Hypertherm HT2000 User Manual
®
HySpeed
®
HT2000
200 Volt
Plasma Arc
Cutting System
Instruction Manual
802460 – Revision 14
Changed Page Description
IM246 Rev 11 to 12 4/10/00
0.02 Replaced text from "to Hypertherm's place of business..." to "to an authorized Hypertherm repair facility..."
4.14 Added remote power on/off signals to machine interface cable
6.13
Added p/ns for retaining cap with IHS tab
8.20
New graphic of chopper
9.08
Added graphic of relays to Fig. 9-4
9.09
Added part numbers for relays
9.21
Changed p/n of PS3 from 005130 to 005227
9.51
Changed p/n of PS3 from 005130 to 005227
10.05-10.13
Uprevved wiring diagrams to RZ
Begin w/serial # 2000-005756
Changed Page Description
IM246 Rev 10 to 11 9/27/99
0.01 Uprevved because of ECNs 10483, 10484, 10639, 10145, 10670
0.02 Added plumbing and electrical codes statement to warranty
0.04
Updated TOC for added section on cutting techniques, beveling consumable parts kit
0.05
Updated TOC for added section on cutting techniques, beveling consumable parts kit
0.08
Updated TOC for added section on cutting techniques, beveling consumable parts kit
1.0-1a.06
New safety sections
3.02
Bolded installation by qualified...; rewrote hard plumbing suggestions
3.03
Bumped page
3.04
Bumped page
6.01
Updated TOC for added section on cutting techniques
6.12
Referenced new section on cutting technique
6.39-6.42
New section on cutting techniques
8.25
Changed graphic of coolant reservoir
8.26
New graphic of coolant reservoir
9.01
Updated TOC for beveling consumable parts kit
9.17
Corrected part no. of adapter from 015157 to 015015
9.18
New coolant reservoir
9.19
New coolant reservoir #, new level switch SA #
9.25
New part number for pressure switches
9.36
New figure of torches
9.37
New torch mounting sleeve #
9.48
Renamed 1st header from consumable parts kit to HT2000 Consumable Parts Kit
9.49
Added HT2000 Beveling Consumable Parts Kit
9.51
Updated power supply recommended spare parts to include new level switch #
9.52
Updated gas console recommended spare parts to include new pressure switches
10.05-10.13
Uprevved wiring diagrams to RX
Begin w/serial # 2000-005600
Begin w/serial # 2000-006387
Changed Page Description
IM246 Rev 12 to 13 8/31/03
9.4 & 9.5
Section 10
Item # 5 changed from 041590 to 041762. Item # 6 081039 (firmware) was removed. Item
numbers following Item #5 changed to agree.
Wiring diagrams Revision change from RZ to SC
Changed Page Description
IM246 Rev 9 to 10 1/18/99
0.01 Uprevved because of ECNs 10078, 10079, 10070, 9753, 10012, 9864, 9742, 10020, 9926
0.05-0.08 Changed TOC for new figure descriptions, headings for parts list
2.04
Added The water muffler cannot be used with the stainless steel torch
2.06
Added new part numbers for torches, call out 2 dimensions for diameter
2.10
Added The water muffler cannot be used with the stainless steel torch
4.18
Added The water muffler cannot be used with the stainless steel torch
4.34
Removed part numbers for torch mounting brackets
6.13
Changed electrode p/ns and swirl ring p/ns in cut chart index
6.14
Changed electrode p/n, clarified production cutting capacity
6.15
Changed electrode p/n and swirl ring p/ns clarified production cutting capacity
6.16
Clarified production cutting capacity
6.17
Clarified production cutting capacity
6.18
Changed electrode p/n and swirl ring p/ns clarified production cutting capacity
6.20
Changed electrode p/n, clarified production cutting capacity
6.21
Clarified production cutting capacity
6.22
Clarified production cutting capacity
6.23
Clarified production cutting capacity
6.24
Changed electrode p/n, clarified production cutting capacity
6.25
Clarified production cutting capacity
6.26
Changed electrode p/n
6.27
Changed electrode p/n, clarified production cutting capacity
6.28
Clarified production cutting capacity
6.29
Clarified production cutting capacity
6.30
Clarified production cutting capacity
6.31
Changed electrode p/n, clarified production cutting capacity
6.32
Clarified production cutting capacity
6.33
Changed swirl ring p/ns, clarified production cutting capacity
6.34
Changed electrode p/n, clarified production cutting capacity
6.35
Changed electrode p/n
9.18
Removed pump clamp from figure
9.19
Removed pump clamp from parts list, changed p/n for motor and pump (now they are kits)
9.21
Changed p/n of SV7
9.25
Changed p/ns of SV1, SV2, SV3
9.27
Changed p/ns of SV4
9.36
Changed figure to cover both 2"diameter torches
9.37
New standard torch p/n, new stainless steel torch, added 2" torch mounting bracket
9.37A
Old standard torch now 1-3/4" optional
9.37B
New p/n for optional torch
9.43
Added p/ns for 2" diameter IHS system
9.49
Changed p/ns for O2 electrode and swirl ring in parts kit
9.51
Changed p/n of SV7
9.52
Changed p/ns of SV1, SV2, SV3, SV4
i1-i6
Updated index
10.01
Uprevved wiring diagrams to RV
Begin w/serial # 2000-005198
Changed Page Description
IM246 Rev 8 to 9 8/21/98
0.01 Uprevved because of ECNs 9763, 9758, 9803
8.25 New graphic of coolant flow
8.26
Updated graphic of coolant tank
9/18
New graphic of rear wall outside
9.19
New part numbers for solenoid valve assembly, water pump assembly
10.01
Added coolant flow diagram to wiring diagrams TOC
10.19
Added coolant flow diagram to wiring diagrams
Begin w/serial # 2000-005025
Changed Page Description
IM246 Rev 6 to 7 5/4/98
0.01 Uprevved because of new 100A electrode and change to cut charts
6.13 Changed index to call out 120547 electrode
6.17
Changed electrode part number to 120547
6.18
Changed electrode part number to 120547; changed flow %
9.49
Updated consumable parts kit contents
Begin w/serial # 2000-004270
Changed Page Description
IM246 Rev 7 to 8 7/24/98
0.01 Uprevved because of ECNs 9523, 9483, grounding appendix, serial # jump to 2000-005000
0.05 Added System Grounding to TOC
0.06
Added System Grounding to TOC
0.07
Bumped page
0.08
Added System Grounding to TOC
3.04
Referenced new grounding appendix
4.03
Referenced new grounding appendix
4.04
Referenced new grounding appendix
7.06
Added more verbiage on H35 cutting
7.07
Bumped page
7.08
Added more verbiage on H35 cutting
8.09
New power distribution PCB graphic, added fuse
8.22
Added error code for phase loss
9.05
New microprocessor board #, new firmware #
9.12
Referenced dwg of chopper with phase loss board
9.13
New graphic of chopper with phase loss board, new phase loss board #
9.51
New microprocessor board #, new firmware #
10.01
Uprevved wiring diagrams to RT
g.01
New system grounding appendix
g.02
New system grounding appendix
g.03
New system grounding appendix
g.04
New system grounding appendix
g.05
New system grounding appendix
i.04
Added phase loss to index
i.05
Added g1-g4 to grounding requirements in index
Begin w/serial # 2000-005000
Changed Page Description
IM246 Rev 5 to 6 1/15/98
0.01 Uprevved because of IOP, ECNs 8912, 8910, 9035, 8746
0.04 Updated TOC
0.06
Updated TOC
4.04
Added torque spec.
4.16
Removed current 400 signal from cable description
6.01
Changed TOC
6.03
Added note to hold down on button for up to 1 minute
6.10
Added note to hold down on button until leds extinguish
6.12
Added note to begin and end cut on plate
6.13
Renumbered pages on cut chart index
6.14-6.15
Added initial torch piercing height to cut charts; combined under+above water on 1 page
6.16
Added initial torch piercing height to cut charts
6.17-6.18
Added initial torch piercing height to cut charts; combined under+above water on 1 page
6.19
Added initial torch piercing height to cut charts
6.20-6.22
Added initial torch piercing height to cut charts; combined under+above water on 1 page
6.23
Added initial torch piercing height to cut charts
6.24
Added initial torch piercing height to cut charts; combined under+above water on 1 page
6.25-6.26
Added initial torch piercing height to cut charts
6.27-6.29
Added initial torch piercing height to cut charts; combined under+above water on 1 page
6.30
Added initial torch piercing height to cut charts
6.31
Added initial torch piercing height to cut charts; combined under+above water on 1 page
6.32-6.34
Added initial torch piercing height to cut charts
6.35
Put all gouging cut charts on 1 page
6.36
Bumped page
6.37
Bumped page; better graphic of main body; removed reference to nozzle o-ring
6.38
Bumped page
8.03
(from)...status LED turn off... (to)...status LED illuminate
8.10
Edited for easier translation
8.11
Edited for easier translation
8.12
Edited for easier translation
8.13
Edited for easier translation
8.14
Edited for easier translation
8.16
Edited for easier translation
8.17
Edited for easier translation
8.18
Edited for easier translation
9.04
New graphic of front panel
9.05
New part numbers for fans - added fan guard; new graphic of THC
9.11
Fuseholder p/n change
9.15
4 ohm resistor p/n change, designation change
9.51
Designation updates in recommended spare parts; added flowswitch
9.52
Added 100 psi pressure gauge to gas console recommended spare parts
10.01
Uprevved wiring diagrams to
10.02
(from) 2 of 9 in the...(to)...2 in the...
e.04
Added spacer to graphic of power supply
e.06
Added spacer and part number to power supply
i.01 to i.06
Updated index
Begin w/serial # 2000-004270
Changed Page Description
IM246 Rev 4 to 5 7/11/97
0.01 Uprevved to 5 because of new valve in RHF console
4.07 New graphic of RHF console
6.13
Eliminated 40A cutting chart for mild steel
6.16
Eliminated 40A cutting chart for mild steel
6.17
Added to note on 020679 swirl ring use
7.05
Rewording minutia
8.04
Added power supply cleaning routine maintenance
8.05
Bumped page
9.09
Changed 003138 from 100A to 20A
9.20
New graphic of RHF console
9.21
New part number for SV7
10.01
Uprevved wiring diagrams to MM
Begin w/serial # 2000-003196
Changed Page Descriptio
n
IM246 Rev 3 to 4 4/14/97
0.01 Uprevved to 4 for additional cables, hoses, new wiring dia., note to 50A cutting
0.06 Added figures to TOC
0.07
Added figures to TOC
2.05
Added tolerances to gas pressures
2.07
Corrected one dimension for gas console
3.02
Reference to Section 2 for gas specs, added caution
3.03
Reference to Section 2 for gas specs
3.10
Changed view of power cable connections to match label
4.06
Referenced to section 9 for additional lengths of hoses and cables
5.03
Added tolerances to gas pressures
6.10
Added tolerances to gas pressures
6.17
Added note to cut chart for using 020679 swirl ring
6.19A
Added note to 50A cut chart about possible cut degradation from N2 in the lines
6.39
Added note to cut chart for using 020679 swirl ring
7.07
Added tolerances to gas pressures
8.03
Referenced torch coolant draining procedure
8.26
Added torch coolant draining procedure
9.38
Additional lengths
9.39
Additional lengths
9.40
Additional lengths
9.41
Additional lengths
9.42
Additional lengths
9.43
Additional lengths
9.44
Additional lengths
9.45
Additional lengths
9.46
Additional lengths
9.47
Additional lengths
10.01
Uprevved wiring diagrams to KK
Begin w/serial # 2000-003090
Changed Page Descriptio
n
IM246 Rev 2 to 3 2/14/97
0.01 Uprevved to 3, added email and web address
0.05 Changed Appendices page #s
2.05
Added 440/460 power supply part #
2.06
Changed part # of machine torch
2.07
Changed part #s of Gas Console and Motor Valve Console
3.05
Added current draw and fuse size for 440V power supply
3.06
Added cable size for 440V power supply
4.06
Added note to installation section about additional part numbers
4.08
Removed reference to unused wires in RHF cable
4.10
Added signals for SV1A and SV1B
4.11
Graphic of new gas console
4.12
Added signals for SV4A and SV4B
4.15
Removed reference to V1 and V2
4.20
Changed page reference from 9-45 to 9-43; corrected length of 024144
4.25
Graphic of new gas console
4.27
Graphic of new gas console
4.31
New figure of new torch
5.04
Graphic of new gas console
6.05
Graphic of new gas console
6.19A
Added note about arc voltage, added scfh flows
7.05
New graphics of torch, new layout, clarification in procedure
7.06
Clarification of procedure
8.11
Removed outdated reference to leaking oil in transformer
9.05
Uprevved firmware to J
9.07
Added 440V power transformer part #
9.09
Added 440V control transformer part #
9.18
Added graphic of pump coupler
9.19
Added part # of pump coupler
9.24
Graphic of new gas console
9.25
New parts list for new gas console
9.26
Graphic of new motor valve console
9.27
New parts list for new motor valve console
9.33
Removed part # for swivel fitting
9.36
New figure of new torch
9.37
New parts list for machine torch
9.38
Clarified hoses in torch leads removed redundant graphic of cable and hose assy
9.52
Changed part # for new Kip valves in gas console and motor valve console
10.01
Uprevved wiring diagrams to JJ
0.c1
Put aeration manifold on 1 pg in appendix
0.d1
Removed advertising for Hankison filters, added description of filtering needs in appendix d
0.f1
Made Standards Index appendix f, removed glossary
Begin w/serial # 2000-003000
Changed Page Description
IM246 Rev 1 to 2 12/20/96
0.01 Uprevved manual due to LVD compliance
0.03-0.08 Updated table of contents
1.01-1.04
New Safety section
1a.01-1a.04
New French Safety section
2.02
Changed reference from 380-415V CE to 400V CE
2.05
Changed reference from 380-415V CE to 400V CE
3.04
Changed warning on propylene glycol to not induce vomiting
3.05
Added specs for 400V
3.06
Added specs for 400V
3.08
Changed figures of transformers to show new configurations
3.09
Changed figures of transformers to show new configurations
3.10
Changed reference from 380-415V CE to 400V CE
5.03
Added "See Status Indicators Before Startup to step 6
6.01
Added STATUS Indicators Before Startup to Sect. 6 TOC
6.02
New STATUS logic
6.03
Added STATUS Indicators Before Startup
6.10
Added "See Status Indicators Before Startup to step 6
7.07
Added "See Status Indicators Before Startup to step 7
8.03
Added 6-month maintenance to power supply
8.04
New figure for cleaning pump strainer
8.05
Bumped page
8.06
New startup logic
8.09
Picture of new power distribution board
8.11
Changed logic of cause 3.3
8.15
New STATUS logic
8.16
New STATUS logic
8.17
New STATUS logic
8.18
New STATUS logic
8.20
Removed reference to old chopper temperature switch
8.21
New graphic of control board
8.22
Changed figure label to Rev. G error codes (no change in actual codes)
8.23
New STATUS logic
8.24
New STATUS logic
9.05
Changed firmware rev level to G
9.06
Changed part no. for PCB5, corrected description of items 3 and 9
9.07
Changed reference from 220-380-415V to 220-380-400-415V
9.09
New part no. for PCB1; changed reference to 220-380-400-415V on T1
9.13
New chopper part no. and temp switch
9.19
New coolant reservoir part no.; added part nos. for gauge, drain valve
9.29
Changed part no. of potentiometer
9.51
Changed part nos. of PCB1, CH1
10.01
Uprevved wiring diagrams to GG
Begin w/serial # 2000-002500
HySpeed HT2000
Instruction Manual
(P/N 802460)
Revision 14 – November, 2013
© Copyright 2013 Hypertherm, Inc.
All Rights Reserved
Hypertherm, HT, HyLife, HySpeed and LongLife 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)
info@hypertherm.com (Main Office Email)
800-643-9878 Tel (Technical Service)
service@hypertherm.com (Technical Service Email)
800-737-2978 Tel (Customer Service)
customer.service@hypertherm.com (Customer Service Email)
Hypertherm Automation, LLC
5 Technology Drive, Suite 300
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 (S) Pte Ltd.
No. 19 Kaki Bukit Road 2
K.B. Warehouse Complex
Singapore 417847, Republic of Singapore
65 6 841 2489 Tel
65 6 841 2490 Fax
65 6 841 2489 (Technical Service)
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
00 800 3324 9737 Tel
00 800 4973 7329 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 Europe B.V.
Vaartveld 9
4704 SE Roosendaal, Nederland
31 165 596907 Tel
31 165 596901 Fax
31 165 596908 Tel (Marketing)
31 165 596900 Tel (ETSO – Technical Service)
00 800 49 73 7843 Tel (ETSO – Technical Service
toll-free in Europe)
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 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
5/23/03
ELECTROMAGNETIC COMPATIBILITY (EMC)
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 af fected 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 Earthing of
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
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 Plasma Systems i
WARRANTY
ii Hypertherm Plasma Systems
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, with the
exception of G3 Series power supplies, which shall be within a
period of three (3) years from the date of 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 suf ficient 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.
HySpeed HT2000 Instruction Manual iii
22
Electromagnetic Compatibility (EMC).......................................................................................................................i
Warranty .....................................................................................................................................................................ii
Section 1 SAFETY..................................................................................................................................................1-1
Recognize Safety Information...................................................................................................................................1-2
Follow Safety Instructions.........................................................................................................................................1-2
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
Grounding Safety......................................................................................................................................................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
Additional Safety Information....................................................................................................................................1-5
Warning Label...........................................................................................................................................................1-6
Section 1a SÉCURITÉ........................................................................................................................................1a-1
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
Section 2 SPECIFICATIONS................................................................................................................................2-1
Introduction ...............................................................................................................................................................2-2
Power Supply ...................................................................................................................................................2-2
Remote High Frequency (RHF) Console .........................................................................................................2-2
Gas Console ....................................................................................................................................................2-3
Motor Valve Console........................................................................................................................................2-3
Argon-Hydrogen Console.................................................................................................................................2-3
Remote Voltage/Current (V/C) Control ............................................................................................................2-3
Initial Height Sensing (IHS) ..............................................................................................................................2-4
Timer/Counter ..................................................................................................................................................2-4
Water Muffler....................................................................................................................................................2-4
Specifications............................................................................................................................................................2-5
System Requirements......................................................................................................................................2-5
Power Supply ...................................................................................................................................................2-5
HySpeed HT2000 Machine Torches ................................................................................................................2-6
TABLE OF CONTENTS
iv HySpeed HT2000 Instruction Manual
19
Remote High Frequency Console ....................................................................................................................2-6
Gas Console ....................................................................................................................................................2-7
Motor Valve Console........................................................................................................................................2-7
Argon/Hydrogen Console.................................................................................................................................2-8
Digital Remote (DR) V/C Control .....................................................................................................................2-8
Programmable Remote (PR) V/C Control ........................................................................................................2-9
Initial Height Sensing .....................................................................................................................................2-10
Timer/Counter ................................................................................................................................................2-10
Water Muffler..................................................................................................................................................2-10
Section 3 PRE-INSTALLATION...........................................................................................................................3-1
Introduction ...............................................................................................................................................................3-2
Gas Requirements....................................................................................................................................................3-2
Air as Plasma Gas ...........................................................................................................................................3-2
Oxygen, Nitrogen, or Argon/Hydrogen as Plasma Gas ...................................................................................3-3
Shield Gas........................................................................................................................................................3-3
Torch Coolant Requirements....................................................................................................................................3-4
Grounding Requirements..........................................................................................................................................3-5
Power Requirements ................................................................................................................................................3-5
Line Disconnect Switch ....................................................................................................................................3-5
Power Cable.....................................................................................................................................................3-5
Positioning the Power Supply ..........................................................................................................................3-6
Electrical Configurations ...........................................................................................................................................3-7
240/480V Linkboard Configurations.................................................................................................................3-7
220/380/415V Transformer T1 and T2 Configurations.....................................................................................3-8
Connecting the Power ............................................................................................................................................3-10
Torch Lifter Requirement ........................................................................................................................................3-11
Optional Equipment ................................................................................................................................................3-11
Water Muffler..................................................................................................................................................3-11
Initial Height Sensing (IHS) ............................................................................................................................3-12
Section 4 INSTALLATION ...................................................................................................................................4-1
Upon Receipt ............................................................................................................................................................4-2
Claims ........................................................................................................................ ..............................................4-2
Module Grounding and Grounding Checks ..............................................................................................................4-3
Noise Levels .............................................................................................................................................................4-3
System Units Placement...........................................................................................................................................4-4
Power Supply Connections.......................................................................................................................................4-6
Initial Height Sensing (IHS) Connections................................................................................................................4-20
Gas Console Connections ......................................................................................................................................4-24
RHF and Motor Valve Consoles to Torch Connections ..........................................................................................4-28
Routing the Torch Leads................................................................................................................................4-28
Connecting the HF Torch Leads to the RHF Console....................................................................................4-28
Connecting the HF Torch Leads to the Torch ................................................................................................4-30
Connecting the Off-Valve Cable and Plasma Hose from the Torch to the Motor Valve Console ..................4-30
Optional Power Supply Connections ......................................................................................................................4-32
TABLE OF CONTENTS
HySpeed HT2000 Instruction Manual v
22
Timer/Counter to Power Supply .....................................................................................................................4-32
Hold Cable Connections (When using Multi-Torch Systems) ........................................................................4-32
Argon-Hydrogen Connections........................................................................................................................4-34
Mounting the Machine Torch ..................................................................................................................................4-34
Torch Alignment .............................................................................................................................................4-34
Section 5 POST-INSTALLATION .........................................................................................................................5-1
Introduction ...............................................................................................................................................................5-2
System Checkout......................................................................................................................................................5-3
Set Switches and Check Torch ........................................................................................................................5-3
Turn Gases On.................................................................................................................................................5-3
Turn Power Supply On and Adjust Voltage/Current.........................................................................................5-3
Adjust Preflow Gases.......................................................................................................................................5-5
Adjust Cut Flow Gases and Check Initial Height Sensing (IHS) ......................................................................5-5
Final Torch Adjustment ....................................................................................................................................5-6
Check Torch Height Control (THC) and V/C Module .......................................................................................5-6
Section 6 OPERATION ........................................................................................................................................6-1
Front Panel Controls and Indicators .........................................................................................................................6-2
Power Supply ...................................................................................................................................................6-2
STATUS Indicators Before Startup ..................................................................................................................6-3
Gas Console ....................................................................................................................................................6-4
Digital Remote (DR) V/C Module .....................................................................................................................6-6
Programmable Remote (PR) V/C Module........................................................................................................6-7
Timer / Counter ................................................................................................................................................6-7
Noise Levels (Decibels) ............................................................................................................................................6-8
Daily Start-Up ...........................................................................................................................................................6-9
Check Torch.....................................................................................................................................................6-9
Turn Gases On.................................................................................................................................................6-9
Turn Power Supply On and Adjust Voltage/Current.......................................................................................6-10
Adjust Preflow Gases.....................................................................................................................................6-10
Adjust Cut Flow Gases and Prepare for Cutting ............................................................................................6-11
Common Cutting Faults ..........................................................................................................................................6-11
Technical Questions ...............................................................................................................................................6-12
Cut Charts...............................................................................................................................................................6-12
Conversions............................................................................................................................................................6-12
Cut Charts and Consumable Parts Index ...............................................................................................................6-13
Changing Consumable Parts..................................................................................................................................6-36
Removal and Inspection.................................................................................................................................6-37
Replacement ..................................................................................................................................................6-38
Changing the Water Tube ..............................................................................................................................6-39
How to Optimize Cut Quality...................................................................................................................................6-40
Tips for Table and Torch ................................................................................................................................6-40
Plasma Set-up Tips........................................................................................................................................6-40
Maximize the Life of Consumable Parts.........................................................................................................6-40
Additional Factors of Cut Quality....................................................................................................................6-41
Additional Improvements................................................................................................................................6-42
TABLE OF CONTENTS
vi HySpeed HT2000 Instruction Manual
22
Section 7 OPERATION: ARGON-HYDROGEN MANIFOLD...............................................................................7-1
Front Panel Controls and Indicators .........................................................................................................................7-2
Installation.................................................................................................................................................................7-3
Operation ..................................................................................................................................................................7-6
Check Torch.....................................................................................................................................................7-6
Turn Gases On.................................................................................................................................................7-6
Turn Power Supply On and Adjust Voltage/Current.........................................................................................7-7
Adjust H35 Gas Flow .......................................................................................................................................7-7
After Cutting with Argon-Hydrogen ..................................................................................................................7-8
Section 8 MAINTENANCE ...................................................................................................................................8-1
Introduction ...............................................................................................................................................................8-2
Routine Maintenance................................................................................................................................................8-3
Torch and Torch Leads ....................................................................................................................................8-3
Power Supply ...................................................................................................................................................8-3
Gas Console ....................................................................................................................................................8-4
Motor Valve Console........................................................................................................................................8-4
RHF Console....................................................................................................................................................8-5
Startup Sequence .....................................................................................................................................................8-5
Initial Checks ............................................................................................................................................................8-7
Troubleshooting ......................................................................................................................................................8-10
STATUS LED Troubleshooting...............................................................................................................................8-15
Chopper Module Test Procedure............................................................................................................................8-19
Error Codes ............................................................................................................................................................8-21
Analog Board LED Functions.........................................................................................................................8-22
Relay Board LED Function List ......................................................................................................................8-23
Relay Board LED Status Conditions ..............................................................................................................8-23
Coolant Flow Test Procedure .................................................................................................................................8-25
Check Reservoir Coolant ...............................................................................................................................8-25
Verify Flow Rate Return from Torch...............................................................................................................8-25
Verify Flow Rate to Torch...............................................................................................................................8-26
Check Pump, Motor and Solenoid Valve .......................................................................................................8-27
Torch Coolant Draining...........................................................................................................................................8-28
Preventive Maintenance Schedule .........................................................................................................................8-29
Section 9 PARTS LIST.........................................................................................................................................9-1
Introduction ...............................................................................................................................................................9-2
System Parts Diagram..............................................................................................................................................9-2
Power Supply
Front Panel.......................................................................................................................................................9-5
THC Assembly .................................................................................................................................................9-5
Control Panel ...................................................................................................................................................9-6
Base Plate and Components ...........................................................................................................................9-7
Center Wall Right Side.....................................................................................................................................9-9
Center Wall Left Side .....................................................................................................................................9-11
Front Wall Inside ............................................................................................................................................9-13
Rear Wall Inside.............................................................................................................................................9-15
TABLE OF CONTENTS
HySpeed HT2000 Instruction Manual vii
22
High Frequency and I/O PCB.........................................................................................................................9-17
Rear Wall Outside ..........................................................................................................................................9-19
Remote High Frequency Console...........................................................................................................................9-21
Spark Gap Assembly .....................................................................................................................................9-23
Gas Console ...........................................................................................................................................................9-25
Motor Valve Console ..............................................................................................................................................9-27
Remote V/C – Digital Remote (DR) Control Station ...............................................................................................9-29
Remote V/C – Programmable (PR) Control Station ...............................................................................................9-31
IHS Console............................................................................................................................................................9-33
Argon-Hydrogen Console .......................................................................................................................................9-34
Timer/Counter.........................................................................................................................................................9-35
Hyspeed HT2000 Machine Torch ...........................................................................................................................9-37
Hyspeed HT2000 Stainless Steel Machine Torch ..................................................................................................9-37
Torch Mounting Bracket..........................................................................................................................................9-37
Hyspeed HT2000 Optional Machine Torch.............................................................................................................9-39
Torch Mounting Bracket..........................................................................................................................................9-39
Torch Leads, Leads, Cables, and Hoses................................................................................................................9-40
Consumable Parts Kits ...........................................................................................................................................9-50
Lead Packages .......................................................................................................................................................9-54
Power Supply to Remote High Frequency Console – Cables and Hoses .....................................................9-54
Remote High Frequency Console to Gas Console - Hoses...........................................................................9-54
Gas Console to Motor Valve Console – Hoses..............................................................................................9-54
Recommended Spare Parts ...................................................................................................................................9-55
Power Supply .................................................................................................................................................9-55
Remote High Frequency Console ..................................................................................................................9-55
Gas Console ..................................................................................................................................................9-56
Motor Valve Console......................................................................................................................................9-56
Section 10 WIRING DIAGRAMS........................................................................................................................10-1
Introduction .............................................................................................................................................................10-1
Wiring Diagram Symbols ........................................................................................................................................10-1
System Wiring Diagrams .......................................................................................................................................10-5
Appendix A IEC SYMBOLS.................................................................................................................................a-1
IEC Symbols Used....................................................................................................................................................a-1
Appendix B PROPYLENE GLYCOL SAFETY DATA .........................................................................................b-2
BENZOTRIAZOLE SAFETY DATA...............................................................................................b-10
Appendix C AERATION MANIFOLD ...................................................................................................................c-1
Appendix D AIR FILTERS ...................................................................................................................................d-1
Appendix E ELECTROMAGNETIC COMPATIBILITY (EMC) .............................................................................e-1
General .....................................................................................................................................................................e-2
Power Cable .............................................................................................................................................................e-2
TABLE OF CONTENTS
viii HySpeed HT2000 Instruction Manual
21
Connect Power Cable...............................................................................................................................................e-2
Power Supply ...................................................................................................................................................e-2
Line Disconnect Switch ....................................................................................................................................e-4
EMI Filter Parts List ..................................................................................................................................................e-5
Appendix F SYSTEM GROUNDING....................................................................................................................g-1
System Grounding Requirements.............................................................................................................................g-1
Suggested Ground Cable Routing............................................................................................................................g-1
Power Supply ...................................................................................................................................................g-1
Equipment Grounding ......................................................................................................................................g-1
Work Table Grounding .....................................................................................................................................g-2
Hypertherm Plasma Systems 1-1
Section 1
SAFETY
In this section:
Recognize Safety Information...................................................................................................................................1-2
Follow Safety Instructions.........................................................................................................................................1-2
Cutting Can Cause Fire or Explosion .......................................................................................................................1-2
Electric Shock Can Kill..............................................................................................................................................1-3
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
Grounding Safety......................................................................................................................................................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
Additional Safety Information....................................................................................................................................1-5
Warning Label...........................................................................................................................................................1-6
SAFETY
1-2 Hypertherm Plasma Systems
11-98
SAFETY
RECOGNIZE SAFETY INFORMATION
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.
DANGER WARNING CAUTION
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 Systems 1-3
8-99
SAFETY
SAFETY
1-4 Hypertherm Plasma Systems
5/6/02
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, and a welding helmet) with appropriate
lens shading to protect your eyes from the arc’s
ultraviolet and infrared rays.
Lens Shade
Arc Current AWS (USA) ISO 4850
Up to 100 A No. 8 No. 11
100-200 A No. 10 No. 11-12
200-400 A No. 12 No. 13
Over 400 A No. 14 No. 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 Systems 1-5
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.
PACEMAKER 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 and
Welding Processes, American National Standards Institute
1430 Broadway, New York, NY 10018
3. ANSI Standard Z87.1, Safe Practices for Occupation and
Educational Eye and Face Protection, American National
Standards Institute, 1430 Broadway, New York, NY 10018
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
550 LeJeune Road, P.O. Box 351040, Miami, FL 33135
5. AWS F5.2, Recommended Safe Practices for Plasma Arc
Cutting, American Welding Society
550 LeJeune Road, P.O. Box 351040, Miami, FL 33135
6. CGA Pamphlet P-1, Safe Handling of Compressed Gases in
Cylinders, Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202
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. NFPA Standard 51B, Cutting and Welding Processes, National
Fire Protection Association
470 Atlantic Avenue, Boston, MA 02210
9. NFPA Standard 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
1-6 Hypertherm 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 plasma 1a-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 Avertissement 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-2 Hypertherm 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.
DANGER AVERTISSEMENT PRÉCAUTION
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 plasma 1a-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-4 Hypertherm Systèmes plasma
5/6/02
Torches à allumage instantané
L’arc plasma s’allume immédiatement après que la torche
soit mise en marche.
L’ARC PLASMA PEUT 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 yeux Les rayons de l’arc plasma
produisent de puissants rayons visibles ou invisibles
(ultraviolets et infrarouges) qui peuvent brûler les yeux et la
peau.
• Utiliser des lunettes de sécurité conformément aux codes
locaux ou nationaux en vigueur.
• Porter des lunettes de protection (lunettes ou masque
muni d’écrans latéraux et encore masque de soudure)
avec des verres teintés appropriés pour protéger les yeux
des rayons ultraviolets et infrarouges de l’arc.
Puissance des verres teintés
Courant de l’arc AWS (É.-U.) ISO 4850
Jusqu’à 100 A No8N
o
11
100-200 A No10 No11-12
200-400 A No12 No13
Plus de 400 A No14 No14
Protection de la peau Porter des vêtements de sécurité
pour se protéger contre les brûlures que peuvent causer les
rayons ultraviolets, les étincelles et le métal brûlant :
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 coupage Préparer la zone de coupage afin de
réduire la réverbération et la transmission de la lumière
ultraviolette :
• Peindre les murs et autres surfaces de couleur sombre
pour réduire la réflexion de la lumière.
• Utiliser des écrans et autres dispositifs de protection afin
de protéger les autres personnes de la lumière et de la
réverbération.
• Prévenir les autres personnes de ne pas regarder l’arc.
Utiliser des affiches ou des panneaux.
Câble de retour Bien 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 travail Raccorder 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 plasma 1a-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
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