Hypertherm HT400 User Manual
®
HT400 /
®
HT4000 /
®
H4001
Air Injected
Water Muffler
System
Instruction Manual
801730 - Rev. 3
®
®®
HT400/HT4000/HT4001
Air Injected
Water Muffler
System
Instruction Manual
IM-173
(P/N 801730)
for systems
beginning with
serial numbers
0767 (HT400)
4000-00000 (HT4000)
4001-00000 (HT4001)
Revision 3 November, 2013
HYPERTHERM, Inc.
P.O. Box 5010
Hanover, New Hampshire 03755-5010
Tel.: (603) 643-3441
Fax: (603) 643-5352
© Copyright 2013 Hypertherm, Inc.
All Rights Reserved
HYPERTHERM and HT are trademarks of Hypertherm, Inc. and are
registered in the United States; International registrations are pending.
Hypertherm, Inc.
Etna Road, P.O. Box 5010
Hanover, NH 03755 USA
603-643-3441 Tel (Main Office)
603-643-5352 Fax (All Departments)
800-643-9878 Tel (Technical Service)
800-737-2978 Tel (Customer Service)
Hypertherm Automation
5 Technology Drive
West Lebanon, NH 03755 USA
603-298-7970 Tel
603-298-7977 Fax
Hypertherm Plasmatechnik GmbH
Technologiepark Hanau
Rodenbacher Chaussee 6
63457 Hanau-Wolfgang, Deutschland
49 6181 58 2100 Tel
49 6181 58 2134 Fax
49 6181 58 2123 (Technical Service)
Hypertherm Singapore Pte Ltd
No. 19 Kaki Bukit Road 2
K.B. Warehouse Complex
Singapore 417847, Republic of Singapore
65 841 2489 Tel
65 841 2490 Fax
65 841 2489 (Technical Service)
Japan
1952-14 Yata-Natsumegi
Mishima City, Shizuoka Pref.
411-0801 Japan
81 0 559 75 7387 Tel
81 0 559 75 7376 Fax
Hypertherm UK Ltd
9 Berkeley Court, Manor Park
Runcorn, Cheshire, England WA7 1TQ
44 1928 579 074 Tel
44 1928 579 604 Fax
France
15 Impasse des Rosiers
95610 Eragny, France
0805 050 111 Tel
0805 050 222 Fax
Hypertherm S.r.L.
Via Torino 2
20123 Milano, Italia
39 02 725 46 312 Tel
39 02 725 46 400 Fax
39 02 725 46 314 (Technical Service)
Hypertherm B.V.
Burg. Haverkampstraat 13
7091 CN Dinxperlo, Nederland
31 315 655866 Tel
31 315 655886 Fax
Hypertherm B.V. (ETSO)
Vaartveld 9
4704 SE Roosendaal, Nederland
00 800 49 73 7843 – toll-free in Europa
31 165 596900 Tel
31 165 596901 Fax
Hypertherm Brasil Ltda.
Rua Visconde de Santa Isabel, 20 – Sala 611
Vila Isabel, RJ
Brasil CEP 20560-120
55 21 2278 6162 Tel
55 21 2578 0947 Fax
10/30/01
WARRANTY
ATTENTION
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 is not covered by the Hypertherm warranty.
Air Injected Water Muffler System Instruction Manual
Page 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 sufficient and
appropriate to defend and to hold Hypertherm harmless in
the event of any cause of action arising from the use of the
Products.
NATIONAL AND LOCAL CODES
National and Local codes governing plumbing and electrical
installation shall take precedent over any instructions
contained in this manual. In no event shall Hypertherm be
liable for injury to persons or property damage by reason of any
code violation or poor work practices.
TRANSFER OF RIGHTS
You may transfer any remaining rights you may have
hereunder only in connection with the sale of all or substantially
all of your assets or capital stock to a successor in interest who
agrees to be bound by all of the terms and conditions of this
Warranty.
TABLE OF CONTENTS
SECTION 1 SAFETY, INTRODUCTION & SPECIFICATIONS .................................................... 1-1
Safety ................................................................................................................................................ 1-2
Introduction ....................................................................................................................................... 1-3
Above-Water Cutting .................................................................................................................. 1-3
Underwater Cutting ..................................................................................................................... 1-3
System Components .................................................................................................................. 1-3
Water Table Requirements ......................................................................................................... 1-3
Specifications .................................................................................................................................... 1-4
SECTION 2 INSTALLATION ......................................................................................................... 2-1
Upon Receipt .................................................................................................................................... 2-2
Damage Claims................................................................................................................................. 2-2
Installation ......................................................................................................................................... 2-3
Install Nozzle Assembly .............................................................................................................. 2-3
Install Pump ................................................................................................................................ 2-3
Install Air Control Box ................................................................................................................. 2-5
Installation Checkout .................................................................................................................. 2-9
Pump Discharge Hose Water Recovery Checkout..................................................................... 2-9
Install Check Valve ................................................................................................................... 2-10
SECTION 3 OPERATION & MAINTENANCE ............................................................................... 3-1
Operation .......................................................................................................................................... 3-2
Daily Setup and Operation ......................................................................................................... 3-2
Above-Water Cutting .................................................................................................................. 3-2
Underwater Cutting ..................................................................................................................... 3-3
Maintenance...................................................................................................................................... 3-3
Nozzle Assembly ........................................................................................................................ 3-3
Pump Unit ................................................................................................................................... 3-4
Filter/Strainer .............................................................................................................................. 3-4
Pump Contactor.......................................................................................................................... 3-4
Air Control Box & Pump Contactor 120-VAC Control Signals .................................................... 3-4
Technical Questions.......................................................................................................................... 3-4
SECTION 4 PARTS LIST .............................................................................................................. 4-1
Water Muffler Systems ...................................................................................................................... 4-2
230/460V, 3 Ph, 60 Hz w/Hoses................................................................................................. 4-2
230/460V, 3 Ph, 60 Hz w/o Hoses.............................................................................................. 4-2
380-415V, 3 Ph, 50 Hz w/Hoses ................................................................................................ 4-3
380-415V, 3 Ph, 50 Hz w/o Hoses ............................................................................................. 4-3
575V, 3 Ph, 60 Hz w/Hoses........................................................................................................ 4-4
575V, 3 Ph, 60 Hz w/o Hoses..................................................................................................... 4-4
Nozzle Assembly with Adapters ........................................................................................................ 4-5
Nozzle Assembly with Swivels .......................................................................................................... 4-6
Water Supply Assembly .................................................................................................................... 4-7
Pump Assembly ................................................................................................................................ 4-9
Pump Discharge Hose Check Valve (Optional) ................................................................................ 4-9
Air Injected Water Muffler System Instruction Manual
Page iii
TABLE OF CONTENTS
APPENDIX ........................................................................................................................................ a-1
Water Muffler Pumps ........................................................................................................................ a-2
ILLUSTRATIONS
Figure 2-1 Nozzle Assembly, Water Sleeve and Air Deflector Sleeve Installation .................. 2-4
Figure 2-2 Filter Strainer, Optional Installation ......................................................................... 2-7
Figure 2-3 Air Injected Water Muffler System Interconnection Diagram .................................. 2-8
Figure 4-1 Nozzle Assembly with Adapters .............................................................................. 4-5
Figure 4-2 Nozzle Assembly with Swivels ................................................................................ 4-6
Figure 4-3 Water Supply Assembly .......................................................................................... 4-8
Page iv
Air Injected Water Muffler System Instruction Manual
SAFETY, INTRODUCTION & SPECIFICATIONS
Section 1 Safety, Introduction & Specifications
In this section:
Safety ..................................................................................................................... 1-2
Introduction ............................................................................................................ 1-3
Above-Water Cutting ........................................................................................ 1-3
Underwater Cutting ........................................................................................... 1-3
System Components ........................................................................................ 1-3
Water Table Requirements ............................................................................... 1-3
Specifications ......................................................................................................... 1-4
Air Injected Water Muffler System Instruction Manual
Page 1-1
SAFETY, INTRODUCTION & SPECIFICATIONS
SAFETY
Listed below are the basic safety precautions that should adhered to when operating
plasma equipment. Refer to the applicable HT400 or HT4000 instruction manual for
detailed safety information.
WARNING
ELECTRIC SHOCK CAN KILL.
• Do not touch live electrical parts.
• Keep all panels and covers in place when the water muffler system is
connected to a power source.
• Insulate yourself from work and ground: wear insulating gloves, shoes and
clothing.
• Keep gloves, shoes, clothing, work area, torch, and this machinery dry.
EXPLOSION WILL RESULT IF PRESSURIZED CONTAINERS ARE CUT.
ARC RAYS CAN INJURE EYES AND BURN SKIN.
• Wear correct eye and body protection.
NOISE CAN DAMAGE HEARING.
• Wear correct ear protection.
FUMES AND GASES CAN INJURE YOUR HEALTH.
• Keep your head out of the fumes.
• Provide ventilation, exhaust at the arc, or both to keep the fumes and
gases from your breathing zone and the general area.
• If ventilation is inadequate, use an approved respirator.
HEAT, SPLATTER AND SPARKS CAUSE FIRE AND BURNS.
• Do not cut near combustible material.
• Do not cut containers that have held combustibles.
• Do not have on your person any combustibles such as a butane lighter or
matches.
• Pilot arc can cause burns. Keep the torch nozzle away from yourself and
others when the switch is depressed.
• Wear correct eye and body protection.
Page 1-2
Air Injected Water Muffler System Instruction Manual
SAFETY, INTRODUCTION & SPECIFICATIONS
INTRODUCTION
The Air Injected Water Muffler System is a plasma cutting torch option which greatly
improves the HT400 and HT4000/4001 plasma cutting systems safety and pollution
control capabilities. This water muffler system can be used to cut both above and
below water. The Air Injected Water Muffler System must be used in conjunction with
the Water Table Pollution Control System.
Above-Water Cutting
When used above water (material at the water line), the system becomes an effective
pollution control attachment which substantially reduces noise levels, ultraviolet
radiation, glare, and airborne particulates. Noise levels less than 86 dBA can be
expected when cutting with oxygen to a maximum current of 260A. Noise levels less
than 90 dBA can be expected when cutting with nitrogen to a maximum current of
400A. In addition, the water muffler improves cut quality by keeping the water table
water away from the cut zone and by continuously flushing the back of the workpiece
with air, preventing hydrogen from accumulating on the underside.
Underwater Cutting
When used underwater, the water muffler provides a water and air shield which
removes water from the cut zone, allowing for optimum operation of the plasma torch.
The water muffler greatly improves the quality of the cuts made underwater and
allows for cutting at the same speeds as above-water cutting. The continuous
flushing of the back of the workpiece with air, prevents hydrogen from accumulating.
Underwater operation also provides the maximum possible noise suppression over
the widest possible range of current levels. Less than 85 dBA can be expected for
both oxygen and nitrogen when cutting three inches or more below the surface of the
water.
System Components
Refer to
Installation,
Water Table Requirements
When cutting above water, the water level in the water table should be up to or
slightly above the bottom surface of the workpiece. The water reservoir located
beneath the plate prevents the high-intensity sound waves from escaping out from
the underside of the workpiece.
When the water muffler is used below water, the water level in the water table must
be three inches or more above the top surface of the workpiece.
Section 2,
Upon Receipt
, for a list of the system components.
The water muffler significantly cools the smoke and fumes generated by plasma
cutting (especially when cutting underwater). Proper ventilation and fume extraction
near the surface of the water table is required.
Air Injected Water Muffler System Instruction Manual
Page 1-3
5-95
SAFETY, INTRODUCTION & SPECIFICATIONS
SPECIFICATIONS
Air Control Box (# 028298)
Input Power ................................................. 120 VAC
Input Air Pressure........................................ 80 -120 psi (5.5-8.3 bar) @ 20 scfm
(566 l/m) minimum
Weight ......................................................... 6 lbs. (2.7 kg)
Dimensions.................................................. 6-1/4" (159mm) (H) x 6-1/4" (159mm)
(W) x 4-1/4" (108mm) (D)
Pump* (# 031006, # 031088, # 031089)
Input Power:
# 031006 .................................................... Pump (3/4 DL) assembly with motor, 2
HP, 3500 RPM 230/460, 3 PH, 60 Hz
# 031088 .................................................... Pump (3/4 DL) assembly with motor, 2
HP, 3500 RPM 380-415V, 3 PH, 50 Hz
# 031089 .................................................... Pump (3/4 DL) assembly with motor, 2
HP, 3500 RPM 575V, 3 PH, 60 Hz
Maximum Working Pressure ....................... 100 psig (6.9 bar)
Duty ............................................................. Continuous
Direction of Rotation .................................... Clockwise (viewed from motor end)
Output.......................................................... 18-20 GPM
Weight ......................................................... 85 lbs. (38.6 kg) (includes base and
pump contactor box)
Dimensions.................................................. 19" (482mm) (H) x 11" (279mm) (W) x
17" (432mm) (D) (includes base and
pump contactor box)
* Refer to the Appendix for additional pump specifications.
Pump Contactor (# 003017)
Page 1-4
Contactor ..................................................... Size 00, 120 VAC Coil
Air Injected Water Muffler System Instruction Manual
INSTALLATION
Section 2 Installation
In this section:
Upon Receipt ......................................................................................................... 2-2
Damage Claims...................................................................................................... 2-2
Installation .............................................................................................................. 2-3
Install Nozzle Assembly .................................................................................... 2-3
Install Pump ...................................................................................................... 2-3
Install Air Control Box ....................................................................................... 2-5
Installation Checkout ........................................................................................ 2-9
Pump Discharge Hose Water Recovery Checkout ........................................... 2-9
Install Check Valve ......................................................................................... 2-10
Air Injected Water Muffler System Instruction Manual
Page 2-1
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