This page contains important safety related information.
It is strongly recommended that you familiarize yourself with the information in this chapter before proceeding through this user manual. Failure to do so could lead to the risk of injury or death.
Health and Safety Factors
There are several factors which have a bearing on the Health and Safety aspects concerned with this induction power supplies and coils. These are as follows:
– Weight: the weight of the induction power supplies and coils and its components.
– Noise levels (at workstation): Noise levels do not normally exceed the levels at which hearing protection is required.
– Voltages: Lethal voltages are generated by induction power supplies and coils.
– Heat: High temperatures are generated during the operation of induction power supplies and coils.
Induction power supplies and coils operate using potentially lethal electrical power and therefore should be treated with the utmost caution and respect.
To avoid the possibility of personal injury or even death, the following points must be closely observed:
Never allow the handling, installation, commissioning, operation, maintenance, fault finding or rectification of the induction power supplies and coils to be carried out by personnel other than those who have been suitably trained and declared competent to carry out such tasks.
Never put the induction power supplies and coils back into use following maintenance or rectification until it has been checked by suitably trained and qualified staff and declared as safe to do so.
Never operate the induction power supplies and coils with any guards, panels or doors removed or open. Always ensure that they are in a serviceable condition, correctly secured and locked prior to switching on the induction power supplies and coils.
Never modify the induction power supplies and coils so that it will operate with any of the safety features disabled i.e. short circuited, linked out or by-passed in any way.
The coolant in the cooling system can exceed 60°C (140°F) during the operation of the induction power supplies and coils.
Sufficient time should be allowed for the coolant to cool to a safe temperature level prior to commencing any work on the cooling system to avoid the risk of scalding.
Lethal voltages are used in the operation induction power supplies and coils. For this reason removable panels and screens are either bolted or screwed in place or, for access reasons, fitted with key operated locks. It is recommended that keys for such locks be held, as controlled items, by a responsible person delegated by the customer. In some cases access doors are fitted with safety switches which automatically switch off the induction power supplies and coils when the door is opened. Users should be aware that such switches are fitted as protection against inadvertent opening of the door and should not be used as a means of switching off the equipment. The induction power supplies and coils must be electrically isolated by means of an external isolator and the removal of the fuses before opening any door or panel.
WARNING: If a mains supply filter is fitted to the equipment, the equipment should be switched off by the total installation isolation switch and a minimum of 30 seconds allowed to elapse before the mains terminals are touched. This delay is essential to allow the voltage across the filter capacitors to discharge through the internal safety resistors. Voltages are present on this filter when the cubicle circuit breaker is set to ‘OFF’, therefore it is imperative that the total installation isolator is switched off if access to the mains supply filter is required.
Induction power supplies and coils operate at a frequency which is within the audible range but at a level which should present no hazard to the user. However the installation as a whole, with the associated equipment, may produce noise at higher audio levels. ALPHA 1 has taken all reasonably practical measures to reduce noise to levels which are safe and without risk to the health of a normally fit operator. It is possible, however, that a noise level in excess of 85dBA may occur. Customers should make sound level measurements of the induction power supplies and coils and associated equipment following installation when operating under normal load conditions within the rating of the equipment. This will take into account the installation as a whole and its environment and enable the appropriate level of action to be determined in accordance with the following guidelines:
a. Below 85dBA, no action required.
b. Above 85dBA, consideration of improvements to the induction power supplies and coils environment to reduce the noise level. At this level and above, consideration should be given to the provision of visual warning signs and the provision of hearing protection for the operator.
Electronic Cardiac Implants
It is possible for electronic cardiac implants to be affected by extraneous electric fields radiated by contactors and similar electromagnetic devices. Personnel, including visitors, fitted with such devices should therefore not stand in the immediate vicinity of the induction power supplies and coils when it is switched on. Further information should be sought from the appropriate area medical authority or from the manufacturer of the implant.
This equipment has been so constructed that it does not cause excessive electromagnetic interference and is not unduly affected by electromagnetic interference.
This equipment should not be operated with any doors or panels open as this may reduce the effectiveness of the electromagnetic radiation and immunity screening.
Regular maintenance procedures as outlined elsewhere in this manual should be observed.
Personnel are to be aware that the weights involved in the induction power supplies and coils and its components make it strongly advisable to use mechanical lifting aids wherever possible.
To avoid the risk of injury, personnel are to ensure that prior to attempting an unaided lift the weight involved does not exceed the recommended limits laid down under the Health and Safety Act, or any other legislation, and that suitable protective clothing is worn.
Safety Clothing And Protective Gear Equipment
Due to the nature of any manufacturing process, the various machine components involved have the potential to cause serious personal injury to unsuspecting or untrained personnel.
Be certain you understand all of the information and procedures contained in your manuals and ensure you are wearing:
- Safety glasses – Approved eye protection should be worn near machinery at all times. Signs are placed conspicuously at the entrances to plant areas where eye protection is required. Observe these signs.
- Safety shoes – Only steel toe leather shoes should be worn near the machine or while working on the machine itself. Open toes, heels, sandals, cloth, canvas or plastic shoes should be strictly prohibited.
- Clothing – Dress appropriately, so that clothing, accessories, and jewelry do not create
a hazard or risk to personal safety. Avoid loose fitting clothing that could catch or become entangled in machinery. Ties, scarves, or other types of accessories must be securely tucked into the clothing to prevent contact with or entanglement in moving machinery. Do not wear jewelry or other accessories that could contact, catch, or become entangled in moving machinery. Such jewelry includes: watches; rings; earrings that hang below the earlobe; bracelets; chains; or similar accessories.
- Additional Gear – Hard hat & other safety items or personal protective equipment (PPE) as required / recommended by OSHA, your current in-house policies or other appropriate regulating authority.
Warnings and Safety Instructions
The need to observe the warnings and safety instructions at all times cannot be emphasized too strongly and, in particular, the potentially lethal consequences of working inside an electrical cabinet with the mains supply switched on.
Only the maintenance engineer, or a suitably qualified member of his staff should attempt to maintain or rectify the induction power supplies and coils or its components.
It is the responsibility of the maintenance engineer to ensure that following any maintenance or rectification tasks, all guards, safety interlocks and earth/ground circuits are correctly fitted, fully functional and the induction power supplies and coils is in a safe condition to be operated.
ALPHA 1 cannot accept any responsibility for accidents or damage caused by over-riding the safety interlock circuits or non-compliance with any warnings issued in this user manual.
Risk and Hazard Assessment
Statement of Designed Method of Operation
Induction power supplies and coils have been designed to the highest safety standards.
Care has been taken, from design and through production, to eliminate or minimise any hazards and risks to the operator of the induction power supplies and coils.
It is the responsibility of ALPHA 1 to make the customer aware of any hazards that may exist to users of ALPHA 1 equipment.
Induction power supplies and coils are designed to produce high frequency electrical power for use in induction heating processes and will therefore be connected to other equipment.
It is the customers responsibility to ensure that any connections, i.e. buss bars etc., to equipment not supplied ALPHA 1 at the time of initial installation are suitably guarded to prevent injury or damage to personnel or equipment.
Risk and Hazard Assessment Parameters
The parameters for risk and hazard evaluation for the induction power supplies and coils during normal working operation are: From the point that the power supply is switched on to the point where it is switched off.
It is the full responsibility of the customer to ensure that the surrounding environment is made safe for the operators, following all the recognized safety standards.
Residual Hazard Identification
This manual is only concerned with any hazards that may concern the operators within the parameters specified above.
Where possible protection has already been provided (i.e. around the busbars) and so therefore these are no longer considered a hazard.
Possible Hazards and Risk Assessment
Electrical power – Electrical power is produced by induction power supplies and coils.
Risk assessment – The risk of electrocution – This risk is considered as probable and within the category as “critical” (serious injury or death). This is considered as unacceptable and action must be taken.
Addressing the Risk – The risk has been minimised by enclosing the buss bars etc. within the casing of the induction power supplies and coils and providing lockable access doors. The remaining risk needs to be accepted by the customer. It is the responsibility of the customer to provide adequate guarding around the external bus bars and ensure that all personnel are aware of the hazards and risks involved and are trained in the safe operation of this induction power supplies and coils.
Heat – Hot components (e.g. cooling water pipes) are made available to the operator:
Risk assessment – The risk of burning bare hands – This risk is considered as occasional (may happen sometimes) and within the category as “marginal” (minor injury or damage). This is considered as undesirable but may be acceptable with authoritative decision.
Addressing the Risk – The risk has been minimised by enclosing the cooling circuits within the casing of the induction power supplies and coils and providing lockable access doors. The remaining risk needs to be accepted by the customer. It is the responsibility of the customer to ensure that all personnel are trained in the safe operation of this induction power supplies and coils.
Induction heating fields – Causing rings or jewelry to heat.
Risk assessment – The risk of burning – This risk is considered as occasional and within the category as marginal” (minor injury or damage). This is considered as undesirable but may be acceptable with authoritative decision.
Addressing the Risk – The risk needs to be accepted by the customer. It is the responsibility of the customer to ensure the operator does not wear rings or jewelry when operating the equipment.
Induction heating fields – Causing electronic cardiac implants to be affected.
Risk assessment – The risk of death – This risk is considered as probable and within the category as “critical” (serious injury or death). This is considered as unacceptable and action must be taken.
Addressing the Risks – The risk is not acceptable. It is the responsibility of the customer to ensure that personnel operating the induction power supplies and coils (or standing near the equipment) do not have cardiac implants, or those that do, have taken advice from the relevant medical authority or the implant manufacturers and received assurance that the particular implant will not be affected.
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