 pounds (6.3 kg) with 50 ft (15 m) lead
20.6 pounds (9.4 kg) with 75 ft (22.5 m) lead

8.3 pounds (3.8 kg) with 25 ft (7.5 m) lead

11.0 pounds (5.0 kg) with 35 ft (10.7 m) lead
T100M-2
15.0 pounds (6.8 kg) with 50 ft (15 m) lead
21.7 pounds (9.9 kg) with 75 ft (22.5 m) lead

2-4 powermax1650 Operator Manual

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 SPECIFICATIONS

Torch dimensions
T100 hand torch

8.9" (226 mm)

1.5"
(38 mm)
4.2"
(107 mm)
2.55"
(65 mm)

1.00"
(25 mm)

T100M-2 machine torch

1.00" 15.47"
(25 mm) (393 mm)

2.35" 8"
(60mm) 1.38"
(203 mm)
(35 mm)
32 pitch .125" (3.2 mm) width

powermax1650 Operator Manual 2-5

3
SPECIFICATIONS

Symbols and markings

S mark

The S mark indicates that the power supply and torch are suitable for use in environments with in-
creased hazard of electrical shock. The hand torches must have shielded consumable parts to
maintain S mark compliance.

CE mark
The CE mark ( ) constitutes a manufacturer’s declaration of conformity to applicable European
directives and standards. Only those versions of Hypertherm products with a CE mark located on or
near the data plate have been tested for compliance with the European Low Voltage Directive and
the European EMC Directive. EMC filters needed to comply with the European EMC Directive are
incorporated within versions of the power supply with a CE mark.

IEC Symbols Used

The following symbols may appear on the power supply data plate, control labels and switches.

Direct current (DC) An inverter-based power

source
Alternating current (AC) Plasma torch in the TEST
position (cooling and cutting
Plasma torch cutting gas exiting nozzle)
and gouging
l Power is ON
AC input power
connection O Power is OFF

The terminal for the Volt/amp curve, "drooping"

external protective (earth) characteristic
conductor

2-6 powermax1650 Operator Manual

2
 Section 3

SETUP

In this section:

Upon receipt.........................................................................................................................................................3-2
Claims ....................................................................................................................................................................3-2
Contents of box ...................................................................................................................................................3-2
Lifting the power supply ....................................................................................................................................3-3
Locating the power supply................................................................................................................................3-4
Power connection ...............................................................................................................................................3-4
Engine drives .............................................................................................................................................3-5
Grounding ............................................................................................................................................................3-6
Power cords .........................................................................................................................................................3-6
Three-phase power cord and plug installation .............................................................................................3-7
Power cord installation ............................................................................................................................3-7
Torch installation..................................................................................................................................................3-8
Plasma gas supply ..........................................................................................................................................3-10
Additional gas filtration .........................................................................................................................3-10
Gas supply installation ....................................................................................................................................3-11
T100M-2 torch alignment ...............................................................................................................................3-11
ON/OFF pendant connection .......................................................................................................................3-12
Machine interface connection .............................................................................................................3-12
Arc voltage...............................................................................................................................................3-13
Changing XFER (start machine motion) from dry contact closure to voltage signal.............3-15

powermax1650 Operator Manual 3-1

3
SETUP

Upon receipt
1. Check that all items on your order have been received. Contact your distributor if any items are
missing or damaged.
2. If there is evidence of damage, refer to Claims, below. All communications regarding this
equipment must include the model number and serial number located on the back of the power
supply.
3. Read the Safety section of this manual before setting up and operating this Hypertherm system.

Claims
Claims for damage during shipment: If your unit was damaged during shipment, you must file a
claim with the carrier. Hypertherm will furnish you with a copy of the bill of lading upon request. If
you need additional assistance, call the nearest Hypertherm office listed in the front of this manual.

Claims for defective or missing merchandise: If any component is missing or defective, contact
your Hypertherm distributor. If you need additional assistance, call the nearest Hypertherm office
listed in the front of this manual.

Contents of the box

Check the items against the illustration.

Hand

OR
Mechanized

OR

(CSA)
OR
(CE)

Operator
Mechanized Manual

Mechanized Quick Setup

Card

3-2 powermax1650 Operator Manual

2
 SETUP

Lifting the power supply

WARNING

• The system with torch weighs up to 150lb / 68 kg.

• Always lift the power supply by TWO handles using two people or a hoist.
• Do not lift the power supply by ONE handle.
• The handle can break, resulting in injury and damage.

Hoist

Approved hoisting strap.

Keep power supply as

horizontal as possible.

Cover in place

powermax1650 Operator Manual 3-3

2
SETUP

Locating the power supply

Locate the Powermax1650 power supply with at least 10 inches (0.25 m) of open space at the
front, back, and fan side of the power supply for proper ventilation.

Power connection
The Powermax1650 is a universal power supply that configures itself to operate with AC voltages
from 200 to 600 3PH (230-400 3PH for the CE model). Use a line disconnect switch for each
power supply so that the operator can turn off the power supply quickly in an emergency. Locate
the switch so it is easily accessible to the operator. The interrupt level of the switch must be equal
to or exceed the continuous rating of the fuses. Use slow-blow fuses rated per local and national
electrical codes.

CSA model Three-phase

Input voltage 200-208 230-240 400 480 600

Input current at 16kw output 53 46 27 22 21

Input current during arc stretch 75 72 42 34 33

Recommend fuse 80 80 50 40 40

CE model Three-phase

Input voltage 230 400

Input current at 16kw output 46 27

Input current during arc stretch 72 42

Recomended fuse 80 50

3-4 powermax1650 Operator Manual

2
 SETUP

Engine drives

When using an engine drive to power the Powermax1650:

• The engine drive must be dedicated to powering the plasma cutting system.

• Engine drive operation:

1. Set the engine drive output to 3 phase-AC.

2. Plug the Powermax1650 power cord into the power outlet.
3. Set the engine drive to the maximum output (see table below).

• Use unshielded consumables if you experience difficulty cutting thicker material (CSA power
supplies only).

CSA power supplies

3-Phase, 50/60 hz, 200 – 600 VAC (480 VAC recommended for best performance)

CE power supplies

3-Phase, 50/60 hz, 230 – 400 VAC (400 VAC recommended for best performance)

Powermax1650
Engine drive rating Performance
output current

30 kw 100 A Full arc stretch

100 A Limited arc stretch

22.5 kw
80 A Full arc stretch
80 A Limited arc stretch
15 kw
60 A Full arc stretch

powermax1650 Operator Manual 3-5

2
SETUP

Grounding
To ensure personal safety and proper operation, and to reduce electromagnetic interference (EMI),
the Powermax1650 must be properly grounded through the power cord according to local and
national electrical codes. Three-phase service must be of the 4-wire type with a green or
green/yellow wire for protective earth ground and must comply with local and national electrical
requirements. Refer to Section 1, Grounding Safety.

Power cords
Use a cord that is certified by local and national codes. The cord should be installed by a licensed
electrician. Refer to the length requirements listed below.

Recommended extension cord gauge size AWG (mm2)

< 10 ft 10-25 ft 25-50 ft 50-100 ft 100-150 ft
<3m 3 – 7.5 m 7.5 – 15 m 15 – 30 m 30 – 45 m
CSA model
Input voltage Phase AWG mm2 AWG mm2 AWG mm2 AWG mm2 AWG mm2
200-208 VAC 3 6 (16) 6 (16) 6 (16) 4 (25) 2 (35)
230 VAC 3 6 (16) 6 (16) 6 (16) 4 (25) 2 (35)
400 VAC 3 8 (10) 8 (10) 8 (10) 8 (10) 8 (10)
480 VAC 3 10 (6) 10 (6) 10 (6) 10 (6) 10 (6)
600 VAC 3 10 (6) 10 (6) 10 (6) 10 (6) 10 (6)
CE model
Input voltage Phase mm2 mm2 mm2 mm2 mm2
230 VAC 3 16 16 16 25 35
400 VAC 3 10 10 10 10 10

Note: The unit was tested with a 2 m power cord to verify EMC standard EN50199 compliance.

3-6 powermax1650 Operator Manual

2
 SETUP

Three-phase power cord and plug installation

The Powermax1650 power supplies are shipped with a 6 AWG 4-wire UL/CSA power cord on
CSA units. A 10 mm2, 4-wire HAR power cord is provided on CE units. To operate the
Powermax1650, use a plug that meets national or local electrical codes. The plug must be
connected to the power cord by a licensed electrician.

Power cord installation

1. Strip and prepare the power cord wires as shown below:

9.5” (241 mm)

CSA CE
L1
L2 L1 Black Black (U)
L3
L2 White Blue (V)
Ground (PE)
L3 Red Brown (W)

#10 Ground
Green Green/Yellow
6” (152 mm) (PE)

2. Connect the power cord to the power switch.

Note: On CE power supplies, L1, L2, and L3 are threaded through 2 ferrites before being
attached ot the switch.
L1 L2 L3
Route power cord
through strain
relief and tighten.

AMPS

60
40

30
80

100

AC V

50

4.0
60
70

5.0
80
PSI

Power switch
Strain relief
6.0
BAR

_
+

Strain relief
inserts (2)
Ground (PE)

powermax1650 Operator Manual 3-7

2
SETUP

Torch installation
1. Turn OFF the power.

OFF

ON

2. Remove the power cord from the power receptacle.

3. Open the Easy Torch Removal (ETR) door and route the lead through the end cap.

AMPS

60
40

30
80

100

AC V

50
60 PSI
70
80

4.0
5.0
6.0
BAR

_
+

ETR door

End cap

3-8 powermax1650 Operator Manual

2
 SETUP

4. Align the marks on the strain relief.

5. Pull back the quick-release collar and insert

the lead’s gas fitting.

Quick-release collar

6. Slide the quick-release collar foward to lock

the gas fitting in place. Make sure that the
gas fitting is secure.

7. Make sure that the red dot on the connector

is on top, then plug in the electrical
connector.

Close the ETR door.

powermax1650 Operator Manual 3-9

2
SETUP

Plasma gas supply

The gas supply for the Powermax1650 can be shop-compressed air or cylinder-compressed air. A
high-pressure regulator must be used on either type of supply and must be capable of delivering
gas to the filter on the power supply at 550 scfh/9.2 scfm (260 l/min), minimum flow rate, at a
minimum pressure of 90 psig (6.1 bar).

Note: If the gas supply quality is poor, cut speeds decrease, cut quality deteriorates,
cutting thickness capability decreases, and parts life shortens.

WARNING

Do not allow the gas supply pressure to exceed 120 psi (8.3 bar). The filter bowl
may explode if this pressure is exceeded.

Additional gas filtration

Use Hypertherm filter kit (part number 128647) when site conditions introduce moisture, oil or
other particulates into the air line. A 3-stage coalescing filtration system, as shown, should be used
in extreme conditions.

Filter kit
128647

Gas supply Powermax1650

OR

Water/particle filter Oil filter Oil vapor filter

Gas supply Powermax1650

3-10 powermax1650 Operator Manual

2
 SETUP

Gas supply installation

Connect the air hose as follows:

1. Air fitting

• For the standard model: Install a 1/4

NPT gas fitting on to the air filter inlet.
The CE model provides a G1/4 adapter
in the CE kit. Use liquid pipe sealant on
the threads.
CAUTION: Never use Teflon tape when
installing the nipple or adapters. Bits of
tape can break off and enter the air line
and harm the pressure regulator,
pressure switch, and valve.

• Nipple/Adapter is found in the

consumables box, located on the side
of the power supply cover.

2. Air hose

• Use an inert gas hose with a 3/8 inch

(9.5 mm) internal diameter. Connect
it to the gas fitting installed in step 1.

Adjust the air pressure according to the

procedure in Section 4, Operation.

T100M-2 torch alignment

Mount the machine torch perpendicular to the workpiece in
order to get a vertical cut. Use a square to align the torch at 0°
and 90°. Torch

0°
90°

powermax1650 Operator Manual 3-11

3
SETUP

ON/OFF pendant connection

For the machine torch (T100), inputs for arc start are available through the machine interface
connection on the rear of the power supply. Plug the Hypertherm remote pendant (see Section 5,
Maintenance and parts, for part numbers) into the connector on the rear panel.

WARNING

The ON/OFF remote pendant will not operate when a hand torch is installed.

Machine interface connection

Signals for arc transfer and start are
available through the machine interface
connection on the rear of the power supply.
Plug the machine interface cable (Part
number 023206) into the connector on the
rear panel.

Powermax1650 power supplies sold as part

of the PowermaxEdge® package include a
machine interface cable with a voltage
divider.

Refer to the following table when

connecting the machine interface cable to
the cutting machine.

Signal Start (start plasma) XFER (start machine motion)

Type: Input Output

Normally open. Dry contact closure
Normally open, 18VDC open circuit when the arc transfers. 120VAC/1A
Notes: voltage at START terminals. REquires maximum at the machine interface relay
dry contact closure to activate. or switching device (supplied by the
customer).
Rear panel
3, 4 12, 14
sockets

Cable wires Green, black Red, black

3-12 powermax1650 Operator Manual

2
 SETUP

WARNING
ELECTRIC SHOCK CAN KILL

Disconnect electrical power before performing any maintenance.

All work requiring removal of the power supply cover must be
performed by a qualified technician.

Arc voltage

If arc voltage is necessary for activating a torch height control, the customer must supply an
18 AWG (1.0 mm2), single pair, unshielded cable rated for 300V or greater. All work must be
performed following applicable local and national codes.

1. Disconnect the power from the power supply.

2. Remove the screws that attach the power supply cover to the chassis. Remove the cover.

3. Route the cable through the strain relief at the rear of the power supply.

powermax1650 Operator Manual 3-13

2
SETUP

4. Find the power board. Use insulated type 1/4-inch faston terminal ends to connect to J15 and
J16.

Signal: Arc voltage (torch height control)

Type: Output

Notes: Full arc voltage. No voltage divider. 300 VDC

maximum. (Signal not available on rear panel
connector.)

J15 +VDC

J16 –VDC

5. Tighten the strain relief.

6. Replace the cover

3-14 powermax1650 Operator Manual

2
 SETUP

Changing XFER (start machine motion) from dry contact closure to

voltage signal

24 VDC (chassis ground reference) at 100ma max is available at J19 on the powerboard to drive
an isolated/floating device such as a 24 VDC relay coil (240 ohms or greater) or a typical industrial
isolated input module (which has an opto-coupler built-in). Shown below are typical connections
for a high-side drive arrangement.

Driving a relay coil

5
V-div –
6 V-div +
4
Start
3 Signal
14
12
13

Shield

J16 J15

J19 XFER START

24VDC
GND

WHT
RED
YEL
BLK

Notes:
1. Customer supplied 24 VDC
relay coil > 240 ohms.
2. Must use suppression diode
BLK

(1A, 100V) such as IN4002

through IN4004 type across
coil.
3. Pins 5 and 6 are used only on
Move the black (BLK) wire
systems that include the
to ground (GND) and add
PowermaxEDGE cable with
a jumper wire as shown.
voltage divider.

powermax1650 Operator Manual 3-15

2
SETUP

Driving an industrial isolated input module

5
V-div –
6 V-div +
4
Start
3
Signal
14
12
13

Isolated input
Shield module
+

J16 J15
–
J19 XFER START
24VDC
GND

WHT
RED
YEL
BLK

Notes:
BLK

1. Customer-supplied
isolated input module.

Move the black (BLK) wire 2. Pins 5 and 6 are used only on
to ground (GND) and add systems that include the
a jumper wire as shown. PowermaxEDGE cable with
voltage divider.

3-16 powermax1650 Operator Manual

2
 SETUP

Driving a relay coil with an external power source

5 V-div –
6 V-div +
4
Start
3
Signal
14
12
13
+
Shield 24 VDC
–

J16 J15

J19 XFER START

24VDC
GND

WHT
RED
YEL
BLK

Notes:
1. Customer-supplied 24 VDC relay
coil > 240 ohms.
2. Customer-supplied 24 VDC power
source.
3. Must use suppression diode
(1A, 100V) such as IN4002
through IN4004 type across coil.
4. Pins 5 and 6 are used only on
systems that include the
PowermaxEDGE cable with voltage
divider.

powermax1650 Operator Manual 3-17

2
SETUP

Driving an industrial isolated input module with an external power source

5 V-div –
6 V-div +
4
Start
3 signal
14
12
13 +
24 VDC
Shield –
Isolated input
module
+

J16 J15

J19 XFER START –

24VDC
GND

WHT
RED
YEL
BLK

Notes:
1. Customer-supplied
isolated input module.
2. Customer-supplied
24 VDC power source.
3. Pins 5 and 6 are used only
on systems that include the
PowermaxEDGE cable
with voltage divider.

3-18 powermax1650 Operator Manual

2
 Section 4

OPERATION

In this section:

Controls and indicators .....................................................................................................................................4-2

Indicator LEDs...........................................................................................................................................4-2
Install the consumables .....................................................................................................................................4-3
T100 consumable configurations....................................................................................................................4-4
Shielded......................................................................................................................................................4-4
Unshielded .................................................................................................................................................4-4
FineCut........................................................................................................................................................4-4
Gouging ......................................................................................................................................................4-5
T100M-2 consumable configurations ............................................................................................................4-5
Shielded......................................................................................................................................................4-5
FineCut........................................................................................................................................................4-6
Ohmic sensing retaining caps...............................................................................................................4-6
Unshielded .................................................................................................................................................4-6
Set the mode switch...........................................................................................................................................4-7
Turn ON the power .............................................................................................................................................4-7
Check the indicator lights..................................................................................................................................4-7
Adjust the gas pressure and current setting ................................................................................................4-8
Hand torch operation .........................................................................................................................................4-9
Safety trigger operation ..........................................................................................................................4-9
Attach the work clamp ..........................................................................................................................4-10
Start a cut from the edge of the workpiece .....................................................................................4-10
Hand torch cutting technique..............................................................................................................4-11
Piercing ....................................................................................................................................................4-12
Gouging ...................................................................................................................................................4-13
Cut charts...........................................................................................................................................................4-14

powermax1650 Operator Manual 4-1

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OPERATION

Controls and indicators

ON (I) / OFF (0) switch

Current (amps)
adjustment / AMPS
Mode switch
gas test knob
60
40

30 80

100

V
AC

PSI
50 60 70 80

4.0 5.0 6.0

BAR

Pressure gauge
_ +

Indicator
LEDs
Pressure
regulator

Indicator LEDs

Green power ON LED

AC When illuminated, indicates that power is applied to the system and the power switch is
ON ( I ).

Gas pressure LED

Yellow: When flashing, indicates that the gas pressure is below 65 psig (4.5 bar) for
cutting, or 40 psig (2.8 bar) for gouging.
Green: When illuminated, indicates that there is acceptable gas pressure for torch
operation.

Yellow torch cap LED

When illuminated, indicates that the retaining cap is loose or not installed.
NOTE: This condition must be corrected and the power turned OFF and then ON
again to clear the LED.

Yellow temperature LED

When illuminated, indicates that the power supply temperature has exceeded its operating
limit.

Red fault LED

When illuminated, indicates that a fault condition exists, which prevents system operation.
A yellow LED should also be illuminated to identify the type of fault.

Yellow line voltage LED

V When illuminated, indicates that line voltage is below 170 VAC, above 680 VAC, or
missing a phase.

4-2 powermax1650 Operator Manual

2
 OPERATION

Install the consumables

WARNING
Instant-On Torches
PLASMA ARC CAN CAUSE INJURY AND BURNS

The plasma arc comes on immediately when the torch switch is

activated. The plasma arc will quickly burn through gloves and skin.
Make sure the power is OFF before changing the consumables.

The instructions for hand torches are shown below. If you are using a machine torch, you may need
to install it on the cutting table prior to installing the consumables.

1 Shield

Retaining cap

Nozzle

Electrode

Swirl ring

2 Note: Hand tighten only.

powermax1650 Operator Manual 4-3

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OPERATION

T100 consumable configurations

Shielded

40A

120929 120928 120932

O-ring
60A 058519

120929 120928 120931 120926 120925

80A

120929 120928 120927

100A

220065 220048 220011 220037 220051

Unshielded
The unshielded consumables available for the T100 hand torch (only for use with non-CE systems)
are the same as those used for the T100M-2. See the illustrations later in this section.

FineCut
30A — 50A O-ring
058519

220325*

120928 220329 120926 220327**

120979
*For use with CE systems.
**The 220327 swirl ring is intended for manual
cutting with FineCut consumables.

4-4 powermax1650 Operator Manual

3
 OPERATION

Gouging

O-ring
058519
60A/80A

120977 120928 220059 120926 120925

100A

120977 220048 220063 220037 220051

T100M-2 consumable configurations

Shielded

40A

120930 120928 120932

60A
O-ring
120930 120928 120931 120926 120925 058519

80A

120930 120928 120927

100A

220047 220048 220011 220037 220051

powermax1650 Operator Manual 4-5

3
OPERATION

FineCut
30A – 50A O-ring
058519

220325*

120928 220329 120926 120925

120979

220404 220061**
* In CE countries, unshielded
Ohmic sensing retaining caps** consumables may only be used in
mechanized torch applications.

Maintain a torch-to-work distance of

40A-80A 100A approximately 1/8 inch (3mm).
220061 220206 ** Use an ohmic sensing cap when a
compatible torch height contoller is
installed.
Unshielded*

40A

120979 120928 220006

60A
O-ring
058519
120979 120928 220007 120926 120925

80A

120979 120928 120980

100A

120979 220048 220064 220037 220051

4-6 powermax1650 Operator Manual

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 OPERATION

Set the mode switch

Use to cut expanded metal.

Automatically reinitiates pilot.

Use to cut plate/sheet metal.

Optimum consumable life.

Use to gouge, or for non-transfered-arc operation.

Turn ON the power

Position the power switch to ON ( I ) as shown.

Note: The cooling fan is automatic and will only operate

when needed.

Check the indicator lights

Check that the power ON lamp is illuminated.

AC

Check that the gas pressure LED illuminates green.

Check that the remaining indicator lamps are NOT illuminated. See Section 5, Maintenance and
parts, for details.

powermax1650 Operator Manual 4-7

2
OPERATION

Adjust the gas pressure and current setting

1 4
AMPS
40
60

25

80

Set the current knob to gas test. Push the regulator knob to lock it.

2 5
AMPS
40
60

25

80

Pull the regulator knob to unlock it. Set the cutting current (30 amps minimum).

3 50 60 70 80 PSI

4.0 5.0 6.0 BAR

35-50 ft
12-15 m

15-25 ft
4.5-7.5 m

15-50 ft
4.5-15 m

Set the pressure as shown above based

on the cutting mode and torch lead length.

4-8 powermax1650 Operator Manual

2
 OPERATION

Hand torch operation

WARNING
Instant-On Torches
PLASMA ARC CAN CAUSE INJURY AND BURNS

The plasma arc comes on immediately when the torch switch is activated.
The plasma arc will quickly burn through gloves and skin.
• Keep away from the torch tip.
• Do not hold the workpiece, and keep your hands clear of the cutting path.
• Never point the torch toward yourself or others.
• Never use with the pendant switch.

Safety trigger operation

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OPERATION

WARNING
SPARKS AND HOT METAL CAN INJURE EYES AND
BURN SKIN

When firing the torch at an angle, sparks and hot metal will spray out
from the nozzle. Point the torch away from yourself and others.

Attach the work clamp

Attach the work clamp securely to the workpiece.
Remove rust, paint or other coatings to ensure
good electrical contact.

Attach the work clamp as close as possible to the

area being cut, to reduce exposure to
electromagnetic fields (EMF).

Do not attach the work clamp to the portion that

will fall away.

Start a cut from the edge of the workpiece

Hold the torch vertical at the edge of the

workpiece.

Start cutting from the edge of the workpiece.

Pause at the edge until the arc has completely cut

through the workpiece.

Then, proceed with the cut.

4-10 powermax1650 Operator Manual

2
 OPERATION

Hand torch cutting technique

Firing the torch unnecessarily reduces nozzle and electrode life.

When cutting, make sure that sparks are exiting from

the bottom of the workpiece.

If sparks are spraying up from the workpiece, you are

moving the torch too fast, or without sufficient power.

Hold the torch vertically and watch the arc as it cuts

along the line.

Unshielded consumables: Maintain a torch-to-work

distance of approximately 3/16 in (4.8 mm).

Shielded consumables: Do not push down on the

torch when cutting. Drag the torch lightly across the
workpiece to maintain a steady cut.

• It is easier to pull the torch through the cut than to push it.
• To cut thin material, reduce the amps until you get the best quality cut.
• For straight-line cuts, use a straight edge as a guide. To cut circles, use a template or the
Hypertherm plasma cutting guide (part number 027668).
• Postflow – After the torch trigger switch is released, the gas will continue to flow for 30
seconds to cool the torch and consumables.
Note: The torch will restart if you activate the trigger switch during the postflow. To stop
the postflow, activate and quickly release the torch trigger.

powermax1650 Operator Manual 4-11

2
OPERATION

Piercing
WARNING
SPARKS AND HOT METAL CAN INJURE
EYES AND BURN SKIN

When firing the torch at an angle, sparks and hot metal will
spray out from the nozzle. Point the torch away from yourself
and others.

Hold the torch so that the nozzle is within 1/8 in (3 mm) from the workpiece before firing the torch.

Fire the torch at an angle to the

workpiece, then slowly rotate it to
an upright position.

When sparks are exiting from the

bottom of the workpiece, the arc
has pierced through the material.

When the pierce is complete,

proceed with the cut.

4-12 powermax1650 Operator Manual

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 OPERATION

Gouging
WARNING
SPARKS AND HOT METAL CAN INJURE
EYES AND BURN SKIN

When firing the torch at an angle, sparks and hot metal will
spray out from the nozzle. Point the torch away from yourself
and others.

Hold the torch so that the nozzle is within 1/16 in (1.5 mm) from the workpiece before firing the
torch.

Hold the torch at a 45° angle to the

workpiece. Pull the trigger to obtain a
pilot arc. Transfer the arc to the work
piece.

Maintain an approximate 45° angle to

the workpiece.

Feed into the gouge.

Direction of travel
45°

Note: A heat shield is available for added hand and torch protection (part number 220049).

powermax1650 Operator Manual 4-13

0
OPERATION

Cut charts
100 amp mechanized shielded consumables
• Torch-to-work distance for the following cut chart is 1/8 in (3.2 mm) for all cuts.

Shield Retaining cap Nozzle Electrode Swirl ring T100M-2

220047 220048 220011 220037 220051 torch

Mild steel
Pierce Material thickness Maximum travel speed Optimum travel speed
Arc current Arc voltage
delay Inches mm IPM mm/min IPM mm/min
153 0.5 1/4” 6.4 208 5283 135 3429
155 0.5 3/8” 9.5 119 3022 77 1955
159 1.0 1/2” 12.7 88 2235 57 1447
100 160 1.0 5/8” 15.9 61 1549 40 1016
161 1.5 3/4” 19.0 47 1193 26 660
163 1 25.4 28 711 18 457
NA
167 1 1/4” 31.8 19 482 12 305
Stainless steel
Pierce Material thickness Maximum travel speed Optimum travel speed
Arc current Arc voltage
delay Inches mm IPM mm/min IPM mm/min
154 0.5 1/4” 6.4 231 5867 150 3810
156 0.5 3/8” 9.5 122 3099 79 2006
161 1.0 1/2” 12.7 79 2006 52 1320
100 162 1.0 5/8” 15.9 52 1320 34 863
164 1.5 3/4” 19.0 39 990 25 635
166 1” 25.4 23 584 15 381
NA
169 1 1/4” 31.8 14 355 9 228

Aluminum
Pierce Material thickness Maximum travel speed Optimum travel speed
Arc current Arc voltage
delay Inches mm IPM mm/min IPM mm/min
154 0.5 1/4” 6.4 253 6426 164 4165
157 0.5 3/8” 9.5 142 3606 92 2336
160 1.0 1/2” 12.7 108 2743 70 1778
100
161 1.0 5/8” 15.9 77 1955 50 1270
162 1,5 3/4” 19.0 57 1447 33 838
165 NA 1” 25.4 33 838 21 533

Maximum travel speeds are the fastest speeds possible for cutting the material without regard to cut quality. Optimum travel
speeds provide the best cut angle, least dross and best cut surface finish. Remember that cut charts are intended to
provide a good starting point for each different cut assignment. Every cutting system requires “fine tuning” for each
cutting application in order to obtain the desired cut quality.

4-14 powermax1650 Operator Manual

3
 OPERATION

80 amp mechanized shielded consumables

• Torch-to-work distance for the following cut chart is 1/16 in (1.5 mm) for all cuts.

Shield Retaining cap Nozzle Electrode Swirl ring T100M-2

120930 120928 120927 120926 120925 torch

Mild steel
Pierce Material thickness Maximum travel speed Optimum travel speed
Arc current Arc voltage
delay Inches mm IPM mm/min IPM mm/min
132 0.25 3/16” 4.8 216 5486 140 3556
134 1/4” 6.4 161 4089 105 2667
137 0.50 3/8” 9.5 94 2388 61 1549
140 1/2” 12.7 60 1524 39 991
80 145 1.0 5/8” 15.9 40 1016 26 660
148 3/4” 19.0 31 787 20 508
150 N/A 7/8” 22.2 23 584 15 381
156 1” 25.4 16 406 10 254
Stainless steel
Pierce Material thickness Maximum travel speed Optimum travel speed
Arc current Arc voltage
delay Inches mm IPM mm/min IPM mm/min
134 0.25 3/16” 4.8 216 5486 140 3556
136 0.50 1/4” 6.4 158 4013 103 2616
139 3/8” 9.5 83 2108 54 1372
0.75
80 142 1/2” 12.7 50 1270 33 838
145 1.0 5/8” 15.9 34 864 22 559
150 3/4” 19.0 24 610 16 406
N/A
153 1” 25.4 14 356 9 229

Aluminum
Pierce Material thickness Maximum travel speed Optimum travel speed
Arc current Arc voltage
delay Inches mm IPM mm/min IPM mm/min
134 1/8” 3.2 454 11532 295 7493
0.25
139 1/4” 6.4 176 4470 114 2896
80 143 3/8” 9.5 121 3073 60 1524
0.75
146 1/2” 12.7 75 1905 37 940
154 N/A 3/4” 19.0 37 940 19 483

Maximum travel speeds are the fastest speeds possible for cutting the material without regard to cut quality. Optimum travel
speeds provide the best cut angle, least dross and best cut surface finish. Remember that cut charts are intended to
provide a good starting point for each different cut assignment. Every cutting system requires “fine tuning” for each
cutting application in order to obtain the desired cut quality.

powermax1650 Operator Manual 4-15

3
OPERATION

60 amp mechanized shielded consumables

• Torch-to-work distance for the following cut chart is 1/16 in (1.5 mm) for all cuts.

Shield Retaining cap Nozzle Electrode Swirl ring T100M-2

120930 120928 120931 120926 120925 torch

Mild steel
Pierce Material thickness Maximum travel speed Optimum travel speed
Arc current Arc voltage
delay Inches mm IPM mm/min IPM mm/min
134 16 Ga 1.5 627 15926 502 12751
0
134 10 Ga 3.4 264 6706 211 5359
138 0.25 1/4” 6.4 132 3353 86 2184
60 141 0.75 3/8” 9.5 63 1600 41 1041
141 1/2” 12.7 42 1067 27 686
147 1.50 5/8” 15.9 31 787 20 512
153 3/4” 19.0 22 559 14 363

Stainless steel
Pierce Material thickness Maximum travel speed Optimum travel speed
Arc current Arc voltage
delay Inches mm IPM mm/min IPM mm/min
134 0 16 Ga 1.5 625 15875 406 10312
136 0.25 10 Ga 3.4 244 6198 159 4039
139 0.50 1/4” 6.4 110 2794 72 1829
60 145 0.75 3/8” 9.5 53 1346 34 864
146 1/2” 12.7 35 889 23 584
149 2.00 5/8” 15.9 26 660 17 429
154 3/4” 19.0 18 457 12 297

Aluminum
Pierce Material thickness Maximum travel speed Optimum travel speed
Arc current Arc voltage
delay Inches mm IPM mm/min IPM mm/min
135 0 1/16” 1.6 666 16916 433 10995
138 1/8” 3.2 400 10160 260 6604
0.25
141 1/4” 6.4 145 3683 94 2388
60
146 0.75 3/8” 9.5 74 1880 48 1219
149 1/2” 12.7 51 1295 30 762
1.50
153 5/8” 15.9 33 838 21 545

Maximum travel speeds are the fastest speeds possible for cutting the material without regard to cut quality. Optimum travel
speeds provide the best cut angle, least dross and best cut surface finish. Remember that cut charts are intended to
provide a good starting point for each different cut assignment. Every cutting system requires “fine tuning” for each
cutting application in order to obtain the desired cut quality.

4-16 powermax1650 Operator Manual

3
 OPERATION

40 amp mechanized shielded consumables

• Torch-to-work distance for the following cut chart is 1/16 in (1.5 mm) for all cuts.

Shield Retaining cap Nozzle Electrode Swirl ring T100M-2

120930 120928 120932 120926 120925 torch

Mild steel
Pierce Material thickness Maximum travel speed Optimum travel speed
Arc current Arc voltage
delay Inches mm IPM mm/min IPM mm/min
147 26 GA 0.5 638 16205 415 10541
25 148 22 GA 0.8 500 12700 325 8255
149 18 GA 1.3 312 7925 203 5156
152 16 GA 1.5 176 4470 114 2896
144 0.25 14 GA 1.9 640 16256 221 5613
146 0.50 10 GA 3.4 151 3835 98 2489
40 147 0.75 3/16” 4.7 97 2464 63 1600
149 1.00 1/4” 6.4 74 1880 48 1219

Stainless steel
Pierce Material thickness Maximum travel speed Optimum travel speed
Arc current Arc voltage
delay Inches mm IPM mm/min IPM mm/min
139 26 GA 0.5 631 16027 410 10414
25
139 22 GA 0.8 496 12598 322 8179
142 0.25 18 GA 1.3 592 15037 335 8509
144 0.25 16 GA 1.5 374 9500 243 6172
144 0.25 14 GA 1.9 221 5613 144 3658
40 147 0.50 10 GA 3.4 107 2718 70 1778
149 0.75 3/16” 4.7 67 1702 44 1118
149 1.00 1/4” 6.4 47 1194 31 787

Aluminum
Pierce Material thickness Maximum travel speed Optimum travel speed
Arc current Arc voltage
delay Inches mm IPM mm/min IPM mm/min
150 1/32” 0.8 610 15494 397 10084
25
152 1/16” 1.5 268 6807 174 4420
146 0.25 3/32” 2.4 293 7442 190 4826
40 149 0.50 1/8” 3.2 204 5182 133 3378
151 1.00 1/4” 6.4 76 1930 49 1245

Maximum travel speeds are the fastest speeds possible for cutting the material without regard to cut quality. Optimum travel
speeds provide the best cut angle, least dross and best cut surface finish. Remember that cut charts are intended to
provide a good starting point for each different cut assignment. Every cutting system requires “fine tuning” for each
cutting application in order to obtain the desired cut quality.

powermax1650 Operator Manual 4-17

3
OPERATION

FineCut consumables
• Torch-to-work distance for the following cut chart is 0.08 inches (2 032 mm) for mild steel and
0.010 inches (0.254 mm) for stainless steel.
Deflector Retaining Nozzle Electrode Swirl ring T100M-2
cap torch

220325*

120928 220329 120926 120925

120979
* For use with CE systems.
** Use an ohmic sensing cap when a compatible
torch height controller is installed.
220404 220061**

Mild steel
Material thickness Approximate travel speeds
Arc current Arc voltage
Inches mm IPM mm/min
50 76 10 Ga 3.4 90 2286
40 83 10 Ga 3.4 50 1270
45 77 12 Ga 2.7 120 3048
81 12 Ga 2.7 70 1778
79 14 Ga 1.9 135 3810
40 79 16 Ga 1.5 150 3810
79 18 Ga 1.2 150 2540
78 20 Ga 0.9 120 2540
30 80 24 Ga 0.6 150 3174

Stainless steel
Material thickness Approximate travel speeds
Arc current Arc voltage
Inches mm IPM mm/min
50 63 10 Ga 3.4 80 1905
40 73 10 Ga 3.4 60 1524
45 63 12 Ga 2.7 100 3174
72 12 Ga 2.7 80 1905
65 14 Ga 1.9 150 3810
40 64 16 Ga 1.5 150 3810
64 18 Ga 1.2 150 3810
65 20 Ga 0.9 150 3810
30 66 24 Ga 0.6 150 3810

4-18 powermax1650 Operator Manual

3
 OPERATION

100 amp mechanized unshielded consumables

• Torch-to-work distance for the following cut chart is 3/16 in (4.8 mm) for all cuts.

Deflector Retaining cap Nozzle Electrode Swirl ring T100M-2

120979 220048 220064 220037 220051 torch

Mild steel
Pierce Material thickness Maximum travel speed Optimum travel speed
Arc current Arc voltage
delay Inches mm IPM mm/min IPM mm/min
136 0.5 1/4” 6.4 210 5334 137 3479
139 0.5 3/8” 9.5 122 3098 79 2006
142 1.0 1/2” 12.7 91 2311 59 1498
100 146 1.0 5/8” 15.9 57 1447 37 939
150 1.5 3/4” 19.0 43 1092 28 711
155 1” 25.4 26 660 17 431
NA
160 1 1/4” 31.8 16 406 10 254

Stainless steel
Pierce Material thickness Maximum travel speed Optimum travel speed
Arc current Arc voltage
delay Inches mm IPM mm/min IPM mm/min
136 0.5 1/4” 6.4 241 6121 157 3987
139 0.5 3/8” 9.5 131 3327 85 2159
142 1.0 1/2” 12.7 81 2057 53 1346
100 146 1.0 5/8” 15.9 51 1295 33 838
150 1.5 3/4” 19.0 33 838 22 558
155 1” 25.4 22 558 14 355
NA
161 1 1/4” 31.8 11 279 7 177

Aluminum
Pierce Material thickness Maximum travel speed Optimum travel speed
Arc current Arc voltage
delay Inches mm IPM mm/min IPM mm/min
137 0.5 1/4” 6.4 255 6477 166 4216
139 0.5 3/8” 9.5 153 3886 99 2514
142 1.0 1/2” 12.7 107 2717 70 1778
100
147 1.0 5/8” 15.9 77 1955 50 1270
150 1.5 3/4” 19.0 51 1295 33 838
154 NA 1” 25.4 31 787 20 508

Maximum travel speeds are the fastest speeds possible for cutting the material without regard to cut quality. Optimum travel
speeds provide the best cut angle, least dross and best cut surface finish. Remember that cut charts are intended to
provide a good starting point for each different cut assignment. Every cutting system requires “fine tuning” for each
cutting application in order to obtain the desired cut quality.

powermax1650 Operator Manual 4-19

3
OPERATION

40 to 60 amp mechanized unshielded consumables

• Torch-to-work distance for the following cut chart is 1/16 inch (1.5 mm) for all cuts.

Deflector Retaining cap Nozzle Electrode Swirl ring T100M-2

120979 120928 220006 120926 120925 torch

Mild steel
Pierce Material thickness Maximum travel speed Optimum travel speed
Arc current Arc voltage
delay Inches mm IPM mm/min IPM mm/min
125 26 GA 0.5 550 13970 353 8966
25 128 22 GA 0.8 484 12294 315 8001
130 18 GA 1.3 238 6045 155 3937
131 16 GA 1.5 167 4242 109 2769
40 129 0.25 14 GA 1.9 326 8280 212 5385

Stainless steel
Pierce Material thickness Maximum travel speed Optimum travel speed
Arc current Arc voltage
delay Inches mm IPM mm/min IPM mm/min
127 26 GA 0.5 561 14249 365 9271
25
127 22 GA 0.8 453 11506 295 7493
123 0.25 18 GA 1.3 500 12700 325 8255
40 127 0.25 16 GA 1.5 367 9322 239 6071
128 0.25 14 GA 1.9 220 5588 143 3632

Aluminum
Pierce Material thickness Maximum travel speed Optimum travel speed
Arc current Arc voltage
delay Inches mm IPM mm/min IPM mm/min
125 1/32” 0.8 564 14326 366 9296
25
127 1/16” 1.5 236 5994 153 3886
40 127 0.25 3/32” 2.4 261 6629 170 4318

Maximum travel speeds are the fastest speeds possible for cutting the material without regard to cut quality. Optimum travel
speeds provide the best cut angle, least dross and best cut surface finish. Remember that cut charts are intended to
provide a good starting point for each different cut assignment. Every cutting system requires “fine tuning” for each
cutting application in order to obtain the desired cut quality.

4-20 powermax1650 Operator Manual

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 Section 5

MAINTENANCE AND PARTS

In this section:

Routine maintenance..........................................................................................................................................5-2
Inspect the consumables........................................................................................................................5-3
Filter element replacement .....................................................................................................................5-4
Controls and indicators .....................................................................................................................................5-5
Basic troubleshooting ........................................................................................................................................5-6
System circuit diagram ......................................................................................................................................5-9
Technical questions..........................................................................................................................................5-10
Parts.....................................................................................................................................................................5-10
Torch parts ...............................................................................................................................................5-10
Power supply parts ................................................................................................................................5-11
Accessories.............................................................................................................................................5-11

powermax1650 Operator Manual 5-1

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MAINTENANCE AND PARTS

Routine maintenance

WARNING
ELECTRIC SHOCK CAN KILL

Disconnect the electrical power before performing any

maintenance. All work requiring removal of the power supply
cover must be performed by a qualified technician.

PSI
50 60 70 80

4.0 5.0 6.0

BAR

Each Use Check the consumables for

Check the gas pressure. wear and proper installation.

Check the torch cap-on safety switch: observe

that red fault LED and yellow torch cap LED
illuminate when cap is loosened.
Each Week

3 Months Check the trigger for damage. Check

the torch body for cracks or exposed
Replace damaged labels.
wires.

Check the pressure hose,

Replace power cord or Replace torch lead filter element, and
plug if damaged. if damaged. connections for leaks.

Clean the inside of

the power supply
with air pressure or
6 Months
vacuum.

5-2 powermax1650 Operator Manual

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 MAINTENANCE AND PARTS

Inspect the consumables

Part Check for Action

Roundness of through hole

Nozzle
Center hole Good Worn Replace

Max. 1/32 inch

Electrode (0.8 mm)

Center surface Maximum pit depth Replace

1/32 inch (0.8 mm)

Swirl ring

External surfaces Damage or debris Replace

Central bore (I.D.) Does electrode slide easily? Replace

Gas holes Blocked holes Replace

Torch o-ring
External surfaces Damage or wear Replace

Dry surface Apply a thin film of

silicone grease
(part number 027055)

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MAINTENANCE AND PARTS

Filter element replacement

1. Disconnect the electrical power and the gas supply. Remove
the filter bowl.
A. Pull down and hold the black release tab. (If you do not see
the tab, check the back of the filter bowl.)
B. Rotate the filter bowl in either direction until it releases. A

C. Pull the filter bowl down to remove it. The bowl has an o-
ring around the top. Do not discard the o-ring. B

If the o-ring shows signs of wear or otherwise needs

replacement, verify that you have the correct o-ring for the filter.
(Each filter has a label on one side of the filter body.) C

• For AF30 filters, use part number 011105.

• For NAF3000 filters, use part number 011094.

2. Use a screwdriver to remove the filter element from the filter

housing. Then install the new filter element.
Note: Do not allow the filter element to turn when loosening
the screw.

3. Re-install filter bowl.

A. Hold down the black tab and slide the filter bowl over
the filter element.
B. Align the marks on filter bowl and the filter body. B

C. Rotate the filter bowl until it locks in place.

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 MAINTENANCE AND PARTS

Basic troubleshooting
Problem Cause / Solution
1. The ON/OFF power switch is set 1.1 The power cord is not plugged into the
to I (ON), and the power ON power receptacle.
(green) lamp is not illuminated. Plug the power cord into the receptacle.

1.2 The disconnect power switch is not set to ON

or there is no power available to the
AC disconnect power switch box.
Turn on the power at the main power panel or
Note: The fan turns on automatically. at the disconnect power switch box.
The fan may not be in operation
when the power is ON.

2. The power ON (green), low gas - 2.1 The gas supply is turned OFF or not
pressure (yellow) is flashing and connected to the power supply.
fault (Red) lamps are Check that the gas is turned on and is
illuminated. connected to the power supply.

2.2 The gas supply pressure is too low.

Set the incoming gas supply pressure to 90-
120 psig / 6.2-8.3 bar. Check that there are no
leaks in the gas supply line.

2.3 Operating gas pressure is set too low for

the selected mode.
Adjust the operating gas pressure. See
Section 4 for pressure settings.

3. The power on, line voltage 3.1 The line voltage is too low, too high, or a
(yellow) and fault (red) lamps are phase is missing.
illuminated. Have a qualified technician check the incoming
power.

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MAINTENANCE AND PARTS

Basic troubleshooting (continued)

Problem Cause / Solution

4. The power ON (green), 4.1 One of the internal thermostat switches

temperature (yellow) and fault has opened due to overheating or
(red) lamps are illuminated. extremely low temperature.
Leave the power supply ON to allow the fan to
cool the power supply (overheating). Move the
power supply to a warm location (extreme
cold).

5. The power ON (green), torch parts 5.1 The retaining cap is loose or removed
loose or removed (yellow) and fault from the torch.
(red) lamps are illuminated. Turn off the power supply and tighten or install
the torch consumables. See Section 4,
Installing the consumables.

If the torch consumables become loose or are

removed while the power supply is on, turn off
the power supply, correct the problem and then
turn on the power supply to clear this fault.

6. The arc does not transfer to the 6.1 The work clamp is not connected to the
workpiece. workpiece, the work clamp is broken, or
there is a loose connection within power
supply.
Connect or repair the work clamp.

6.2 The work clamp is not making good

metal-to-metal contact.
Clean the area where the clamp contacts the
workpiece.

6.3 The torch is too far from the workpiece.

Move the torch closer to the workpiece and
start the torch again.
See Section 4, Torch operation.

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 MAINTENANCE AND PARTS

Basic troubleshooting (continued)

Problem Cause / Solution
7. The arc blows out, but re-ignites 7.1 The consumable parts are worn or
when the torch switch is pressed damaged.
again. Inspect and change the consumables, as
necessary. See Inspect the consumables, in
this section. See Section 4, Torch operation.

7.2 The gas pressure is incorrect.

Adjust the operating gas pressure. See Section
4, Check and adjust the gas pressure. Check
that the gas supply pressure to the power
supply is not less than 90 psig (6.1 bar) at a
flow of 9.2 scfm (260 l/min).

7.3 The gas filter element outside the power

supply is contaminated.
Replace the filter element. See Air filter element
replacement, in this section.

8. The arc sputters and hisses. 8.1 The gas filter element outside the power
supply is contaminated.
Replace the filter element.

8.2 There is water in the air line.

Drain the air filter(s) and/or add additional air
filtration to the power supply. See Section 3,
Additional gas filtration.

8.3 Worn or incorrectly installed

consumables.
Inspect the consumables. Replace them if
necessary.

9. Cut quality is not good. 9.1 Consumables are worn or the torch is
being used incorrectly.
See Inspect the consumables, in this section.
See Section 4, Hand torch operation.

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Basic troubleshooting (continued)

Problem Cause / Solution
10. The power ON (green) and fault 10.1 Self-diagnostic failure.
(red) lamps are flashing. The system needs repair.

11. The power ON (green) and fault 11.1 The start signal is ON when the ON/OFF
(red) lamps are illuminated after switch is activated.
the power is turned on. Turn the start signal OFF. Turn the power OFF
and then ON again.

12. The power ON (green) and 12.1 The consumables are stuck or jammed.
fault (red) lamps are Turn the power OFF and check the
illuminated for 10 seconds consumables.
after the trigger is activated.

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 Designator Component
D1 .......................Input diode bridge
D2 .......................Output diode bridge
L1 ........................Boost inductor
L2 ........................Output inductor
M1.......................Fan
PCB1 .................EMI filter board
PCB2 .................Power board
PCB3 .................Control board
PCB3 Control Board PS1.....................Pressure sensor
Q1.......................Boost IGBT
Q2.......................Inverter IGBT
UP CPA
MID NORMAL Q3.......................Pilot arc IGBT
CURRENT DOWN GOUGE
S1........................On/off switch

powermax1650 Operator Manual

J1.........................Connector
System circuit diagram

TS1,TS2.............Heatsink temperature sensor

V
AC
TS3 .....................Transformer temperature sensor
T2 ........................Power transformer
GAS
STATUS 45 50 55 60 65 70 75 80 85 V1........................Solenoid valve

L1 D2
D1 Output
Input Q2 Diode
Diode L2
Invertor Bridge
Bridge
Q1 IGBT
Boost -
S1 PCB1 Torch
+ IGBT ~ Q3 J1
EMI Filter ~ ~ PA Electrode
AC Input ~ PCB2 +
Board ~ T2 IGBT Nozzle
(CE Only) - Power Power
PE Work
Board xfmr

IFB Transfer
Workpiece
Sensor
Start Switch
Cap Switch
TS1 TS2 TS3 M1

PS1
Pressure
Sensor (gas)

Air/Gas V1 Air/Gas
Filter Regulator Solenoid to
Source
Valve (gas) Torch

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MAINTENANCE AND PARTS
MAINTENANCE AND PARTS

Technical questions
If you are unable to fix a problem with your Powermax by following the steps in Basic
troubleshooting in this section, or if you need further assistance:

1. Call your Hypertherm distributor or authorized Hypertherm repair facility.

2. Call the nearest Hypertherm Technical Service team listed in the front of this manual.

Parts

Torch parts
059264 T100 hand torch assembly, 25 ft (7.5 m)
059270 T100 hand torch assembly, 50 ft (15 m)
059299 T100 hand torch assembly, 75 ft (22.9 m)
059315 T100M-2 machine torch assembly, 25 ft (7.5 m)
059324 T100M-2 machine torch assembly, 35 ft (10.7 m)
059325 T100M-2 machine torch assembly, 50 ft (15 m)
059326 T100M-2 machine torch assembly, 75 ft (22.9 m)
059333 T100M-2 machine torch, 35 mm (no gear rack), 25 ft (7.5 m)
059334 T100M-2 machine torch, 35 mm (no gear rack), 35 ft (10.7 m)
059335 T100M-2 machine torch, 35 mm (no gear rack), 50 ft (15 m)
059336 T100M-2 machine torch, 35 mm (no gear rack), 75 ft (22.9 m)
027055 Silicone grease, 1/4 oz. tube
015337 Quick disconnect nipple: 1/4 NPT steel (CSA)
015145 Adapter: 1/4 NPT x G1/4 BSPP brass (CE)
058519 Torch o-ring
128644 T100 hand torch handle replacement kit (5 screws included)
075586 T100 hand torch handle screw (5 required)
220061 Shield cap: T60M/T80M ohmic contact
220206 Shield cap: T100M-2 ohmic contact

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 MAINTENANCE AND PARTS

Power Supply Parts

128740 Cover assembly, CSA (14 screws included)
128762 Cover assembly, CE (14 screws included)
075533 Cover screws (Individual cover screw)
128627 Air filter bowl with fittings
011092 Replacement filter element
129654 ETR door assembly
129405 Consumable box
123654 20 ft ground clamp with cable and strain-relief
128750 Kit: Powermax1650 labels, CSA
128758 Kit: Powermax1650 labels, CE

Accessories

128788 Stationary mounting kit

128647 Optional air filtration kit
011092 Replacement filter for optional air filtration kit
027668 Plasma cutting guide – deluxe
127102 Plasma cutting guide – basic
027684 Replacement bushing for the plasma cutting guide assembly
127100 Powermax1650 dust cover
123655 50 ft (15M) work cable with clamp and strain-relief
023206 CNC interface cable
220049 Gouging heat shield for hand torch
128650 On/off pendant for machine torch, 25 ft (7.5 m)
128651 On/off pendant for machine torch, 50 ft (15 m)
128652 On/off pendant for machine torch, 75 ft (22.9 m)
024548 Leather torch lead sheathing
128888 FineCut kit: Powermax1000/1250/1650
128889 FineCut kit: Powermax1000/1250/1650 CE
804470 Powermax1650 service manual

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