Removed reference to using two 401's in parallel. Two
parallel. Added note in chart (235VDC for high current cutting). Changed power
factor from 0.90 to 0.47.
2.3
Added note in chart (235VDC for high current cutting). Changed power factor from
0.90 to 0.47.
Added information on preferred power supply placement. Place parallel to rails, or if
3.2
front must face rails leave 48" (1200mm) of space. Added art to show preferred
placement.
3.3Reference to strain relief added to Power Cables and Fuses section of text.
3.4New picture. Added holes should be modified to accommodate cables to #1.
3.5Moved picture of buses from pg 3.4.
3.6
3.7
Added pictures of 401 & 601 shunts. Text change on # 1 under PAC500 with H401
or H601 section
Added note about PAC500L cable. Referenced 500L manual 800460. Added
picture of terminal strip location and rearranged art.
Removed art showing 401/401 parallel hookup. Now shows 401/601 & 601/601.
3.8
Added reference to Letter designators for terminal strip as called out in other
manuals.
Corrected art to show jumper between terminals 8 & 9 (was 7 & 8) and wire
connected to #9 (was #7). Step 1 references terminals 7 & 8 (was 8 & 9). Step 2
3.10
references terminals 8 & 9 (was 7 & 8). Added reference to letter designators of
terminal #s 6-10 (H,J,M,N,G). Added note. Programmable remote will not function,
digital remote will function
Corrected jumper positions under "current control potentiometer not functioning".
5.3
From front panel, jumper between 7 & 8 (was 8 & 9). From remote, jumper between
8 & 9 (was 7 & 8).
Section 6Parts lists, old sections 6 & 7 combined into one list.
6.2Added part # for amber lamp assembly.
6.6Added part # for resistors(4) located on capacitors.
Section 7This is now the wiring diagrams section. Updated schematics from HDR.
Hypertherm, HT, and PAC are trademarks of Hypertherm, Inc.
and may be registered in the United States and/or other countries
Hypertherm, Inc.
Hanover, NH USA
www.hypertherm.com
Hypertherm, Inc.
Etna Road, P.O. Box 5010
Hanover, NH 03755 USA
603-643-3441 Tel (Main Office)
603-643-5352 Fax (All Departments)
800-643-9878 Tel (Technical Service)
800-737-2978 Tel (Customer Service)
Hypertherm Automation
5 Technology Drive
West Lebanon, NH 03755 USA
603-298-7970 Tel
603-298-7977 Fax
Hypertherm Plasmatechnik GmbH
Technologiepark Hanau
Rodenbacher Chaussee 6
63457 Hanau-Wolfgang, Deutschland
49 6181 58 2100 Tel
49 6181 58 2134 Fax
49 6181 58 2123 (Technical Service)
Hypertherm Singapore Pte Ltd
No. 19 Kaki Bukit Road 2
K.B. Warehouse Complex
Singapore 417847, Republic of Singapore
65 841 2489 Tel
65 841 2490 Fax
65 841 2489 (Technical Service)
Japan
1952-14 Yata-Natsumegi
Mishima City, Shizuoka Pref.
411-0801 Japan
81 0 559 75 7387 Tel
81 0 559 75 7376 Fax
Hypertherm UK Ltd
9 Berkeley Court, Manor Park
Runcorn, Cheshire, England WA7 1TQ
44 1928 579 074 Tel
44 1928 579 604 Fax
France
15 Impasse des Rosiers
95610 Eragny, France
0805 050 111 Tel
0805 050 222 Fax
Hypertherm S.r.L.
Via Torino 2
20123 Milano, Italia
39 02 725 46 312 Tel
39 02 725 46 400 Fax
39 02 725 46 314 (Technical Service)
Hypertherm B.V.
Burg. Haverkampstraat 13
7091 CN Dinxperlo, Nederland
31 315 655866 Tel
31 315 655886 Fax
Hypertherm B.V. (ETSO)
Vaartveld 9
4704 SE Roosendaal, Nederland
00 800 49 73 7843 – toll-free in Europa
31 165 596900 Tel
31 165 596901 Fax
Hypertherm Brasil Ltda.
Rua Visconde de Santa Isabel, 20 – Sala 611
Vila Isabel, RJ
Brasil CEP 20560-120
55 21 2278 6162 Tel
55 21 2578 0947 Fax
10/30/01
ELECTROMAGNETIC COMPATIBILITY (EMC) AND CE SAFETY
EMC INTRODUCTION
Hypertherm's CE-marked equipment is built
in compliance with standard EN50199. The
equipment should be installed and used in
accordance with the information below to
achieve electromagnetic compatibility.
The limits required by EN50199 may not be
adequate to completely eliminate interference when the affected equipment is in
close proximity or has a high degree of
sensitivity. In such cases it may be necessary to use other measures to further reduce interference.
This plasma equipment is designed for use
only in an industrial environment.
INSTALLATION AND USE
The user is responsible for installing and
using the plasma equipment according to
the manufacturer's instructions. If electromagnetic disturbances are detected then it
shall be the responsibility of the user to
resolve the situation with the technical
assistance of the manufacturer. In some
cases this remedial action may be as simple
as earthing the cutting circuit, see Earthingof Workpiece. In other cases it could involve
constructing an electromagnetic screen
enclosing the power source and the work
complete with associated input filters. In all
cases electromagnetic disturbances must
be reduced to the point where they are no
longer troublesome.
ASSESSMENT OF AREA
Before installing the equipment the user
shall make an assessment of potential
electromagnetic problems in the surrounding area. The following shall be taken into
account:
a. Other supply cables, control cables,
signalling and telephone cables; above,
below and adjacent to the cutting
equipment.
b. Radio and television transmitters and
receivers.
c. Computer and other control equipment.
d. Safety critical equipment, for example
guarding of industrial equipment.
e. Health of the people around, for
example the use of pacemakers and
hearing aids.
f. Equipment used for calibration or
measurement.
g. Immunity of other equipment in the
environment. User shall ensure that other
equipment being used in the environment is
compatible. This may require additional
protection measures.
h. Time of day that cutting or other activities
are to be carried out.
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 workpiece to earth should
be made by a direct connection to the
workpiece, but in some countries where
direct connection is not permitted, the
bonding should be achieved by suitable
capacitances selected according to national
regulations.
Note. The cutting circuit may or may not be
earthed for safety reasons. Changing the
earthing arrangements should only be
authorized by a person who is competent to
assess whether the changes will increase
the risk of injury, for example, by allowing
parallel cutting current return paths which
may damage the earth circuits of other
equipment. Further guidance is given in IEC
TC26 (sec)94 and IEC TC26/108A/CD Arc
Welding Equipment Installation and Use.
Screening and Shielding
Selective screening and shielding of other
cables and equipment in the surrounding
area may alleviate problems of interference.
Screening of the entire plasma cutting
installation may be considered for special
applications.
CE Safety
Power supplies are intended for an over
voltage category III power source. See
Section 6.1 of IEC 60974-1.
Power suplies are intended for environmental conditions of pollution degree 3
minimum. See Section 6.1 of IEC 60974-1.
Power supplies must not be used for a
pipe-thawing application. See Section
17N of IEC 60974-1.
The size of the surrounding area to be
considered will depend on the structure of
the building and other activities that are
taking place. The surrounding area may
extend beyond the boundaries of the
premises.
METHODS OF REDUCING EMISSIONS
Mains Supply
Cutting equipment must be connected to the
mains supply according to the manufacturer's recommendations. If interference
occurs, it may be necessary to take
additional precautions such as filtering of
the mains supply. Consideration should be
given to shielding the supply cable of
permanently installed cutting equipment, in
metallic conduit or equivalent. Shielding
should be electrically continuous throughout
its length. The shielding should be connected to the cutting mains supply so that
good electrical contact is maintained between the conduit and the cutting power
source enclosure
Maintenance of Cutting Equipment
The cutting equipment must be routinely
maintained according to the manufacturer's
recommendations. All access and service
doors and covers should be closed and
properly fastened when the cutting equipment is in operation. The cutting equipment
should not be modified in any way except for
those changes and adjustments covered in
the manufacturer's instructions. In particular, the spark gaps of arc striking and
stabilizing devices should be adjusted and
maintained according to the manufacturer's
recommendations.
Cutting Cables
The cutting cables should be kept as short
as possible and should be positioned close
together, running at or close to the floor
level.
Equipotential Bonding
Bonding of all metallic components in the
cutting installation and adjacent to it should
be considered. However, metallic components bonded to the workpiece will increase
the risk that the operator could receive a
shock by touching these metallic components and the electrode at the same time.
The operator should be insulated from all
such bonded metallic components.
Hypertherm CE Power Suppliesi
WARRANTY
iiHypertherm Warranty
9-01
WARNING
Genuine Hypertherm parts are the factory-recommended
replacement parts for your Hypertherm system. Any damage
caused by the use of other than genuine Hypertherm parts
may not be covered by the Hypertherm warranty.
WARNING
You are responsible for the safe use of the Product.
Hypertherm does not and cannot make any guarantee or
warranty regarding the safe use of the Product in your
environment.
GENERAL
Hypertherm, Inc. warrants that its Products shall be free from
defects in materials and workmanship, if Hypertherm is
notified of a defect (i) with respect to the power supply within
a period of two (2) years from the date of its delivery to you,
and (ii) with respect to the torch and leads within a period of
one (1) year from its date of delivery to you. This warranty
shall not apply to any Product which has been incorrectly
installed, modified, or otherwise damaged. Hypertherm, at its
sole option, shall repair, replace, or adjust, free of charge,
any defective Products covered by this warranty which shall
be returned with Hypertherm’s prior authorization (which
shall not be unreasonably withheld), properly packed, to
Hypertherm’s place of business in Hanover, New Hampshire,
or to an authorized Hypertherm repair facility, all costs,
insurance and freight prepaid. Hypertherm shall not be liable
for any repairs, replacement, or adjustments of Products
covered by this warranty, except those made pursuant to this
paragraph or with Hypertherm’s prior written consent. The
warranty above is exclusive and is in lieu of all other
warranties, express, implied, statutory, or otherwise with
respect to the Products or as to the results which may be
obtained therefrom, and all implied warranties or
conditions of quality or of merchantability or fitness
for a particular purpose or against infringement.
The foregoing shall constitute the sole and exclusive
remedy for any breach by Hypertherm of its warranty.
Distributors/OEMs may offer different or additional warranties,
but Distributors/OEMs are not authorized to give any
additional warranty protection to you or make any
representation to you purporting to be binding upon
Hypertherm.
PATENT INDEMNITY
Except only in cases of products not manufactured by
Hypertherm or manufactured by a person other than
Hypertherm not in strict conformity with Hypertherm’s
specifications and in cases of designs, processes,
formulae, or combinations not developed or purported to be
developed by Hypertherm, Hypertherm will defend or settle,
at its own expense, any suit or proceeding brought against
you alleging that the use of the Hypertherm product, alone
and not in combination with any other product not supplied by
Hypertherm, infringes any patent of any third party. You shall
notify Hypertherm promptly upon learning of any action or
threatened action in connection with any such alleged
infringement, and Hypertherm’s obligation to indemnify shall
be conditioned upon Hypertherm’s sole control of, and the
indemnified party’s cooperation and assistance in, the
defense of the claim.
LIMITATION OF LIABILITY
In no event shall Hypertherm be liable to any person or
entity for any incidental, consequential, indirect, or
punitive damages (including but not limited to lost
profits) regardless of whether such liability is based on
breach of contract, tort, strict liability, breach of
warranties, failure of essential purpose or otherwise and
even if advised of the possibility of such damages.
LIABILITY CAP
In no event shall Hypertherm’s liability, whether such
liability is based on breach of contract, tort, strict
liability, breach of warranties, failure of essential purpose
or otherwise, for any claim action suit or proceeding
arising out of or relating to the use of the Products
exceed in the aggregate the amount paid for the
Products that gave rise to such claim.
INSURANCE
At all times you will have and maintain insurance in such
quantities and types, and with coverage sufficient and
appropriate to defend and to hold Hypertherm harmless in the
event of any cause of action arising from the use of the
Products.
NATIONAL AND LOCAL CODES
National and Local codes governing plumbing and electrical
installation shall take precedent over any instructions
contained in this manual. In no event shall Hypertherm be
liable for injury to persons or property damage by reason of
any code violation or poor work practices.
TRANSFER OF RIGHTS
You may transfer any remaining rights you may have
hereunder only in connection with the sale of all or
substantially all of your assets or capital stock to a successor
in interest who agrees to be bound by all of the terms and
conditions of this Warranty.
Cutting Can Cause Fire or Explosion .......................................................................................................................1-2
Electric Shock Can Kill..............................................................................................................................................1-3
Cutting Can Produce Toxic Fumes...........................................................................................................................1-3
A Plasma Arc Can Cause Injury and Burns..............................................................................................................1-4
Arc Rays Can Burn Eyes and Skin...........................................................................................................................1-4
Compressed Gas Equipment Safety ........................................................................................................................1-5
Gas Cylinders Can Explode If Damaged..................................................................................................................1-5
Noise Can Damage Hearing.....................................................................................................................................1-5
Pacemaker and Hearing Aid Operation....................................................................................................................1-5
A Plasma Arc Can Damage Frozen Pipes................................................................................................................1-5
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
Le coupage peut produire des vapeurs toxiques....................................................................................................1a-3
L'arc plasma peut provoquer des blessures ou des brûlures .................................................................................1a-4
Mise à la masse et à la terre...................................................................................................................................1a-4
Les rayons de l'arc peuvent brûler les yeux et la peau...........................................................................................1a-4
Sécurité des bouteilles de gaz comprimé...............................................................................................................1a-5
Les bouteilles de gaz comprimé peuvent exploser en cas de dommages .............................................................1a-5
Le bruit peut provoquer des problèmes auditifs......................................................................................................1a-5
Pacemakers et prothéses auditives........................................................................................................................1a-5
Étiquette de sécurité...............................................................................................................................................1a-6
H401 or H601 with HT4001..............................................................................................................................2-2
H401 or H601 with PAC500.............................................................................................................................2-2
H401 Power Supply .........................................................................................................................................2-2
H601 Power Supply .........................................................................................................................................2-3
Positioning the Power Supply ..........................................................................................................................3-2
Power Requirements ................................................................................................................................................3-3
Power Cables and Fuses.................................................................................................................................3-3
Connecting the Primary Power.................................................................................................................................3-4
Line Disconnect Switch....................................................................................................................................3-5
PAC500 with H401 or H601.............................................................................................................................3-6
PAC500 Control Cable with H401 or H601......................................................................................................3-7
Parallel Power Supply Connections.................................................................................................................3-8
PAC500 Water Muffler and Water Supply System Connections......................................................................3-9
Water supply connections................................................................................................................................3-9
Current Control Potentiometer Connections..................................................................................................3-10
HT4001 with H401 or H601............................................................................................................................3-10
Section 4OPERATION
Controls and Indicators.............................................................................................................................................4-2
H401 or H601 with HT4001..............................................................................................................................4-3
H401 or H601 with PAC500.............................................................................................................................4-3
Output Current for Power Supply Dial Settings................................................................................................4-4
Power Supply Circuit Description .............................................................................................................................5-2
Front Panel Outside.........................................................................................................................................6-2
SCR and Shunt Detail......................................................................................................................................6-3
Transformer and Inductor.................................................................................................................................6-4
Temperature Switches.....................................................................................................................................6-5
System Grounding Requirements.............................................................................................................................a-1
Power Supply...................................................................................................................................................a-1
Work Table Grounding.....................................................................................................................................a-2
Cutting Can Cause Fire or Explosion..............................................................................................................1-2
Electric Shock Can Kill....................................................................................................................................1-3
Cutting Can Produce Toxic Fumes..................................................................................................................1-3
A Plasma Arc Can Cause Injury and Burns.....................................................................................................1-4
Arc Rays Can Burn Eyes and Skin .................................................................................................................1-4
The symbols shown in this section are used to
identify potential hazards. When you see a safety
symbol in this manual or on your machine, understand
the potential for personal injury, and follow the related
instructions to avoid the hazard.
FOLLOW SAFETY INSTRUCTIONS
Read carefully all safety messages in this manual and
safety labels on your machine.
• Keep the safety labels on your machine in good
condition. Replace missing or damaged labels
immediately.
• Learn how to operate the machine and how to use
the controls properly. Do not let anyone operate it
without instruction.
• Keep your machine in proper working condition.
Unauthorized modifications to the machine may
affect safety and machine service life.
DANGERWARNINGCAUTION
A signal word DANGER or WARNING is used with a
safety symbol. DANGER identifies the most serious
hazards.
• DANGER and WARNING safety labels are located
on your machine near specific hazards.
• WARNING safety messages precede related
instructions in this manual that may result in injury
or death if not followed correctly.
• CAUTION safety messages precede related
instructions in this manual that may result in
damage to equipment if not followed correctly.
Fire Prevention
• Be sure the area is safe before doing any cutting.
Keep a fire extinguisher nearby.
• Remove all flammables within 35 feet (10 m) of the
cutting area.
• Quench hot metal or allow it to cool before handling
or before letting it touch combustible materials.
• Never cut containers with potentially flammable
materials inside – they must be emptied and
properly cleaned first.
• Ventilate potentially flammable atmospheres before
cutting.
• When cutting with oxygen as the plasma gas, an
exhaust ventilation system is required.
Explosion Prevention
• Do not use the plasma system if explosive dust or
vapors may be present.
• Do not cut pressurized cylinders, pipes, or any
closed container.
• Do not cut containers that have held combustible
materials.
CUTTING CAN CAUSE FIRE OR EXPLOSION
WARNING
Explosion Hazard
Argon-Hydrogen and Methane
Hydrogen and methane are flammable gases that
present an explosion hazard. Keep flames away from
cylinders and hoses that contain methane or hydrogen
mixtures. Keep flames and sparks away from the torch
when using methane or argon-hydrogen plasma.
WARNING
Hydrogen Detonation with Aluminum Cutting
• When cutting aluminum underwater, or with the
water touching the underside of the aluminum, free
hydrogen gas may collect under the workpiece and
detonate during plasma cutting operations.
• Install an aeration manifold on the floor of the water
table to eliminate the possibility of hydrogen
detonation. Refer to the Appendix section of this
manual for aeration manifold details.
Touching live electrical parts can cause a fatal shock
or severe burn.
• Operating the plasma system completes an
electrical circuit between the torch and the
workpiece. The workpiece and anything touching
the workpiece are part of the electrical circuit.
• Never touch the torch body, workpiece or the water
in a water table when the plasma system is
operating.
Electric Shock Prevention
All Hypertherm plasma systems use high voltage
in the cutting process (200 to 400 VDC are
common). Take the following precautions when
operating this system:
• Wear insulated gloves and boots, and keep your
body and clothing dry.
• Do not stand, sit or lie on – or touch – any wet
surface when using the plasma system.
• Insulate yourself from work and ground using dry
insulating mats or covers big enough to prevent any
physical contact with the work or ground. If you must
work in or near a damp area, use extreme caution.
• Provide a disconnect switch close to the power
supply with properly sized fuses. This switch allows
the operator to turn off the power supply quickly in
an emergency situation.
• When using a water table, be sure that it is correctly
connected to earth ground.
ELECTRIC SHOCK CAN KILL
• Install and ground this equipment according to the
instruction manual and in accordance with national
and local codes.
• Inspect the input power cord frequently for damage
or cracking of the cover. Replace a damaged power
cord immediately. Bare wiring can kill.
• Inspect and replace any worn or damaged torch
leads.
• Do not pick up the workpiece, including the waste
cutoff, while you cut. Leave the workpiece in place
or on the workbench with the work cable attached
during the cutting process.
• Before checking, cleaning or changing torch parts,
disconnect the main power or unplug the power
supply.
• Never bypass or shortcut the safety interlocks.
• Before removing any power supply or system
enclosure cover, disconnect electrical input power.
Wait 5 minutes after disconnecting the main power
to allow capacitors to discharge.
• Never operate the plasma system unless the power
supply covers are in place. Exposed power supply
connections present a severe electrical hazard.
• When making input connections, attach proper
grounding conductor first.
• Each Hypertherm plasma system is designed to be
used only with specific Hypertherm torches. Do not
substitute other torches which could overheat and
present a safety hazard.
Cutting can produce toxic fumes and gases that
deplete oxygen and cause injury or death.
• Keep the cutting area well ventilated or use an
approved air-supplied respirator.
• Do not cut in locations near degreasing, cleaning or
spraying operations. The vapors from certain
chlorinated solvents decompose to form phosgene
gas when exposed to ultraviolet radiation.
• Do not cut metal coated or containing toxic materials, such as zinc (galvanized), lead, cadmium or
CUTTING CAN PRODUCE TOXIC FUMES
beryllium, unless the area is well ventilated and the
operator wears an air-supplied respirator. The
coatings and any metals containing these elements
can produce toxic fumes when cut.
• Never cut containers with potentially toxic materials
inside – they must be emptied and properly cleaned
first.
• This product, when used for welding or cutting,
produces fumes or gases which contain chemicals
known to the State of California to cause birth
defects and, in some cases, cancer.
Hypertherm Plasma Systems1-3
8-99
SAFETY
SAFETY
1-4Hypertherm Plasma Systems
4-99
SAFETY
Instant-On Torches
Plasma arc comes on immediately when the torch
switch is activated.
A PLASMA ARC CAN CAUSE INJURY AND BURNS
The plasma arc will cut quickly through gloves and
skin.
• Keep away from the torch tip.
• Do not hold metal near the cutting path.
• Never point the torch toward yourself or others.
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, or a welding helmet) with appropriate
lens shading to protect your eyes from the arc’s
ultraviolet and infrared rays.
Lens Shade
Arc CurrentAWS (USA)ISO 4850
Up to 100 ANo. 8No. 11
100-200 ANo. 10No. 11-12
200-400 ANo. 12No. 13
Over 400 ANo. 14No. 14
ARC RAYS CAN BURN EYES AND SKIN
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.
Work Cable Attach the work cable securely to the
workpiece or the work table with good metal-to-metal
contact. Do not connect it to the piece that will fall
away when the cut is complete.
Work Table Connect the work table to an earth
ground, in accordance with appropriate national or
local electrical codes.
GROUNDING SAFETY
Input Power
• Be sure to connect the power cord ground wire to
the ground in the disconnect box.
• If installation of the plasma system involves
connecting the power cord to the power supply, be
sure to connect the power cord ground wire
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.
SAFETY
Hypertherm Plasma Systems1-5
11-98
SAFETY
• Never lubricate cylinder valves or regulators with oil
or grease.
• Use only correct gas cylinders, regulators, hoses
and fittings designed for the specific application.
• Maintain all compressed gas equipment and
associated parts in good condition.
• Label and color-code all gas hoses to identify the
type of gas in each hose. Consult applicable
national or local codes.
GAS CYLINDERS CAN
EXPLODE IF DAMAGED
COMPRESSED GAS EQUIPMENT SAFETY
Gas cylinders contain gas under high pressure. If
damaged, a cylinder can explode.
• Handle and use compressed gas cylinders in
accordance with applicable national or local codes.
• Never use a cylinder that is not upright and secured
in place.
• 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.
Prolonged exposure to noise from cutting or gouging
can damage hearing.
• Use approved ear protection when using plasma
system.
• Warn others nearby about the noise hazard.
NOISE CAN DAMAGE HEARING
Pacemaker and hearing aid operation can be affected
by magnetic fields from high currents.
Pacemaker and hearing aid wearers should consult a
doctor before going near any plasma arc cutting and
gouging operations.
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 the
work cable.
• Do not wrap or drape the torch lead or work cable
around your body.
• Keep as far away from the power supply as
possible.
P ACEMAKER AND HEARING
AID OPERATION
ADDITIONAL SAFETY INFORMATION
1. ANSI Standard Z49.1, Safety in Welding and Cutting, American
Welding Society, 550 LeJeune Road
P.O. Box 351020, Miami, FL 33135
2. ANSI Standard Z49.2, Fire Prevention in the Use of Cutting andWelding Processes, American National Standards Institute
1430 Broadway, New York, NY10018
3. ANSI Standard Z87.1, Safe Practices for Occupation andEducational Eye and Face Protection, American National
Standards Institute, 1430 Broadway, New York, NY10018
4. AWS F4.1, Recommended Safe Practices for the Preparation for
Welding and Cutting of Containers and Piping That Have Held
Hazardous Substances, American Welding Society
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 inCylinders, Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202
7. CSA Standard W117.2, Code for Safety in Welding and Cutting,
Canadian Standards Association Standard Sales
178 Rexdale Boulevard, Rexdale, Ontario M9W 1R3, Canada
8. NFPAStandard 51B, Cutting and Welding Processes, National
Fire Protection Association
470 Atlantic Avenue, Boston, MA 02210
9. NFPAStandard 70–1978, National Electrical Code, National Fire
Protection Association, 470 Atlantic Avenue, Boston, MA 02210
10. OSHA, Safety and Health Standards, 29FR 1910
U.S. Government Printing Office, Washington, D.C. 20402
A PLASMA ARC CAN
DAMAGE FROZEN PIPES
Frozen pipes may be damaged or can burst if you
attempt to thaw them with a plasma torch.
SAFETY
1-6Hypertherm Plasma Systems
8-99
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.
1.Cutting sparks can cause explosion or fire.
1.1 Keep flammables away from cutting.
1.2 Keep a fire extinguisher nearby, and have
a watchperson ready to use it.
1.3 Do not cut on any closed containers.
2.The plasma arc can cause injury and
burns.
2.1 Turn off power before disassembling torch.
2.2 Do not hold the material near cutting path.
2.3 Wear complete body protection.
3.Electric shock from torch or wiring can kill.
Protect yourself from electric shock.
3.1 Wear insulating gloves. Do not wear wet or
damaged gloves.
3.2 Insulate yourself from work and ground.
3.3 Disconnect input plug or power before
working on machine.
4.Breathing cutting fumes can be hazardous
to your health.
4.1 Keep your head out of the fumes.
4.2 Use forced ventilation or local exhaust to
remove the fumes.
4.3 Use ventilating fan to remove the fumes.
5.Arc rays can burn eyes and injure skin.
5.1 Wear hat and safety glasses. Use ear
protection and button shirt collar. Use
welding helmet with correct shade of filter.
Wear complete body protection.
6.Become trained and read the instructions
before working on the machine or cutting.
7.Do not remove or paint over (cover)
warning labels.
Hypertherm Systèmes plasma1a-1
2/12/01
Section 1a
SÉCURITÉ
Dans cette section :
Identifier les consignes de sécurité...............................................................................................................1a-2
Suivre les instructions de sécurité.................................................................................................................1a-2
Danger A vertissement Précaution...............................................................................................................1a-2
Le coupage peut provoquer un incendie ou une explosion...........................................................................1a-2
Prévention des incendies, Prévention des explosions .........................................................................1a-2
Risque d’explosion argon-hydrogène et méthane................................................................................1a-2
Détonation de l’hydrogène lors du coupage de l’aluminium.................................................................1a-2
Les chocs électriques peuvent être fatals.....................................................................................................1a-3
Prévention des chocs électriques.........................................................................................................1a-3
Le coupage peut produire des vapeurs toxiques..........................................................................................1a-3
L’arc plasma peut provoquer des blessures ou des brûlures........................................................................1a-4
Torches à allumage instantané.............................................................................................................1a-4
Les rayons de l’arc peuvent brûler les yeux et la peau.................................................................................1a-4
Protection des yeux, Protection de la peau, Zone de coupage ..........................................................1a-4
Mise à la masse et à la terre.........................................................................................................................1a-4
Câble de retour, Table de travail, Alimentation.....................................................................................1a-4
Sécurité des bouteilles de gaz comprimé .....................................................................................................1a-5
Les bouteilles de gaz comprimé peuvent exploser en cas de dommages....................................................1a-5
Le bruit peut provoquer des problèmes auditifs............................................................................................1a-5
Pacemakers et prothèses auditives..............................................................................................................1a-5
Un arc plasma peut endommager les tuyaux gelés......................................................................................1a-5
Étiquette de sécurité .....................................................................................................................................1a-6
SÉCURITÉ
1a-2Hypertherm Systèmes plasma
2/12/01
IDENTIFIER LES CONSIGNES
DE SÉCURITÉ
Les symboles indiqués dans cette section sont utilisés pour
identifier les risques éventuels. Si vous trouvez un symbole
de sécurité, que ce soit dans ce manuel ou sur
l’équipement, soyez conscient des risques de blessures et
suivez les instructions correspondantes afin d’éviter ces
risques.
SUIVRE LES INSTRUCTIONS
DE SÉCURITÉ
Lire attentivement toutes les consignes de sécurité dans le
présent manuel et sur les étiquettes de sécurité se trouvant
sur la machine.
• Les étiquettes de sécurité doivent rester lisibles.
Remplacer immédiatement les étiquettes manquantes ou
abîmées.
• Apprendre à faire fonctionner la machine et à utiliser
correctement les commandes. Ne laisser personne utiliser
la machine sans connaître son fonctionnement.
• Garder la machine en bon état. Des modifications non
autorisées sur la machine peuvent engendrer des
problèmes de sécurité et raccourcir la durée d’utilisation
de l’équipement.
DANGERAVERTISSEMENTPRÉCAUTION
Les signaux DANGER ou AVERTISSEMENT sont utilisés
avec un symbole de sécurité, DANGER correspondant aux
risques les plus sérieux.
• Les étiquettes de sécurité DANGER et AVERTISSEMENT
sont situées sur la machine pour signaler certains
dangers spécifiques.
• Les messages d’AVERTISSEMENT précèdent les
instructions d’utilisation expliquées dans ce manuel et
signalent les risques de blessures ou de mort au cas où
ces instructions ne seraient pas suivies correctement.
• Les messages de PRÉCAUTION précèdent les
instructions d’utilisation contenues dans ce manuel et
signalent que le matériel risque d’être endommagé si les
instructions ne sont pas suivies correctement.
Prévention des incendies
• Avant de commencer, s’assurer que la zone de coupage
ne présente aucun danger. Conserver un extincteur à
proximité.
• Éloigner toute matière inflammable à une distance d’au
moins 10 m du poste de coupage.
• Tremper le métal chaud ou le laisser refroidir avant de
le manipuler ou avant de le mettre en contact avec des
matériaux combustibles.
• Ne jamais couper des récipients pouvant contenir des
matières inflammables avant de les avoir vidés et
nettoyés correctement.
• Aérer toute atmosphère potentiellement inflammable
avant d’utiliser un système plasma.
• Lors de l’utilisation d’oxygène comme gaz plasma, un
système de ventilation par aspiration est nécessaire.
Prévention des explosions
• Ne pas couper en présence de poussière ou de vapeurs.
• Ne pas couper de bouteilles, de tuyaux ou autres
récipients fermés et pressurisés.
• Ne pas couper de récipients contenant des matières
combustibles.
LE COUPAGE PEUT PROVOQUER UN INCENDIE
OU UNE EXPLOSION
AVERTISSEMENT
Risque d’explosion
argon-hydrogène et méthane
L’hydrogène et le méthane sont des gaz inflammables et
potentiellement explosifs. Conserver à l’écart de toute
flamme les bouteilles et tuyaux contenant des mélanges à
base d’hydrogène ou de méthane. Maintenir toute flamme
et étincelle à l’écart de la torche lors de l’utilisation d’un
plasma d’argon-hydrogène ou de méthane.
AVERTISSEMENT
Détonation de l’hydrogène lors du
coupage de l’aluminium
• Lors du coupage de l’aluminium sous l’eau, ou si l’eau
touche la partie inférieure de la pièce d’aluminium, de
l’hydrogène libre peut s’accumuler sous la pièce à couper
et détonner lors du coupage plasma.
• Installer un collecteur d’aération au fond de la table à eau
afin d’éliminer les risques de détonation de l’hydrogène.
Se référer à l’annexe du manuel pour plus de
renseignements sur les collecteurs d’aération.
SÉCURITÉ
Hypertherm Systèmes plasma1a-3
2/12/01
Toucher une pièce électrique sous tension peut provoquer
un choc électrique fatal ou des brûlures graves.
• La mise en fonctionnement du système plasma ferme un
circuit électrique entre la torche et la pièce à couper. La
pièce à couper et tout autre élément en contact avec cette
pièce font partie du circuit électrique.
• Ne jamais toucher le corps de la torche, la pièce à couper
ou l’eau de la table à eau pendant le fonctionnement du
système plasma.
Prévention des chocs électriques
Tous les systèmes plasma Hypertherm utilisent des hautes
tensions pour le coupage (souvent de 200 à 400 V). On
doit prendre les précautions suivantes quand on utilise le
système plasma :
• Porter des bottes et des gants isolants et garder le corps
et les vêtements au sec.
• Ne pas se tenir, s’asseoir ou se coucher sur une surface
mouillée, ni la toucher quand on utilise le système plasma.
• S’isoler de la surface de travail et du sol en utilisant des
tapis isolants secs ou des couvertures assez grandes
pour éviter tout contact physique avec le travail ou le sol.
S’il s’avère nécessaire de travailler dans ou près d’un
endroit humide, procéder avec une extrême prudence.
• Installer un sectionneur avec fusibles appropriés, à
proximité de la source de courant. Ce dispositif permet à
l’opérateur d’arrêter rapidement la source de courant en
cas d’urgence.
• En cas d’utilisation d’une table à eau, s’assurer que cette
dernière est correctement mise à la terre.
LES CHOCS ÉLECTRIQUES PEUVENT ÊTRE FATALS
• Installer et mettre à la terre l’équipement selon les
instructions du présent manuel et conformément aux
codes électriques locaux et nationaux.
• Inspecter fréquemment le cordon d’alimentation primaire
pour s’assurer qu’il n’est ni endommagé, ni fendu.
Remplacer immédiatement un cordon endommagé.
Un câble dénudé peut tuer.
• Inspecter et remplacer les câbles de la torche qui sont
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
table de travail, le câble de retour connecté lors du
coupage.
• Avant de vérifier, de nettoyer ou de remplacer les pièces
de la torche, couper l’alimentation ou débrancher la prise
de courant.
• Ne jamais contourner ou court-circuiter les verrouillages
de sécurité.
• Avant d’enlever le capot du système ou de la source de
courant, couper l’alimentation électrique. Attendre en
suite
5 minutes pour que les condensateurs se déchargent.
• Ne jamais faire fonctionner le système plasma sans que
les capots de la source de courant ne soient en place.
Les raccords exposés de la source de courant sont
extrêmement dangereux.
• Lors de l’installation des connexions, attacher tout d’abord
la prise de terre appropriée.
• Chaque système plasma Hypertherm est conçu pour être
utilisé uniquement avec des torches Hypertherm
spécifiques. Ne pas utiliser des torches inappropriées qui
pourraient surchauffer et présenter des risques pour la
sécurité.
Le coupage peut produire des vapeurs et des gaz toxiques
qui réduisent le niveau d’oxygène dans l’air et peuvent
provoquer des blessures, voire la mort.
• Conserver le poste de coupage bien aéré ou utiliser un
masque respiratoire homologué.
• Ne pas procéder au coupage près d’endroits où
s’effectuent le dégraissage, le nettoyage ou la vaporisation. Certains solvants chlorés se décomposent sous
l’effet des rayons ultraviolets et forment du phosgène.
• Ne pas couper des métaux peints ou contenant des
matières toxiques comme le zinc (galvanisé), le plomb, le
cadmium ou le béryllium, à moins que la zone de travail
LE COUPAGE PEUT PRODUIRE DES VAPEURS TOXIQUES
soit très bien ventilée et que l’opérateur porte un masque
respiratoire. Les revêtements et métaux contenant ces
matières peuvent produire des vapeurs toxiques lors du
coupage.
• Ne jamais couper de récipients pouvant contenir des
matières inflammables avant de les avoir vidés et
nettoyés correctement.
• Quand on utilise ce produit pour le soudage ou le
coupage, il dégage des fumées et des gaz qui
contiennent des produits chimiques qui, selon l’État de
Californie, provoquent des anomalies congénitales et,
dans certains cas, le cancer.
SÉCURITÉ
1a-4Hypertherm Systèmes plasma
2/12/01
Torches à allumage instantané
L’arc plasma s’allume immédiatement après que la torche
soit mise en marche.
L’ARC PLASMAPEUT PROVOQUER DES BLESSURES OU DES BRÛLURES
L’arc plasma coupe facilement les gants et la peau.
• Rester éloigné de l’extrémité de la torche.
• Ne pas tenir de métal près de la trajectoire de coupe.
• Ne jamais pointer la torche vers soi ou d’autres
personnes.
Protection des yeuxLes 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 ou encore masque de soudure)
avec des verres teintés appropriés pour protéger les yeux
des rayons ultraviolets et infrarouges de l’arc.
Puissance des verres teintés
Courant de l’arcAWS (É.-U.)ISO 4850
Jusqu’à 100 ANo8N
o
11
100-200 ANo10No11-12
200-400 ANo12No13
Plus de 400 ANo14No14
Protection de la peauPorter des vêtements de sécurité
pour se protéger contre les brûlures que peuvent causer les
rayons ultraviolets, les étincelles et le métal brûlant :
LES RAYONS DE L’ARC PEUVENT BRÛLER LES YEUX ET LA PEAU
• 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 coupagePréparer 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.
Câble de retourBien fixer le câble de retour (ou de
masse) à la pièce à couper ou à la table de travail de façon
à assurer un bon contact métal-métal. Ne pas fixer le câble
de retour à la partie de la pièce qui doit se détacher.
Table de travailRaccorder la table de travail à la terre,
conformément aux codes de sécurité locaux ou nationaux
appropriés.
MISE À LA MASSE ET À LA TERRE
Alimentation
• S’assurer que le fil de terre du cordon d’alimentation est
connecté à la terre dans le coffret du sectionneur.
• S’il est nécessaire de brancher le cordon d’alimentation à
la source de courant lors de l’installation du système,
s’assurer que le fil de terre est correctement branché.
• 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
Hypertherm Systèmes plasma1a-5
2/12/01
• Ne jamais lubrifier les robinets des bouteilles ou les
régulateurs avec de l’huile ou de la graisse.
• Utiliser uniquement les bouteilles, régulateurs, tuyaux et
accessoires appropriés et conçus pour chaque application
spécifique.
• Entretenir l’équipement et les pièces d’équipement à gaz
comprimé afin de les garder en bon état.
• Étiqueter et coder avec des couleurs tous les tuyaux de
gaz afin d’identifier le type de gaz contenu dans chaque
tuyau. Se référer aux codes locaux ou nationaux en
vigueur.
LES BOUTEILLES DE GAZ
COMPRIMÉ PEUVENT EXPLOSER
EN CAS DE DOMMAGES
SÉCURITÉ DES BOUTEILLES DE
GAZ COMPRIMÉ
Les bouteilles de gaz contiennent du gaz à haute pression.
Si une bouteille est endommagée, elle peut exploser.
• Manipuler et utiliser les bouteilles de gaz comprimé
conformément aux codes locaux ou nationaux.
• Ne jamais utiliser une bouteille qui n’est pas placée à la
verticale et bien assujettie.
• Le capuchon de protection doit être placé sur le robinet
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.
Une exposition prolongée au bruit du coupage ou du
gougeage peut provoquer des problèmes auditifs.
• Utiliser un casque de protection homologué lors de
l’utilisation du système plasma.
• Prévenir les personnes aux alentours des risques
encourus en cas d’exposition au bruit.
LE BRUIT PEUT PROVOQUER DES
PROBLÈMES AUDITIFS
Les champs magnétiques produits par les courants à haute
tension peuvent affecter le fonctionnement des prothèses
auditives et des pacemakers. Les personnes portant ce
type d’appareil doivent consulter un médecin avant de
s’approcher d’un lieu où s’effectue le coupage ou le
gougeage plasma.
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.
• Faire passer le faisceau de la torche le plus près possible
du câble de retour.
• Ne pas s’enrouler le faisceau de la torche ou le câble de
retour autour du corps.
• Se tenir le plus loin possible de la source de courant.
PACEMAKERS ET
PROTHÈSES AUDITIVES
Les tuyaux gelés peuvent être endommagés ou éclater
si l'on essaie de les dégeler avec une torche plasma.
UN ARC PLASMA
PEUT ENDOMMAGER
LES TUYAUX GELÉS
SÉCURITÉ
1a-6Hypertherm Systèmes plasma
2/12/01
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.
1.Les étincelles produites par le coupage
peuvent provoquer une explosion ou un
incendie.
1.1 Pendant le coupage, éloigner toute matière
inflammable.
1.2 Conserver un extincteur à proximité et
s’assurer qu’une personne soit prête à
l’utiliser.
1.3 Ne jamais couper de récipients fermés.
2.L’arc plasma peut provoquer des blessures
et des brûlures.
2.1 Couper l’alimentation avant de démonter la
torche.
2.2 Ne pas tenir la surface à couper près de la
trajectoire de coupe.
2.3 Porter des vêtements de protection
couvrant tout le corps.
3.Un choc électrique causé par la torche ou
les câbles peut être fatal. Se protéger
contre les risques de chocs électriques.
3.1 Porter des gants isolants. Ne pas porter de
gants mouillés ou abîmés.
3.2 S’isoler de la surface de travail et du sol.
3.3 Débrancher la prise ou la source de
courant avant de manipuler l’équipement.
4.L’inhalation des vapeurs produites par le
coupage peut être dangereuse pour la
santé.
4.1 Garder le visage à l’écart des vapeurs.
4.2 Utiliser un système de ventilation par
aspiration ou d’échappement localisé pour
dissiper les vapeurs.
4.3 Utiliser un ventilateur pour dissiper les
vapeurs.
5.Les rayons de l’arc peuvent brûler les yeux
et provoquer des lésions de la peau.
5.1 Porter un casque et des lunettes de
sécurité. Se protéger les oreilles et porter
une chemise dont le col peut être
déboutonné. Porter un casque de soudure
dont la protection filtrante est suffisante.
Porter des vêtements protecteurs couvrant
la totalité du corps.
6.Se former à la technique du coupage et lire
les instructions avant de manipuler
l’équipement ou de procéder au coupage.
7.Ne pas retirer ou peindre (recouvrir) les
étiquettes de sécurité.
H401 or H601 with HT4001..............................................................................................................................2-2
H401 or H601 with PAC500.............................................................................................................................2-2
H401 Power Supply .........................................................................................................................................2-2
H601 Power Supply .........................................................................................................................................2-3
Refer to HT4001 instruction manuals 802470 for 200V HT4001 power supplies; or 802000 for all other voltage
HT4001 power supplies.
H401 or H601 with PAC500
The H401 provides power to cut stainless steel and non-ferrous metals up to 1-inch thick and mild steel up to
1/2-inch thick. The H601 provides power to cut stainless and non-ferrous metals up to 2-inches thick and mild steel
up to 1-inch thick.
One H401 and one H601, or two H601s in parallel can provide the full power capacity of the PAC500 torch and cut
at 1000 amps. At 1000 amps, the PAC500 torch can cut stainless steel to 5-inches thick, and aluminum and other
non-ferrous metals to 6-inches thick.
Specifications
H401 Power Supply
Maximum OCV (U0)400 VDC
Current Adjustment Range (I2)200 to 500 A
Output Voltage (U2)80 to 200 VDC (235VDC for high current cutting)
60% @ 100 kW, 104° F (40° C)
Duty Cycle Rating (X)
100% @ 80 kW, 104° F (40° C)
Temperature Rating14° F ( -10° C) to 104° F (40° C)
Power Factor(cosϕ)0.47
CoolingForced Air (Class F)
Input Power (U1– Input Voltage; I1– Input Current)
036038200 VAC (U1), 3 Phase, 50 Hz, 492 A (I1)
036036400 VAC (U1), 3 Phase, 50 Hz, 247 A (I1)
036035480 VAC (U1), 3 Phase, 60 Hz, 206 A (I1)
036037600 VAC (U1), 3 Phase, 60 Hz, 164 A (I1)
Dimensions and Weight
Width40" (1015 mm)
Maximum Height53" (1345 mm)
Maximum Depth50" (1270 mm)
Weight2250 lbs (1022 kg)
SPECIFICATIONS
H401 & H601 Instruction Manual2-3
5
H601 Power Supply
Maximum OCV (U0)400 VDC
Current Adjustment Range (I2)200 to 750 A
Output Voltage (U2)80 to 200 VDC (235VDC for high current cutting)
60% @ 150 kW, 104° F (40° C)
Duty Cycle Rating (X)
100% @ 120 kW, 104° F (40° C)
Temperature Rating14° F ( -10° C) to 104° F (40° C)
Power Factor(cosϕ)0.47
CoolingForced Air (Class F)
Input Power (U1– Input Voltage; I1– Input Current)
036034200 VAC (U1), 3 Phase, 50 Hz, 740 A (I1)
036032400 VAC (U1), 3 Phase, 50 Hz, 370 A (I1)
036031480 VAC (U1), 3 Phase, 60 Hz, 310 A (I1)
036033600 VAC (U1), 3 Phase, 60 Hz, 246 A (I1)
Dimensions and Weight
Width40" (1015 mm)
Maximum Height53" (1345 mm)
Maximum Depth50" (1270 mm)
Weight2250 lbs (1022 kg)
SPECIFICATIONS
2-4H401 & H601 Instruction Manual
4
H401 % Duty Cycle
H401 Volt-ampere Curves
H601 % Duty Cycle
H601 Volt-ampere Curves
Arc Current
Arc Current
Note:
The duty cycle of a power supply is
the percentage of a 10-minute period
that a power supply can safely be
operated at a given output.
Note:
The voltage/amp curves, show the
output voltage available at any given
output current within the limits of the
minimum and maximum current
control settings. Load voltage is
determined by arc characteristics and
torch height above the workpiece.
Positioning the Power Supply ..........................................................................................................................3-2
Power Requirements ................................................................................................................................................3-3
Power Cables and Fuses.................................................................................................................................3-3
Connecting the Primary Power.................................................................................................................................3-4
Line Disconnect Switch....................................................................................................................................3-5
PAC500 with H401 or H601.............................................................................................................................3-6
PAC500 Control Cable with H401 or H601......................................................................................................3-7
Parallel Power Supply Connections.................................................................................................................3-8
PAC500 Water Muffler and Water Supply System Connections......................................................................3-9
Current Control Potentiometer Connections..................................................................................................3-10
HT4001 with H401 or H601............................................................................................................................3-10
INSTALLATION
3-2H401 & H601 Instruction Manual
5
Installation Requirements
Direct any technical questions to the nearest Hypertherm Technical Service Department listed in the front of this
manual, or your authorized Hypertherm distributor.
Positioning the Power Supply
Note:A lifting eye is provided for moving the power supply into place with a crane or hoist. It may also be moved
by forklift if the forks are long enough to extend the entire length of the base. Take care when lifting with
the forks so that the underside of the power supply is not damaged. Do not lift the power supply by the
cross members supporting the transformer windings.
• Place the power supply in an area that is free of excessive moisture, has proper ventilation, and is
relatively clean. The preferred placement is with the power supply parallel to the rails (see below left). If
the front of the machine must face the rails, allow for at least 48" (1200 mm) of open space between
them. Allow at least 24" (600 mm) on all other sides of the power supply for free air flow, and for
accessing the sides of the power supply for servicing. Do not place any additional filter device over the air
intake locations. This reduces cooling efficiency and VOIDS THE WARRANTY.
WARNING
ELECTRICAL SHOCK CAN KILL
All installation and service of the electrical components must conform to national or local electrical
codes. This work should be performed only by qualified, licensed personnel.
WARNING
ELECTRICAL SHOCK CAN KILL
Remove all electrical connections to power supply before moving, positioning or servicing.
Transporting the power supply can cause personal injury and equipment damage.
FRONT
TOP
AIR FLOW
AIR FLOW
AIR FLOW
24" (600MM) Minimum
RIGHT SIDE
RAILS
AIR FLOW
INSTALLATION
H401 & H601 Instruction Manual3-3
5
Grounding Requirements
Proper grounding is essential for personal safety and to prevent emission of high-frequency interference. See the
Appendix section for system grounding requirements.
Connect the worktable to a high-quality earth ground from within 20 feet (6 m) of the table. A suitable ground
consists of a solid copper rod of at least 3/4-inch (19 mm) diameter driven to a depth of at least 8 feet (2.5 m) into
the earth below the permanent moisture level. Ensure that all grounding connections are tight to avoid excessive
heating. See also Grounding in the Safety section. For additional information consult national or local electric
codes.
Noise Levels
Acceptable noise levels as defined by national or local codes may be exceeded by this plasma system. Always
wear proper ear protection when cutting or gouging. See also Noise Protection in the Safety section of this manual.
Power Requirements
All switches, slow-blow fuses and power cables are customer supplied and must be chosen as outlined by
applicable national or local electrical codes. Installation must be performed by a licensed electrician. If
slow-blow fuses are not available or not allowed per applicable codes, use a motor-start circuit breaker.
Power Cables and Fuses
Wire sizes vary based on the distance of the receptacle from the main box. Use a 4-conductor Type SO input
power cable with a conductor temperature rating of 140°F (60°C). The proper strain relief should be used to
prevent damage to input power cables. The cable should be installed only by a licensed electrician. Always connect
the power cable to the power supply before connecting to the line disconnect switch.
Refer to the data tag on the rear of the power supply to verify the correct line voltage requirements and to
determine the continuous current draw for the unit.
Fuse sizes should never exceed the capacity of the power line conductors. Use FRS type fuses.
INSTALLATION
3-4H401 & H601 Instruction Manual
5
Connecting the Primary Power
Power Cable to H401 or H601 Power Supply
Run the input conductors of the power cable within a flexible conduit or use heavy rubber jacketed cable.
1. Insert the primary power cables through the access holes on the left side panel of the power supply. Holes
should be modified to accommodate cables.
2. Connect the power leads to the L1, L2, and L3 buses located off the contactor and accessible behind the center
wall. See picture on next page.
3. Connect the ground to the designated ground point in the power supply. See picture below.
WARNING
ELECTRICAL SHOCK CAN KILL
All line disconnect switches for all components of the plasma system must be in the OFF position
before making the power cable connections! In the U.S., use a "lock-out/tag-out" procedure until
installation is complete. In other countries, follow appropriate local or national safety procedures.
Primary Input Power Knock-outs (5)
(Use Proper Strain-Relief)
Primary power ground location
INSTALLATION
H401 & H601 Instruction Manual3-5
5
L1
Line Disconnect Switch
The line disconnect switch serves as the supply voltage disconnecting (isolating) device. Install this switch on a
wall near the power supply (supplies) for easy accessibility by the operator. The line disconnect switch must beinstalled by qualified personnel following all applicable national or local codes. The switch should:
• isolate the electrical equipment and disconnect all live conductors from the supply voltage when in the
“OFF” position
• have one "OFF" and one “ON” position clearly marked with “0” (OFF) and “1” (ON)
• have an external operating handle capable of being locked in the “OFF” position
• contain a power operated mechanism that serves as an emergency stop
• have slow-blow fuses installed for the proper breaking capacity
• have slow-blow fuses installed for the proper breaking capacity
• Provide power to only one power supply (parallel operation requires a seperate and unique disconnect
switch for each power supply)
Refer to the data plate on the rear of the power supply to verify the correct line voltage and current draw
requirements for the power supply.
L3
L2
WARNING
ELECTRICAL SHOCK CAN KILL
The line disconnect switch must be in the OFF position and remain in the OFF position for the
remainder of the installation of the H401 or H601 power supply.
WARNING
Parallel Systems
ELECTRICAL SHOCK CAN KILL
If the power supply is used in parallel with another power supply, or used as a slave unit with
another power supply, both line disconnect switches must be in the OFF position and remain in the
OFF position during installation and maintenance work.
INSTALLATION
3-6H401 & H601 Instruction Manual
5
PAC500 with H401 or H601
1. Connect the negative cables to the electrode at the cathode block in the plumbing compartment of the PAC500
plasma console. See instruction manual 800370 Figure 7.
2. Connect the positive cables to the star ground on the water table.
Secondary Connections
1. Use 4/0 gauge (100mm2), 600 volt welding cable for secondary connections.
2. Pass secondary cables through the front panel access hole of the power supply.
3. Connect the positive and negative cables to the terminals located on the floor of the power supply as shown. If
the total arc current will exceed 500 amps, use 4/0 (100mm2)cables in pairs; 2 cables for the negative and 2
cables for the positive connections.
H401
Positive
Negative
Negative
Positive
H601
INSTALLATION
H401 & H601 Instruction Manual3-7
5
PAC500 Control Cable with H401 or H601
The power supply control cable from the PAC500 console to the H401 or H601 power supply carries signals for the
contactor control relay, and the pilot arc ground. Note: For PAC500L use cable as designated in manual 800460.
Contactor control relay connection
Location: Power supply center wall
White wire #57
Black wire #58
Pilot arc ground connection
Location: +DC output
Red wire #27
Caution:The power supply contactor (CON) is energized by the control relay (CR1).
Energizing the contactor directly with the plasma console circuitry will result
in damage to the console flow switches due to excessive inrush currents.
PAC500 Control Cable Connections
Part No.Length
02800950 ft (15 m)
128088150 ft (46 m)
128089175 ft (53 m)
2RECP-AWhite57T-1Machine Start
2RECP-BBlack58T-2Machine Start
2RECP-CRed27+ DC OutputP.A. Ground
2RECP-DGreenGndNo ConnectionSpare
E F (ref)
58
57
1 2 3
Machine Start
27
INSTALLATION
3-8H401 & H601 Instruction Manual
5
WARNING
Parallel Systems
ELECTRICAL SHOCK CAN KILL
If the power supply is used in parallel with another power supply, or used as a slave unit with
another power supply, both line disconnect switches must be in the OFF position and remain in the
OFF position during installation and maintenance work.
Parallel Power Supply Connections
For increased capacity, power supplies may be connected in parallel. See figures below. This arrangement will also
cause the panel ammeter on power supply #1 to indicate the total arc current produced by both power supplies.
The panel ammeter on power supply #2 will indicate only the part of the arc current produced by power supply #2.
Power Supply 1
Connect the contactor control relays in parallel.
Power Supply 2
H601-Power Supply 2
H601-Power Supply 1
Single 600 Volt 4/0 Cable
Single 600 Volt 4/0 Cable
600 Volt 4/0 Cable Pairs
To
Plasma Console
Negative (-)
To
Water Table
Star Ground
Positive (+)
SHUNT
To
Remote
Current Displ
SHUNT
SHUNT
SHUNT
E F (ref)
H401-Power Supply 2
To
Plasma Console
Negative (-)
SHUNT
Single 600 Volt 4/0 Cable
Single 600 Volt 4/0 Cable
600 Volt 4/0 Cable Pairs
H601-Power Supply 1
To
Water Table
Star Ground
Positive (+)
SHUNT
SHUNT
57
To
Remote
Current Display
58
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
INSTALLATION
H401 & H601 Instruction Manual3-9
4
PAC500 Water Muffler and Water Supply System Connections
Connect each pump to a separate wall-mounted disconnect switch that is also connected to a master line
disconnect switch. See Line Disconnect Switch earlier in this section.
The power supply provides 120VAC for the operation of the water supply system and water muffler pump
contactors.
Water Supply System Connections
Connect the water supply system to run continuously when the power supply primary power is turned on.
Water supply connections
Location: Power supply center wall
Water Muffler System Connections
Connect the water muffler system to run when the power supply contactor is closed.
Note: Install a jumper between terminals 14 and 15 as shown.
Water muffler pump connections
Location: Power supply center wall
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
120 VAC
Control Power
Output
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1C
Auxiliary
Contacts
W.M.
Pump
Coil
120 VAC
Control Power
Output
INSTALLATION
3-10H401 & H601 Instruction Manual
5
Current Control Potentiometer Connections
Remote current adjustment of the H401 or H601 power supplies is possible from Hypertherm remote current
control and the THC-1/RVC height control system. Refer to the instruction manuals provided with these units for
the correct method of wiring.
Note: The programmable remote will not function with the H401/H601. The digital remote will function with the
H401/H601.
To operate the current control from a remote potentiometer:
1. Remove the jumper between terminals 7 and 8.
2. Install the jumper between terminals 8 and 9.
3. Make connections as shown below.
HT4001 with H401 or H601
Refer to HT4001 instruction manuals 802470 for 200V HT4001 power supplies, or 802000 for all other voltage
HT4001 power supplies.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Remote current control connections
Location: Power supply center wall
H J M NG (ref)
H401 & H601 Instruction Manual4-1
5
Section 4
OPERATION
In this section:
Controls and Indicators.............................................................................................................................................4-2
H401 or H601 with HT4001..............................................................................................................................4-3
H401 or H601 with PAC500.............................................................................................................................4-3
Output Current for Power Supply Dial Settings................................................................................................4-4
OPERATION
4-2H401 & H601 Instruction Manual
4
Controls and Indicators
Voltmeter 1 VM
Displays active arc voltage
Current Control P1
Adjusts the cutting current
Ammeter 1 AM
Displays the cutting current
Control Power Circuit Breaker 1CB
Turns the power supply control circuits
ON or OFF
DC ON Indicator 1PL
Illuminates when the main
contactor 1C closes
Over Temperature Indicator 2PL
Illuminates when the transformer
has overheated. See Maintenance
for corrective action if this lamp
illuminates.
OPERATION
H401 & H601 Instruction Manual4-3
4
Operation
H401 or H601 with HT4001
Refer to HT4001 instruction manual 802470 for 200V HT4001 power supplies or 802000 for all other voltage
HT4001 power supplies.
H401 or H601 with PAC500
1. Turn the line disconnect switch on. When the primary power is applied, the power supply cooling fan(s) and the
water supply system will turn on immediately. The DC ON indicator will be extinguished and the power supply
voltmeter will read zero volts.
2. Find the correct current setting from the operating data charts in the PAC500 or PAC500L instruction manuals.
3. Determine the proper power supply dial setting from Figure 4-1. After an arc is established, the setting may be
readjusted to the exact current desired.
4. The start sequence of the plasma arc control in "RUN" mode will close the power supply contactor.
See the PAC500 instruction manual 800370 or PAC500L instruction manual 800460 to operate the PAC500
system.
When the power supply contactor closes, the red DC ON indicator on the front of the power supply (1PL) will
illuminate and the voltmeter will read 400V. After arc ignition, the voltage will drop to 120 – 220 volts, depending on
the operating conditions selected.
Caution:When primary power is applied to the power supply, the water supply system,
if connected, will be energized. Always verify that the water supply line is open
to avoid damage to the pump.
OPERATION
4-4H401 & H601 Instruction Manual
4
Figure 4-1Output Current for Power Supply Dial Settings
(Dial Setting is a % of Power Supply Current Output)
Power Supply Circuit Description .............................................................................................................................5-2
Clean, service and inspect the H401 and H601 power supplies at 6-month intervals.
Power Supply Circuit Description
The H401 and H601 power supplies are 3-phase transformer-rectifier type, D.C. power sources using SCRs in a
full-wave bridge rectifier circuit. Low rms ripple current is achieved through use of 6 SCRs into an inductor. Filters
are provided to protect the SCRs from high-voltage transients and high-frequency currents from the plasma arc
ignition circuit. A thermostat protects transformer windings from overload and overheated conditions. The
thermostat resets automatically when the transformers return to safe operating temperatures. Circuit boards control
the SCRs. The current can be adjusted from the front panel mounted potentiometer or by a remote potentiometer.
• Remove side panels and blow out any dust with a low pressure dry air line.
• Clean air passages and cooling fans.
• Check for loose wiring and components. Make repairs as necessary.
• Lubricate the fan motor(s) every 2 years with SAE 20 weight motor oil.
WARNING
ELECTRICAL SHOCK CAN KILL
Shut off all power supplies at their primary disconnect switches. In the U.S., use a “lock-out/tag-out”
procedure. In other countries, follow appropriate local or national safety procedures. Shut off all
plasma control circuits to prevent control power from entering the power supply. Verify with a
voltmeter that no power is present on the power supply primary and control circuit terminals
(L1, L2, L3, 1T-1 and 1T-2).
WARNING
Parallel Systems
ELECTRICAL SHOCK CAN KILL
If the power supply is used in parallel with another power supply, or used as a slave unit with
another power supply, both line disconnect switches must be in the OFF position and remain in the
OFF position during installation and maintenance work.
MAINTENANCE AND TROUBLESHOOTING
H401 & H601 Instruction Manual5-3
5
Troubleshooting
Correct malfunctions of the solid-state control circuits by replacing the printed circuit boards.
Current control potentiometer not functioning:
• Jumper is positioned incorrectly. To adjust the current from the front panel potentiometer, place the jumper
between terminals 7 and 8. A remote potentiometer requires a jumper between terminals 8 and 9.
DC ON indicator (1PL) is illuminated, but there is no voltage:
• Contactor has failed.
DC ON indicator (1PL) is extinguished during the plasma start sequence:
• PAC500 plasma console is in “TEST” mode.
• DC ON lamp is burned out. If output voltage is indicated on the front panel voltmeter, the lamp is probably
burned out.
• Control relay CR1 has failed.
• There is an interface failure. Check the wiring to the PAC500 plasma console and console flow switches.
• The thermal switch is open. If the power supply has been operating above the rated output, the situation will
be corrected when the main transformer cools down.
Over-temperature indicator (2PL) is illuminated.
• A transformer or inductor thermal switch is open. If the power supply has been operating above the rated
output, allow the main transformer to cool down by letting the fans run for 5 minutes or longer before
attempting to cut again.
• Thermal switch failure. Thermal switches are normally closed and open when there is an over temperature
condition. Check switches and associated wiring.
Open circuit voltage present, but the arc does not start:
• Surge injection circuit has failed. Check resistor R1 and capacitors C13A and C13B. These components
are located across the power supply output. See the Parts List section to locate components.
• PAC500 plasma console high frequency generator or pilot arc circuits have failed.
Low output current and/or low open circuit voltage:
• A fuse is open in the 3-phase primary voltage supply.
• A transformer winding is open.
• Line voltage is low.
H401 & H601 Instruction Manual6-1
5
Section 6
PARTS LIST
In this section:
Front Panel Outside..................................................................................................................................................6-2
SCR and Shunt Detail...............................................................................................................................................6-3
Transformer and Inductor ........................................................................................................................................6-4
Temperature Switches..............................................................................................................................................6-5
1040249Transformer, Main Power, 200/400V1T1
1040250Transformer, Main Power, 480V1T1
1040252Transformer, Main Power, 600V1T1
2040251Choke (Inductor)1 CH1
1040241Transformer, Main Power, 200/400V1T1
1040242Transformer, Main Power, 480V1T1
1040243Transformer, Main Power, 600V1T1
2040244Choke (Inductor)1 CH1
THIS DRAWING AND ALL INFORMATION
CONTAINED THEREON IS CONSIDERED
PROPRIETARY AND MAY NOT BE USED
FOR MANUFACTURING OR FABRICATION
PURPOSES WITHOUT PERMISSION
FROM HYPERTHERM, INC.
RED
WHT
8
8
7
J2
REMOTE
CURRENT ADJUST
0
1 VM
0
1 AM
16
15A
119
6
1CR
4
118
116
10
115
8
9
8
7
6
CW
10
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS ARE IN INCHES.
TOLERANCES ARE:
2 PL DECIMAL ±.01
3 PL DECIMAL ±.005
FRACTIONS ±1/64
ANGULAR ±.5∞
PART MUST BE FREE OF BURRS AND SHARP
EDGES. BREAK SHARP EDGES IF NECESSARY
WITH CHAMFER OR RADIUS .015 MAX.
+
-
500VDC
+
-
600ADC
1
FEEDBACK CIRCUIT
8
7
54
SEE NOTE
SH 1
600A/50MV
109
110
109 110
2
910
(2 PCB)
6
CW
5K
P1
DESCRIPTION
ITEM NO.FILE NAME
107
111
C10A
112
C10B
113
114
108
LOCAL
NOTES:
1)
WIRING COLOR CODE:
BLACK - HIGH VOLTAGE/CURRENT AC OR DC
RED - AC CONTROL
BLUE - DC CONTROL
GREEN - GROUND
RED/WHITE (TWISTED) - SCR CATHODE(RED) GATE(WHT)
2) MOVE JUMPER BETWEEN TERMINALS
7 & 8 FOR REMOTE CURRENT CONTROL POTENTIOMETER
3) C1, 2, 3 ARE 40µf @ 460VDC
C4 THRU C9 ARE .05µf @ 1KV
C10A & B ARE 800µf @ 350VDC
Box-5010 Hanover, NH 03755-5010 603/643-3441
HDR:SCH PS H401 200V INPUT
040264040264C
DATE
R2A
10K, 5W
R2B
10K, 5W
R1
4Ω, 300W
SCALE
APPROVED BYDRAWN BY
(+)
POSITIVE
DC OUTPUT
(-)
NEGATIVE
SHEET
NTS1 OF 1
DATE
MWW1-14-02DJR1-16-02
D
C
B
A
A
4321
4
7-5
5
D
INCOMING
POWER
400V, 3PH
50/60HZ
C
GRND
L3
L2
L1
1FM
2FM
122
121
105
H1H3H2
X1
1T
1C
C11
.1µf.1µf.1µf
1CB
106
X2
H4 H5
X3
X4
C12
1L3
C3
1L2
C2
1L1
C13
2T
C1
16
H12
H8
H4
(SIMPLIFIED)
(SEE BELOW)
321
REVISIONS
APPROVEDDATEDRAWNDATEECNREV
A127991-11-02MWW1-16-02DJR
1 CH
SCR1B
2L3
X3
2L2
X2
2L1
X1
SCR1A
SCR2A
SCR2B
SCR3A
SCR3B
+
-
0
500VDC
1 VM
+
-
0
600ADC
1 AM
SH 1
600A/50MV
109
110
107
108
C10A
C10B
111
112
113
114
R2A
10K, 5W
R2B
10K, 5W
R1
4Ω, 300W
D
(+)
POSITIVE
DC OUTPUT
(-)
NEGATIVE
C
XFMR
O/T
1CR
104
TRANSFORMER 1T PRIMARY CONNECTIONS
B
A
101102
2CR
400V
1L3
1L2
1L1
CHOKE
O/T
120
H12
H10
H11
H9
H8
H6
H7
H5
H4
H2
H3
H1
2CR
2PL
1PL
1C
"O/T"
1CR
103
"ON"
Y
R
15
1FU
KTK-R1
3T
120/24V
1C
13
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
120VAC
ON/OFF
CONTROL
14
REMOTE CURRENT
CW (5K)
ADJUST
0
120
1C
AUX
CONTACTS
YEL
GRN
120VAC
CONTROL
POWER
OUTPUT
2
(2 PCB)
109 110
910
6
CW
5K
P1
LOCAL
NOTES:
1)
WIRING COLOR CODE:
BLACK - HIGH VOLTAGE/CURRENT AC OR DC
RED - AC CONTROL
BLUE - DC CONTROL
GREEN - GROUND
RED/WHITE (TWISTED) - SCR CATHODE(RED) GATE(WHT)
2) MOVE JUMPER BETWEEN TERMINALS
7 & 8 FOR REMOTE CURRENT CONTROL POTENTIOMETER
3) C1, 2, 3 ARE 40µf @ 460VDC
C4 THRU C9 ARE .05µf @ 1KV
C10A & B ARE 800µf @ 350VDC
B
16
6
4
10
8
7
CW
15A
119
1CR
118
8910
116
115
1
FEEDBACK CIRCUIT
8
7
54
SEE NOTE
RED
WHT
1
J12J2
1
2
RED
WHT
2
1
1CR
117
RED
5
4
(1 PCB)
WHT
J2
RED
5
WHT
4
J1
FIRING CIRCUIT
2CR
12
120VAC
ON/OFF
CONTROL
MATERIAL
RED
WHT
WHT
8
7
7
J1
J2
CURRENT ADJUST
RED
8
6
REMOTE
A
Box-5010 Hanover, NH 03755-5010 603/643-3441
HDR:SCH PS H401 400V INPUT
040263040263C
MWW1-11-02DJR1-16-02
DATE
SCALE
APPROVED BYDRAWN BY
SHEET
NTS1 OF 1
DATE
A
THIS DRAWING AND ALL INFORMATION
CONTAINED THEREON IS CONSIDERED
PROPRIETARY AND MAY NOT BE USED
FOR MANUFACTURING OR FABRICATION
PURPOSES WITHOUT PERMISSION
FROM HYPERTHERM, INC.
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS ARE IN INCHES.
TOLERANCES ARE:
PART MUST BE FREE OF BURRS AND SHARP
EDGES. BREAK SHARP EDGES IF NECESSARY
WITH CHAMFER OR RADIUS .015 MAX.
DESCRIPTION
ITEM NO.FILE NAME
4321
4
7-7
5
D
GRND
INCOMING
POWER
480V, 3PH
60HZ
122
1C
C11
.1µf.1µf.1
1CB
106
H4 H5
C12
1L3
C3
1L2
C2
1L1
C13
C1
µf
2T
H3
H2
H1
L3
L2
L1
121
1FM
2FM
105
H1H3H2
1T
321
REVISIONS
APPROVEDDATEDRAWNDATEECNREV
A127991-11-02MWW1-16-02DJR
1 CH
SCR1B
2L3
X3
2L2
X2
2L1
X1
SCR1A
SCR2B
SCR2A
SCR3A
SCR3B
+
-
0
500VDC
1 VM
+
-
0
600ADC
1 AM
SH 1
600A/50MV
109
110
107
108
C10A
C10B
111
112
113
114
R2A
10K, 5W
R2B
10K, 5W
R1
4Ω , 300W
D
(+)
POSITIVE
DC OUTPUT
(-)
NEGATIVE
X1
C
104
XFMR
1CR
O/T
CHOKE
101102
2CR
B
O/T
120
X4
X3
X2
2CR
2PL
1PL
1C
"O/T"
1CR
103
"ON"
Y
R
16
15
1FU
KTK-R1
3T
120/24V
1C
1314
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
0
120
YEL
GRN
C
2
(2 PCB)
109 110
910
6
CW
5K
P1
LOCAL
CURRENT
NOTES:
1)
WIRING COLOR CODE:
BLACK - HIGH VOLTAGE/CURRENT AC OR DC
RED - AC CONTROL
BLUE - DC CONTROL
GREEN - GROUND
RED/WHITE (TWISTED) - SCR CATHODE(RED) GATE(WHT)
2) MOVE JUMPER BETWEEN TERMINALS
7 & 8 FOR REMOTE CURRENT CONTROL POTENTIOMETER
3) C1, 2, 3 ARE 40
C4 THRU C9 ARE .05
C10A & B ARE 800
µf
@ 460VDC
µf
µf
@ 350VDC
@ 1KV
B
16
6
4
10
8
7
CW
15A
119
1CR
118
116
115
8910
1
FEEDBACK CIRCUIT
8
7
54
SEE NOTE
RED
WHT
2
1
J12J2
RED
1CR
117
WHT
1
1
2
RED
5
(1 PCB)
WHT
4
J2
RED
5
WHT
4
J1
FIRING CIRCUIT
2CR
12
120VAC
ON/OFF
CONTROL
RED
WHT
WHT
8
7
7
J2
J1
CURRENT ADJUST
RED
8
6
REMOTE
120VAC
ON/OFF
A
CONTROL
REMOTE CURRENT
ADJUST
CW (5K)
CONTACTS
1C
AUX
120VAC
CONTROL
POWER
OUTPUT
MATERIAL
THIS DRAWING AND ALL INFORMATION
CONTAINED THEREON IS CONSIDERED
PROPRIETARY AND MAY NOT BE USED
FOR MANUFACTURING OR FABRICATION
PURPOSES WITHOUT PERMISSION
FROM HYPERTHERM, INC.
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS ARE IN INCHES.
TOLERANCES ARE:
2 PL DECIMAL ±.01
3 PL DECIMAL ±.005
FRACTIONS ±1/64
ANGULAR ±.5∞
PART MUST BE FREE OF BURRS AND SHARP
EDGES. BREAK SHARP EDGES IF NECESSARY
WITH CHAMFER OR RADIUS .015 MAX.
DESCRIPTION
ITEM NO.FILE NAME
Box-5010 Hanover, NH 03755-5010 603/643-3441
HDR:SCH PS H401 480V INPUT
040258040258C
MWW1-11-02DJR1-16-02
DATE
SCALE
APPROVED BYDRAWN BY
NTS1 OF 1
SHEET
DATE
A
A
4321
4
7-9
5
321
REVISIONS
APPROVEDDATEDRAWNDATEECNREV
1 CH
GRND
SCR1B
SCR2B
SCR3B
D
122
1C
.1µf.1µf.1µf
106
H4 H5
X3
X2
X4
C11
2T
C12
1CB
C13
1L3
C3
1L2
C2
1L1
C1
H3
H2
H1
16
L3
INCOMING
POWER
600V, 3PH
60HZ
L2
L1
121
1FM
2FM
105
H1H3H2
X1
C
1T
2L3
X3
+
-
2L2
X2
2L1
X1
SCR1A
SCR2A
SCR3A
0
500VDC
1 VM
+
-
0
600ADC
1 AM
SH 1
600A/50MV
109 110
A127991-11-02MWW1-16-02DJR
107
108
111
C10A
112
C10B
113
114
R2A
10K, 5W
R2B
10K, 5W
R1
4 , 300W
(+)
POSITIVE
DC OUTPUT
(-)
NEGATIVE
D
C
15
1FU
KTK-R1
3T
120/24V
1C
1314
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
120VAC
ON/OFF
CONTROL
REMOTE CURRENT
CW (5K)
ADJUST
0
120
1C
AUX
CONTACTS
YEL
GRN
120VAC
CONTROL
POWER
OUTPUT
2
(2 PCB)
109 110
910
6
CW
5K
P1
LOCAL
CURRENT
NOTES:
1)
WIRING COLOR CODE:
BLACK - HIGH VOLTAGE/CURRENT AC OR DC
RED - AC CONTROL
BLUE - DC CONTROL
GREEN - GROUND
RED/WHITE (TWISTED) - SCR CATHODE(RED) GATE(WHT)
2) MOVE JUMPER BETWEEN TERMINALS
7 & 8 FOR REMOTE CURRENT CONTROL POTENTIOMETER
3) C1, 2, 3 ARE 40 µf @ 460VDC
C4 THRU C9 ARE .05 µf @ 1KV
C10A & B ARE 800µf @ 350VDC
B
16
6
4
10
8
7
CW
15A
119
1CR
118
8910
116
115
1
FEEDBACK CIRCUIT
8
7
54
SEE NOTE
RED
WHT
2
1
J12J2
RED
1CR
117
WHT
1
1
2
RED
5
J1
(1 PCB)
WHT
4
J2
RED
5
WHT
4
FIRING CIRCUIT
2CR
12
120VAC
ON/OFF
CONTROL
MATERIAL
RED
WHT
WHT
8
7
7
J1
J2
CURRENT ADJUST
RED
8
6
REMOTE
A
Box-5010 Hanover, NH 03755-5010 603/643-3441
HDR:SCH PS H401 600V INPUT
040257040257C
DATE
SCALE
NTS1 OF 1
APPROVED BYDRAWN BY
SHEET
DATE
MWW1-11-02DJR1-16-02
A
THIS DRAWING AND ALL INFORMATION
CONTAINED THEREON IS CONSIDERED
PROPRIETARY AND MAY NOT BE USED
FOR MANUFACTURING OR FABRICATION
PURPOSES WITHOUT PERMISSION
FROM HYPERTHERM, INC.
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS ARE IN INCHES.
TOLERANCES ARE:
2 PL DECIMAL ±.01
3 PL DECIMAL ±.005
FRACTIONS ±1/64
ANGULAR ±.5∞
PART MUST BE FREE OF BURRS AND SHARP
EDGES. BREAK SHARP EDGES IF NECESSARY
WITH CHAMFER OR RADIUS .015 MAX.
DESCRIPTION
ITEM NO.FILE NAME
104
XFMR
O/T
1CR
101102
2CR
CHOKE
O/T
120
2CR
2PL
"O/T"
Y
1CR
103
1PL
"ON"
R
1C
B
A
4321
4
7-11
5
321
REVISIONS
APPROVEDDATEDRAWNDATEECNREV
A127991-11-02MWW1-16-02DJR
TO PARALLELED
POWER SUPPLY
1000A/50MV
110
SH 2
209
210
107
108
C10A
C10B
111
112
113
114
R2A
10K, 5W
R2B
10K, 5W
R1
4Ω , 300W
D
(+)
POSITIVE
DC OUTPUT
(-)
NEGATIVE
C
+
-
500VDC
+
-
SH 1
1000A/50MV
109
1 CH
D
INCOMING
POWER
200V, 3PH
50/60HZ
C
GRND
L3
L2
L1
1FM
2FM
122
121
105
H1H3H2
X1
X2
1CB
1C
X3
C11
.1µf.1µf.1µf
H4 H5
X4
C12
1T
(SIMPLIFIED)
(SEE BELOW)
1L3
C3
1L2
C2
1L1
C13
2T
C1
H12
H8
H4
16
2L3
X3
2L2
X2
2L1
X1
SCR1B
SCR1A
SCR2A
SCR2B
SCR3A
SCR3B
0
1 VM
0
1000ADC
1 AM
XFMR
O/T
1CR
104
TRANSFORMER 1T PRIMARY CONNECTIONS
B
A
101102
2CR
200V
1L3
1L2
1L1
CHOKE
O/T
120
H12
H10
H11
H9
H8
H6
H7
H5
H4
H2
H3
H1
2CR
2PL
1PL
1C
"O/T"
1CR
103
"ON"
Y
R
15
1FU
KTK-R1
3T
120/24V
1C
1314
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
120VAC
ON/OFF
CONTROL
REMOTE CURRENT
CW (5K)
ADJUST
0
120
1C
AUX
CONTACTS
YEL
GRN
120VAC
CONTROL
POWER
OUTPUT
2
(2 PCB)
109 110
910
6
CW
5K
P1
LOCAL
CURRENT
NOTES:
1)
WIRING COLOR CODE:
BLACK - HIGH VOLTAGE/CURRENT AC OR DC
RED - AC CONTROL
BLUE - DC CONTROL
GREEN - GROUND
RED/WHITE (TWISTED) - SCR CATHODE(RED) GATE(WHT)
2) MOVE JUMPER BETWEEN TERMINALS
7 & 8 FOR REMOTE CURRENT CONTROL POTENTIOMETER
3) C1, 2, 3 ARE 40µf @ 460VDC
C4 THRU C9 ARE .05µf @ 1KV
C10A & B ARE 800µf @ 350VDC
B
16
6
4
10
8
7
CW
15A
119
1CR
118
8910
116
115
1
FEEDBACK CIRCUIT
8
7
54
SEE NOTE
RED
WHT
2
1
J12J2
RED
1CR
117
WHT
1
1
2
RED
J1
(1 PCB)
RED
WHT
5
5
4
J2
WHT
4
FIRING CIRCUIT
2CR
12
120VAC
ON/OFF
CONTROL
RED
WHT
8
7
J1
CURRENT ADJUST
MATERIAL
WHT
7
J2
REMOTE
RED
8
6
A
Box-5010 Hanover, NH 03755-5010 603/643-3441
HDR:SCH PS H601 200V INPUT
DATE
SCALE
APPROVED BYDRAWN BY
SHEET
NTS1 OF 1
DATE
MWW1-11-02DJR1-16-02
A
THIS DRAWING AND ALL INFORMATION
CONTAINED THEREON IS CONSIDERED
PROPRIETARY AND MAY NOT BE USED
FOR MANUFACTURING OR FABRICATION
PURPOSES WITHOUT PERMISSION
FROM HYPERTHERM, INC.
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS ARE IN INCHES.
TOLERANCES ARE:
2 PL DECIMAL ±.01
3 PL DECIMAL ±.005
FRACTIONS ±1/64
ANGULAR ±.5∞
PART MUST BE FREE OF BURRS AND SHARP
EDGES. BREAK SHARP EDGES IF NECESSARY
WITH CHAMFER OR RADIUS .015 MAX.
DESCRIPTION
ITEM NO.FILE NAME
040259040259C
4321
4
7-13
5
321
REVISIONS
APPROVEDDATEDRAWNDATEECNREV
TO PARALLED
POWER SUPPLY
+
-
500VDC
+
-
1000ADC
SH 1
1000A/50MV
109 110
1 CH
D
INCOMING
POWER
400V, 3PH
50/60HZ
C
GRND
L3
L2
L1
1FM
2FM
122
121
105
H1H3H2
X1
1T
1C
C11
.1µf.1µf.1µf
1CB
106
H4 H5
X3
X2
X4
C12 C13
2T
1L3
C3
1L2
C2
1L1
C1
16
H12
H8
H4
(SIMPLIFIED)
(SEE BELOW)
2L3
X3
2L2
X2
2L1
X1
SCR1B
SCR1A
SCR2B
SCR2A
SCR3A
SCR3B
0
1 VM
0
1 AM
SH 2
1000A/50MV
209
210
A127991-11-02MWW1-16-02DJR
107
108
C10A
C10B
111
112
113
114
R2A
10K, 5W
R2B
10K, 5W
R1
4Ω, 300W
(+)
POSITIVE
DC OUTPUT
(-)
NEGATIVE
D
C
XFMR
O/T
1CR
104
TRANSFORMER 1T PRIMARY CONNECTIONS
B
A
101102
2CR
400V
1L3
1L2
1L1
CHOKE
O/T
H12
H10
H11
H9
H8
H6
H7
H5
H4
H2
H3
H1
120
2CR
2PL
1PL
1C
"O/T"
1CR
103
"ON"
CONTROL
Y
R
15
1FU
KTK-R1
3T
120/24V
1C
13
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
120VAC
ON/OFF
14
CW (5K)
REMOTE CURRENT
ADJUST
0
120
1C
AUX
CONTACTS
CONTROL
YEL
GRN
120VAC
POWER
OUTPUT
2
(2 PCB)
109 110
910
6
CW
5K
P1
LOCAL
NOTES:
1)
WIRING COLOR CODE:
BLACK - HIGH VOLTAGE/CURRENT AC OR DC
RED - AC CONTROL
BLUE - DC CONTROL
GREEN - GROUND
RED/WHITE (TWISTED) - SCR CATHODE(RED) GATE(WHT)
2) MOVE JUMPER BETWEEN TERMINALS
7 & 8 FOR REMOTE CURRENT CONTROL POTENTIOMETER
3) C1, 2, 3 ARE 40µf @ 460VDC
C4 THRU C9 ARE .05µf @ 1KV
C10A & B ARE 800µf @ 350VDC
B
16
7
CW
15A
1
119
6
1CR
4
118
116
10
115
8
9
8
10
FEEDBACK CIRCUIT
8
7
54
SEE NOTE
RED
WHT
1
J12J2
1
2
RED
WHT
2
1
1CR
117
RED
5
4
(1 PCB)
WHT
J2
RED
5
WHT
4
J1
FIRING CIRCUIT
2CR
12
120VAC
ON/OFF
CONTROL
MATERIAL
RED
WHT
WHT
8
7
7
J2
J1
REMOTE
CURRENT ADJUST
RED
8
6
A
Box-5010 Hanover, NH 03755-5010 603/643-3441
HDR:SCH PS H601 400V INPUT
040262040262C
DATE
SCALE
NTS1 OF 1
APPROVED BYDRAWN BY
SHEET
DATE
MWW1-11-02DJR1-16-02
A
THIS DRAWING AND ALL INFORMATION
CONTAINED THEREON IS CONSIDERED
PROPRIETARY AND MAY NOT BE USED
FOR MANUFACTURING OR FABRICATION
PURPOSES WITHOUT PERMISSION
FROM HYPERTHERM, INC.
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS ARE IN INCHES.
TOLERANCES ARE:
2 PL DECIMAL ±.01
3 PL DECIMAL ±.005
FRACTIONS ±1/64
ANGULAR ±.5∞
PART MUST BE FREE OF BURRS AND SHARP
EDGES. BREAK SHARP EDGES IF NECESSARY
WITH CHAMFER OR RADIUS .015 MAX.
DESCRIPTION
ITEM NO.FILE NAME
4321
4
7-15
5
321
REVISIONS
APPROVEDDATEDRAWNDATEECNREV
TO PARALLED
POWER SUPPLY
+
-
500VDC
+
-
1000ADC
SH 1
1000A/50MV
109
1 CH
D
INCOMING
POWER
480V, 3PH
60HZ
C
GRND
L3
L2
L1
1FM
2FM
122
121
105
H1H3H2
X1
1C
C11
.1µf.1µf.1µf
1CB
106
H4 H5
X3
X2
X4
C12
1L3
C3
1L2
C2
1L1
C13
C1
2T
H3
H2
H1
16
1T
2L3
X3
2L2
X2
2L1
X1
SCR1B
SCR1A
SCR2A
SCR2B
SCR3A
SCR3B
0
1 VM
0
1 AM
1000A/50MV
110
SH 2
209
A127991-11-02MWW1-16-02DJR
210
107
108
C10A
C10B
111
112
113
114
R2A
10K, 5W
R2B
10K, 5W
R1
4Ω, 300W
(+)
POSITIVE
(-)
NEGATIVE
D
DC OUTPUT
C
15
1FU
KTK-R1
3T
120/24V
1C
13
12345678910111213141516
120VAC
ON/OFF
14
REMOTE CURRENT
CW (5K)
ADJUST
0
120
1C
AUX
CONTACTS
120VAC
CONTROL
POWER
OUTPUT
YEL
GRN
2
(2 PCB)
109 110
910
6
CW
5K
P1
LOCAL
NOTES:
1)
WIRING COLOR CODE:
BLACK - HIGH VOLTAGE/CURRENT AC OR DC
RED - AC CONTROL
BLUE - DC CONTROL
GREEN - GROUND
RED/WHITE (TWISTED) - SCR CATHODE(RED) GATE(WHT)
2) MOVE JUMPER BETWEEN TERMINALS
7 & 8 FOR REMOTE CURRENT CONTROL POTENTIOMETER
3) C1, 2, 3 ARE 40µf @ 460VDC
C4 THRU C9 ARE .05µf @ 1KV
C10A & B ARE 800µf @ 350VDC
B
16
6
4
10
8
7
CW
15A
119
1CR
118
116
115
8910
1
FEEDBACK CIRCUIT
8
7
54
SEE NOTE
RED
WHT
2
1
J12J2
RED
1CR
117
WHT
1
1
2
RED
5
(1 PCB)
WHT
4
J2
RED
5
WHT
4
J1
FIRING CIRCUIT
2CR
12
120VAC
ON/OFF
CONTROL
MATERIAL
RED
WHT
WHT
8
7
7
J1
J2
CURRENT ADJUST
RED
8
6
REMOTE
A
Box-5010 Hanover, NH 03755-5010 603/643-3441
HDR:SCH PS H601 480V INPUT
040260040260C
DATE
SCALE
APPROVED BYDRAWN BY
SHEET
NTS1 OF 1
DATE
MWW1-11-02DJR1-16-02
A
THIS DRAWING AND ALL INFORMATION
CONTAINED THEREON IS CONSIDERED
PROPRIETARY AND MAY NOT BE USED
FOR MANUFACTURING OR FABRICATION
PURPOSES WITHOUT PERMISSION
FROM HYPERTHERM, INC.
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS ARE IN INCHES.
TOLERANCES ARE:
2 PL DECIMAL ±.01
3 PL DECIMAL ±.005
FRACTIONS ±1/64
ANGULAR ±.5∞
PART MUST BE FREE OF BURRS AND SHARP
EDGES. BREAK SHARP EDGES IF NECESSARY
WITH CHAMFER OR RADIUS .015 MAX.
DESCRIPTION
ITEM NO.FILE NAME
104
XFMR
1CR
O/T
101102
2CR
CHOKE
O/T
120
2CR
2PL
1PL
1C
"O/T"
1CR
103
"ON"
Y
R
B
A
CONTROL
4321
4
7-17
5
321
REVISIONS
TO PARALLELED
POWER SUPPLY
1 CH
D
INCOMING
POWER
600V, 3PH
60HZ
C
GRND
L3
L2
L1
1FM
2FM
122
121
105
H1H3H2
X1
1C
C11
.1µf.1µf.1µf
106
H4 H5
X3
X2
X4
1CB
2T
C12
C13
1L3
C3
1L2
C2
1L1
C1
H3
H2
H1
16
1T
2L3
X3
2L2
X2
2L1
X1
SCR1B
SCR1A
SCR2B
SCR2A
SCR3A
SCR3B
0
500VDC
1 VM
0
1000ADC
1 AM
1000A/50MV
+
-
+
-
SH 1
109
1000A/50MV
110
SH 2
209
109
210
110
A127991-11-02MWW1-16-02DJR
107
108
C10A
C10B
111
112
113
114
R2A
10K, 5W
R2B
10K, 5W
R1
4Ω, 300W
(+)
POSITIVE
DC OUTPUT
(-)
NEGATIVE
APPROVEDDATEDRAWNDATEECNREV
D
C
15
1FU
KTK-R1
3T
120/24V
1C
13
12345678910111213141516
120VAC
ON/OFF
CONTROL
14
CW (5K)
REMOTE CURRENT
ADJUST
0
120
1C
AUX
CONTACTS
CONTROL
YEL
GRN
120VAC
POWER
OUTPUT
2
(2 PCB)
109 110
910
6
CW
5K
P1
LOCAL
CURRENT
NOTES:
1)
WIRING COLOR CODE:
BLACK - HIGH VOLTAGE/CURRENT AC OR DC
RED - AC CONTROL
BLUE - DC CONTROL
GREEN - GROUND
RED/WHITE (TWISTED) - SCR CATHODE(RED) GATE(WHT)
2) MOVE JUMPER BETWEEN TERMINALS
7 & 8 FOR REMOTE CURRENT CONTROL POTENTIOMETER
3) C1, 2, 3 ARE 40µf @ 460VDC
C4 THRU C9 ARE .05µf @ 1KV
C10A & B ARE 800µf @ 350VDC
B
16
6
4
10
7
CW
15A
119
1CR
118
8
8910
116
115
SEE NOTE
1
FEEDBACK CIRCUIT
8
7
54
RED
WHT
2
1
J12J2
RED
1CR
117
WHT
1
1
2
RED
5
J1
(1 PCB)
WHT
4
J2
RED
5
WHT
4
FIRING CIRCUIT
2CR
12
120VAC
ON/OFF
CONTROL
MATERIAL
RED
WHT
WHT
8
7
7
J1
J2
CURRENT ADJUST
RED
8
6
REMOTE
A
Box-5010 Hanover, NH 03755-5010 603/643-3441
HDR:SCH PS H601 600V INPUT
040261040261C
DATE
SCALE
NTS1 OF 1
APPROVED BYDRAWN BY
SHEET
DATE
MWW1-11-02DJR1-16-02
A
THIS DRAWING AND ALL INFORMATION
CONTAINED THEREON IS CONSIDERED
PROPRIETARY AND MAY NOT BE USED
FOR MANUFACTURING OR FABRICATION
PURPOSES WITHOUT PERMISSION
FROM HYPERTHERM, INC.
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS ARE IN INCHES.
TOLERANCES ARE:
2 PL DECIMAL ±.01
3 PL DECIMAL ±.005
FRACTIONS ±1/64
ANGULAR ±.5∞
PART MUST BE FREE OF BURRS AND SHARP
EDGES. BREAK SHARP EDGES IF NECESSARY
WITH CHAMFER OR RADIUS .015 MAX.
DESCRIPTION
ITEM NO.FILE NAME
104
XFMR
O/T
1CR
2CR
101
CHOKE
O/T
120
102
2CR
2PL
1PL
1C
"O/T"
1CR
103
"ON"
Y
R
B
A
4321
H401 & H601 Instruction Manuala-1
4
System Grounding Requirements
The plasma system must be grounded for safety reasons and to suppress EMI:
• Safety The entire system—power supply, accessory enclosures, and worktable—must be grounded to protect it
and the operator from a ground fault. The protective earth (PE) ground connections must be installed by a
licensed electrician and conform to national or local codes.
• EMI Suppression If allowed by national or local codes, the ground system can also be used to suppress EMI
(electromagnetic interference). Below is a guide to configure the plasma system for minimal EMI. See
Electromagnetic Compatibility in this manual for additional information.
Suggested Ground Cable Routing
Power Supply
Connect the power supply to the PE ground terminal, using a properly sized color-coded conductor. This PE ground
is connected to the service ground through the line disconnect switch. See the Installation section for further
information on the power cord and the line disconnect switch.
Equipment Grounding
All accessory modules that receive power from the plasma power supply must also use the power supply’s
ground—either by connection to the PE terminal of the power supply, or by direct connection to the equipment
ground conductor. Each module should have only one connection to ground to avoid ground loops and stray
currents. If any enclosure is grounded to the work table, the work table must be grounded to the power supply.
Effective grounding for EMI reduction is highly dependent upon the installation configuration. Two acceptable
configurations are shown in Figures a-1 and a-2.
The ignition console should be installed near the work table, and grounded directly to it. Other modules should be
installed near the power supply, and grounded directly to it (Figure a-1).
All modules may also be installed near the work table, and grounded directly to it (Figure a-2). Do not ground the
ignition console directly to the power supply.
The customer must furnish all conductors for equipment grounding. Grounding conductors may be purchased
through Hypertherm in any length specified by the customer (Part No. 047058). The conductor may also be
Appendix A
SYSTEM GROUNDING
APPENDIX A – SYSTEM GROUNDING
a-2H401 & H601 Instruction Manual
4
purchased locally, using a minimum 8 AWG ULType MTW cable (USAspecification) or the appropriate cable
specified by national and local codes.
Consult the appropriate manufacturer’s instructions to ground equipment that does not receive power from the
power supply.
Work Table Grounding
If a supplementary ground rod is installed near the worktable to reduce EMI, it must be connected directly to the
PE ground of the building structure, connected to the service ground; or to earth, providing the resistance between
the ground rod and the service ground meets national or local codes. Place the supplementary ground rod within
20 ft (6 m) of the worktable according to national or local codes.
If any module is grounded to the work table, the work table must be grounded to the power supply, or the
configuration must be changed to comply with applicable national and local electrical codes.
A ferrite choke can be placed in the conductor between the work table ground rod and the PE ground, with a
number of turns through the choke to isolate the safety ground (at 60 Hz) from any electromagnetic interference
(frequencies above 150 Khz). The more turns the better. Asuitable ferrite choke can be made by wrapping 10 turns
or more of the ground lead through Magnetics part number 77109-A7, Fair-Rite part number 59-77011101, or other
equivalent ferrite choke. Locate the choke as close as possible to the plasma power supply.
The preferred cable routing for this configuration is as shown, but it is acceptable to “daisy-chain” the grounds for
the gas console and other equipment to the ignition console.
Plasma Power Supply
(PE)
Power Cord
Ground
Ferrite Choke
Supplementary
Grounding Rod
Gas Console
Other Equipment
receiving power from the
plasma power supply
Work Table
(PE)
(PE)
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