Hypertherm HT4001 User Manual

HT4001
®
Plasma Arc Cutting System
Instruction Manual 802000 – Revision 18
EN60974-1 EN50199
Changed Page Description
IM200 Rev 12 to 13 4/10/2000
2.12
chan
g
ed dimensions for new 401 power suppl
y
7.23
new
grap
hic of chopper
a.02
chan
g
ed slave modification because of HDR 401 power suppl
y
a.03-11
chan
g
ed slave modification because of HDR 401 power suppl
y
8.10 of 14
u
p
dated 401 wiring diagram portion of HT4001 schematic
Changed Page Description
IM200 Rev 13 to 14 5/25/2000
4.07
new
grap
hic of center bail with new rela
y
4.12
new si
g
nals for remote on/off
4.13
added
grap
hic TB4 with note about jumper
4.37
new TB4
grap
hic
6.10
New
grap
hic of power supply rear bail
6.11
p
art number addition for on/off rela
y
8.05
U
p
revved wiring diagrams to KY (14 pages)
a.4 & 5
new location of disablin
g
surge injection circuit
Changed Page Description
IM200 Rev 14 to 15 9/18/01
1.1-1a.6 Updated safety sections 0
Updated addresses on subsidiary page
Changed Page Description IM200 Rev 15 to 17
8/31/03
3.11 & 7.12 Removed neon/
p
ilot light. Updated warning box to remove reference to light.
6.5
Item # 13 changed from 041588 to 041763. Part number below 041588
(
firmware) was removed.
6.14 U
p
dated art to remove pilot light
6.15 Removed item # 15 (pilot light) Bumped following #s up 1
6.16 & 6.17 Updated art to remove pilot light. Removed item # 10 (pilot light)
6.47 Changed contactor part number from 003116 (170A) to 003217 (185A)
7.3
Kit numbers changed. Third bullet point under Power Supplies. 129227 to 129972 & 129228 to 129973. Text re-flowed. #1 under Protecting Copper Surfaces is now on page 7.4
Section 8 Wiring diagrams Revision change from KY to KZ
Changed Page Description
IM200 Rev 9 to 10 4/15/98
0.01
U
p
revved to 10 - 4/15/98 with serial #4001-000805
4.36
Chan
g
ed name of cable because serial i/o board is no longer required.
6.04
New
grap
hic of power supply front panel
6.05
Chan
g
ed p/n of relay pcb, control board pcb, and firmware.
6.40
Chan
g
ed graphic, part number and description of fig. 6-41
a.02
Chan
g
ed slave kit number and contents.
a.03
Chan
g
ed graphic of inside of H-401 power supply-i/o board eliminated.
a.04
New directions for installation - serial i/o board eliminated
a.05
Chan
g
ed labels
a.06
bum
p
ed page
a.08
New
grap
hic, p/n and signal description
a.09
Chan
g
ed graphic from serial i/o pcb to current setpoint pcb c.04-c.06 & d.03&.04
New graphic of TB5
8.05
U
p
revved wiring diagrams to KS (14 pages)
Changed Page Description
IM200 Rev 10 to 11 7/24/98
3.04 & 4.03
Added reference to
g
rounding appendix
5.13
Clarified settin
g
current
5.14 & 15
bum
p
ed page
6.47
Corrected PCB2 and firmware
p
art numbers
7.13
New
grap
hic of power distribution board, fuse f4
7.24-27
U
p
dated LEDs on Relay board
f.01-04
Added s
y
stem grounding appendix
8.05
U
p
revved wiring diagrams to KU (14 pages)
0.05
Added s
y
stem grounding to TOC
0.10
Added s
y
stem grounding figures to TOC
4.19
New TB3 fi
g
ure
4.37
New TB3 fi
g
ure
6.21
006109 re
p
lacing 006066
6.23
006109 re
p
lacing 006066
6.47
006109 re
p
lacing 006066
Changed Page Description
IM200 Rev 11 to 12 2/1/99
0.01
u
p
revved because of new 340A electrodes
5.20,21 & 26
chan
g
ed 340A electrodes
6.01
Fixed TOC
6.06 & 07
Removed 4 diodes from rear of front
p
anel
6.42, 44 & 46
chan
g
ed pn of 340A electrode
6.47
removed diodes from recommended s
p
are parts
8.05
U
p
revved wiring diagrams to KV (14 pages)
4.12
added note about DC rela
y
kit
6.21 & 47
chan
g
ed ps1 and ps2 to 005243
7.21
chan
g
ed 100 psi to 80 psi
0.02
added
p
lumbing and electrical codes statement to warrant
y
3.02
bolded installation b
y q
ualified...; rewrote hard plumbing suggestions
4.14
Added note to check uP board before connectin
g
V/C cable
3.05
Added 90¡ C recommended
p
ower cables
Changed Page Description
IM200 Rev 6 to 7 11/1/97
0.01
U
p
revved to 7 - implement 11/1 with serial#603
2.06
Added 440/480
p
ower supply numbers
3.04
Added 440V current and fuse s
p
ecs
3.05
Added 440V cable size recomendation
3.09
Added 440V Transformer
p
icture
4.04
Added tor
q
ue specification
6.11
Added 440V control xfrmr number
6.13
Added 440V
p
ower xfrmr number
8.05
U
p
revved wiring diagrams to KM (14 pages)
4.26
Added note to see tor
q
ue specs
4.30
Added note to see tor
q
ue specs
Changed Page Description
IM200 Rev 7 to 8 1/16/98
0.01
U
p
revved to 8 - 1/15/98 with serial # 715
0.06
Added 2 new fi
g
ure #s
0.07-.10
bum
p
ed page
2.01
Re
pag
inated due to additional pages
2.05
Added
p
ower factor
2.07
Added fi
g
ures of torches with dimensions
2.08-.14
bum
p
ed page
4.08,10 & 20
corrected cable desi
g
nation in table
6.15
Added chassis SA
p
/n for in-rush circuit
6.31
Added 60 len
g
ths to cables
i.1-i.6
u
p
dated index
Changed Page Description IM200 Rev 8 to 9 3/27/98
3.04
Added note about volta
g
e needing to be within 15%
4.07 & 6.08
New
grap
hic of start circuit II
6.05
New rev firmware
6.09
New
p
art no. for start circuit II
6.14
New
grap
hic of in-rush protection circuit
6.15
New
p
art no. for in-rush protection circuit
7.18
bum
p
ed text from pg. 7-19
7.19
Added troubleshootin
g
for voltage dropping below 15%
7.28
Minor text chan
g
e
7.29
Added error code #15
6.06
Added
grap
hic of phase loss protection circuit
6.07
Added
p
hase loss protection circuit part no.
8.05
U
p
revved wiring diagrams to KR (14 pages)
0.01
U
p
revved to 9 - 3/27/98 with serial #4001-000800
Changed Page Description
IM200 Rev 4 to 5 4/14/97
5.25&26
Chan
g
ed 120468, 120469 to 120470, 120471
2.05,3.02,5.09& 13
Added tolerance to gas pressures
6.10 &.11
Removed resistor, ca
p
from I/O panel
6.21
Added 011081 float sto
p
6.42-45
removed
qty
s from consumable parts list
6.46
removed non-ce retainin
g
caps from CE consumable parts kits
6.47
Added 011081 float sto
p
8.05
U
p
revved wiring diagrams to EE (14 pgs)
0.05
U
p
dated TOC for torch coolant drainin
g
7.01
Added torch coolant drainin
g
7.03
Referenced torch coolant drainin
g
7.30
Added torch coolant drainin
g p
rocedure
4.10
Added omitted si
g
nals to gas console cable
0.01
U
p
revved to 5 - implement 4/14 with serial#514
2.09
Corrected dimension on
g
as console holes
5.20
Corrected reference to PAC611 - to PAC620
4.06
Referenced to section 6 for com
p
lete list of cable and hose lengths
6.31-.40
additional len
g
ths
Changed Page Description
IM200 Rev 5 to 6 8/15/97
7.03
added note to check contactor contacts
7.04 & 05
bum
p
ed page
0.01
U
p
revved to 6 - implement 8/15 with serial#539
0.02
Chan
g
ed customer service tel. #
3.11
Chan
g
ed light...contactor to lights...contactors
4.02
Chan
g
ed customer service tel. #
6.14
Chan
g
ed dwg of power supply rear wall inside
6.15
Added in-rush com
p
onents to parts list
7.09 & 10
Added CON2 to se
q
uence of operation
7.12
Chan
g
ed light...contactor to lights...contactors
8.05
U
p
revved wiring diagrams to GG (14 pgs)
2.05
chan
g
ed OCV spec to 361V
7.22 & 23
Corrected cho
pp
er test procedure
Changed Page Description
IM200 Rev 3 to 4 12/20/96
0.01
U
p
revved due to LVD changes, 360A Beveling consumables, Kip valves
0.03
u
p
dated TOC with new safety sections
0.04
chan
g
ed page of changing consumable parts
1.01-1a.04
new safet
y
section
2.02
removed reference to CE com
p
liance
2.06
removed 380 and 415VAC references
3.11
removed 380-415VAC reference
5.01
chan
g
ed page numbers for changing consumable parts
5.02 & 5.09
Chan
g
ed operation of STATUS indicators
5.20
Added 340A bevelin
g
, changed 120390 to 120392, added CE warnin
g
5.21-5.24
Added CE retainin
g
caps
5.25
Added CE retainin
g
caps, changed 120390 to 120392
5.26
340A bev ct chrt & consums, CE ret ca
p
, chngd 120390 to 120292
5.27-5.32
Added CE retainin
g
caps
5.33
pag
e bump, added cap removal tool for CE caps
6.05
New Interlock PCB #, new firmware rev (L)
6.07
New cho
pp
er #
6.11
New
p
ower distribution board #
6.46
New
p
ower distribution board #, chopper #, interlock PCB #
7.06
Flow chart chan
g
e for chopper temp switch and status LED functionin
g
7.11
removed reference to 380-415V CE
p
ower supplies
7.13
New
p
ower distribution board graphic
7.15,20 & 21
Chan
g
ed operation of STATUS indicators
7.23
Removed reference to tem
p
switch on chopper
8.05
U
p
revved wiring diagrams to Z (14 pgs)
6.43&45
Removed 120392 ret ca
p
2.07
Added warnin
g
to use CE retaining caps
2.09
New
g
as console part no.
4.11,23,27 & 29
New
p
icture of gas console rear
4.30
New
p
icture and part no. for off valve cable and hose ass
y
6.01
Added new CE consumable
p
arts kits to TOC
6.20
New
p
icture of gas console rear
6.21
new
p
art numbers for valves
6.22
New
p
icture of motor valve console
6.23
new
p
art numbers for valves
6.25
New
p
art number for potentiometer
6.38
New
p
icture and part no. for off valve cable and hose ass
y
6.47
Chan
g
ed p/n of valve in gas console-recommended spare part
7.14,17 & 18
Chan
g
ed "light" to "illuminate" - international translation ease
7.28
Added
p
ostflow gas control and new picture of control board
5.20-5.45
Chan
g
ed 120392 to 120390
6.05,7.06 & 20
Chan
g
ed 24VAC to 12VDC for interlock voltage
6.38
Chan
g
ed p/n of off-valve cable
6.11 & 46
New
p
ower distribution board #
4.10
Added si
g
nals for extra valves in cable diagram
4.28
Added si
g
nals for extra valves in cable diagram
HT4001
®
Instruction Manual
(P/N 802000)
Revision 18 – November, 2013
Hypertherm, Inc.
Hanover, NH USA
www.hypertherm.com
© Copyright 2013 Hypertherm, Inc.
All Rights Reserved
Hypertherm, HyDefinition, HT, LongLife and PAC are trademarks of Hypertherm, Inc.,
and may be registered in the United States and/or other countries
5/23/03
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)
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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)
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411-0801 Japan
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Vila Isabel, RJ
Brasil CEP 20560-120
55 21 2278 6162 Tel
55 21 2578 0947 Fax

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 affected equipment is in close proximity or has a high degree of sensitivity. In such cases it may be neces­sary to use other measures to further reduce interference.
This plasma equipment is designed for use only in an industrial environment.
INSTALLATION AND USE
The user is responsible for installing and using the plasma equipment according to the manufacturer's instructions. If electro­magnetic disturbances are detected then it shall be the responsibility of the user to re­solve the situation with the technical assis­tance of the manufacturer. In some cases this remedial action may be as simple as earthing the cutting circuit, see 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.
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.
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.
Hypertherm Plasma Systems i

WARRANTY

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.
ii Hypertherm Plasma Systems
9-01

TABLE OF CONTENTS

HT4001 Instruction Manual iii
17
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 DESCRIPTION & SPECIFICATIONS...................................................................................................2-1
Description................................................................................................................................................................2-2
HT4001 Power supply......................................................................................................................................2-2
Remote High Frequency (RHF) Console .........................................................................................................2-2
Gas Console ....................................................................................................................................................2-3
Motor Valve Console ........................................................................................................................................2-3
Remote Voltage/Current (V/C) Control – Optional ...........................................................................................2-3
Timer/Counter – Optional.................................................................................................................................2-4
Water Chiller – Optional ...................................................................................................................................2-4
Initial Height Sensing (IHS) – Optional.............................................................................................................2-4
H401 Slave Power Supply – Optional..............................................................................................................2-4
Water Muffler – Optional ..................................................................................................................................2-4
TABLE OF CONTENTS
iv HT4001 Instruction Manual
17
Specifications............................................................................................................................................................2-5
System Requirements......................................................................................................................................2-5
HT4001 Power Supply .....................................................................................................................................2-5
HT4001 Power Supply with Slave....................................................................................................................2-5
PAC620 Machine Torches ................................................................................................................................2-7
Remote High Frequency Console ....................................................................................................................2-8
Digital Remote (DR) V/C Control .....................................................................................................................2-9
Programmable Remote (PR) V/C Control ........................................................................................................2-9
Gas Console ..................................................................................................................................................2-10
Motor Valve Console ......................................................................................................................................2-10
Initial Height Sensing......................................................................................................................................2-11
Timer/Counter.................................................................................................................................................2-11
Water Chiller...................................................................................................................................................2-12
H401 Power Supply .......................................................................................................................................2-12
Water Muffler..................................................................................................................................................2-12
IEC Symbols Used..................................................................................................................................................2-13
Section 3 PRE-INSTALLATION ...........................................................................................................................3-1
Introduction ...............................................................................................................................................................3-2
Gas Requirements....................................................................................................................................................3-2
Water Supply Requirements.....................................................................................................................................3-3
Grounding Requirements..........................................................................................................................................3-4
Power Requirements ................................................................................................................................................3-4
Line Disconnect Switch ....................................................................................................................................3-5
Power Cables...................................................................................................................................................3-5
Positioning the Power Supplies........................................................................................................................3-6
Transformer Configurations ......................................................................................................................................3-7
Connecting the Power.............................................................................................................................................3-11
Torch Lifter Requirement ........................................................................................................................................3-12
Optional Equipment ................................................................................................................................................3-12
Water Muffler..................................................................................................................................................3-12
Initial Height Sensing (IHS) ............................................................................................................................3-13
Section 4 INSTALLATION .....................................................................................................................................4-1
Upon Receipt ............................................................................................................................................................4-2
Claims.......................................................................................................................................................................4-2
Module Grounding and Grounding Checks ..............................................................................................................4-3
Noise Levels (Decibels) ............................................................................................................................................4-3
System Units Placement...........................................................................................................................................4-4
HT4001 Interconnection Reference Map..................................................................................................................4-5
Power Supply Connections.......................................................................................................................................4-6
RHF Console Connections .....................................................................................................................................4-22
Gas Console Connections ......................................................................................................................................4-26
Motor Valve Console Connections..........................................................................................................................4-30
Initial Height Sensing Connections .........................................................................................................................4-32
Optional Power Supply Connections ......................................................................................................................4-36
TABLE OF CONTENTS
HT4001 Instruction Manual v
17
Mounting the Machine Torch...................................................................................................................................4-38
Torch Alignment..............................................................................................................................................4-38
Section 5 OPERATION..........................................................................................................................................5-1
Controls and Indicators.............................................................................................................................................5-2
HT4001 Power Supply Front Panel..................................................................................................................5-2
HT4001 Power Supply Rear Panel Control......................................................................................................5-2
Gas Console ....................................................................................................................................................5-4
Digital Remote (DR) V/C Module .....................................................................................................................5-6
Programmable Remote (PR) V/C Module........................................................................................................5-7
Timer/Counter ..................................................................................................................................................5-7
Pre-Operation System Checkout ..............................................................................................................................5-8
Final Torch Adjustment ...................................................................................................................................5-11
Daily Start-Up .........................................................................................................................................................5-13
How to Optimize Cut Quality...................................................................................................................................5-15
Tips for Table and Torch .................................................................................................................................5-15
Plasma Set-up Tips........................................................................................................................................5-15
Maximize the Life of Consumable Parts.........................................................................................................5-15
Additional Factors of Cut Quality....................................................................................................................5-16
Additional Improvements................................................................................................................................5-17
Common Cutting Faults ..........................................................................................................................................5-18
Technical Questions................................................................................................................................................5-19
Cut Charts...............................................................................................................................................................5-19
Cut Chart and Consumable Parts Index .................................................................................................................5-20
Changing Consumable Parts..................................................................................................................................5-33
Removal and Inspection.................................................................................................................................5-33
Replacement ..................................................................................................................................................5-33
Changing the Water Tube ..............................................................................................................................5-35
Section 6 MAINTENANCE ...................................................................................................................................6-1
Introduction ...............................................................................................................................................................6-2
Routine Maintenance................................................................................................................................................6-3
Torch and Torch Leads .....................................................................................................................................6-3
Power Supplies ................................................................................................................................................6-3
Gas Console ....................................................................................................................................................6-4
Motor Valve Console ........................................................................................................................................6-4
Remote HF Console.........................................................................................................................................6-4
HT4001 Initialization and Sequence of Operation ....................................................................................................6-5
Initial Checks...........................................................................................................................................................6-11
Troubleshooting ......................................................................................................................................................6-14
STATUS LED Troubleshooting................................................................................................................................6-20
Chopper Module Test Procedure ............................................................................................................................6-22
Relay Board PCB4 Status Indicators......................................................................................................................6-24
Error Codes ............................................................................................................................................................6-28
Torch Coolant Draining ...........................................................................................................................................6-30
TABLE OF CONTENTS
vi HT4001 Instruction Manual
17
Section 7 PARTS LIST .........................................................................................................................................7-1
Introduction ...............................................................................................................................................................7-2
Finding Part Numbers...............................................................................................................................................7-2
HT4001 Interconnection Reference Map..................................................................................................................7-3
HT4001 Power Supply
Outside Front Panel .........................................................................................................................................7-5
Inside Front Panel ............................................................................................................................................7-7
Front Bail..........................................................................................................................................................7-9
Rear Bail.........................................................................................................................................................7-11
Inside Floor ....................................................................................................................................................7-13
Rear Wall Inside.............................................................................................................................................7-15
Rear Wall Outside ..........................................................................................................................................7-17
Remote High Frequency Console...........................................................................................................................7-19
Gas Console ...........................................................................................................................................................7-21
Motor Valve Console...............................................................................................................................................7-23
Remote V/C – Digital Remote (DR) Control Module...............................................................................................7-25
Remote V/C – Programmable (PR) Control Module...............................................................................................7-27
IHS Console............................................................................................................................................................7-29
Timer/Counter.........................................................................................................................................................7-30
HT4001 Cables, Leads, Torch Leads and Hoses ...................................................................................................7-31
PAC620 Machine Torch Assembly..........................................................................................................................7-41
Torch Mounting Bracket ..........................................................................................................................................7-41
Consumable Parts Kits ...........................................................................................................................................7-42
PAC620: HT4001 without Slave, Standard ....................................................................................................7-42
PAC620: HT4001 without Slave, Bevel..........................................................................................................7-43
PAC620: HT4001 with Slave, Standard .........................................................................................................7-44
PAC620: HT4001 with Slave, Bevel...............................................................................................................7-45
PAC620: HT4001 CE without Slave, Standard ..............................................................................................7-46
PAC620: HT4001 CE with Slave, Standard ...................................................................................................7-46
Recommended Spare Parts ...................................................................................................................................7-47
Power Supply .................................................................................................................................................7-47
Remote High Frequency Console ..................................................................................................................7-47
Gas Console ..................................................................................................................................................7-47
IHS System and Components ................................................................................................................................7-48
IHS Leads Packages and Components..................................................................................................................7-48
Section 8 WIRING DIAGRAMS............................................................................................................................8-1
Introduction ...............................................................................................................................................................8-2
Wiring Diagram Symbols ..........................................................................................................................................8-2
HT4001 System Wiring Diagrams ............................................................................................................................8-5
Appendix A H-401 POWER SUPPLY AS SLAVE ................................................................................................a-1
H401 Slave Modification ...........................................................................................................................................a-2
H401 Slave Connections ..........................................................................................................................................a-6
Connecting the Power......................................................................................................................................a-6
TABLE OF CONTENTS
HT4001 Instruction Manual vii
17
Appendix B AERATION MANIFOLD ...................................................................................................................b-1
Aeration Manifold for Plasma Cutting Aluminum ......................................................................................................b-2
Introduction ......................................................................................................................................................b-2
Making an Aeration Manifold............................................................................................................................b-2
Appendix C ELECTROMAGNETIC COMPATIBILITY .........................................................................................c-1
EMC Introduction ......................................................................................................................................................c-2
General .....................................................................................................................................................................c-3
Power Cable .............................................................................................................................................................c-3
Connect Power Cable ...............................................................................................................................................c-3
Power Supply ...................................................................................................................................................c-3
Line Disconnect Switch ....................................................................................................................................c-5
EMI Filter Parts List...................................................................................................................................................c-6
Appendix D POWER CABLE INSTALLATION FOR 200/220V POWER SUPPLIES .........................................d-1
General .....................................................................................................................................................................d-2
Power Cable .............................................................................................................................................................d-2
Connect Power Cable...............................................................................................................................................d-2
Power Supply ...................................................................................................................................................d-2
Line Disconnect Switch ....................................................................................................................................d-4
Appendix E BENZOTRIAZOLE SAFETY DATA..................................................................................................e-1
Appendix F SYSTEM GROUNDING.....................................................................................................................f-1
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
SÉCURITÉ
1a-6 Hypertherm Systèmes plasma
2/12/01
Étiquette de sécurité
Cette étiquette est affichée sur la source de courant. Il est important que l’utilisateur et le technicien de maintenance comprennent la signification des symboles de sécurité. Les numéros de la liste correspondent aux numéros des images.
1. Les étincelles produites par le coupage peuvent provoquer une explosion ou un incendie.
1.1 Pendant le coupage, éloigner toute matière inflammable.
1.2 Conserver un extincteur à proximité et s’assurer qu’une personne soit prête à l’utiliser.
1.3 Ne jamais couper de récipients fermés.
2. L’arc plasma peut provoquer des blessures et des brûlures.
2.1 Couper l’alimentation avant de démonter la torche.
2.2 Ne pas tenir la surface à couper près de la trajectoire de coupe.
2.3 Porter des vêtements de protection couvrant tout le corps.
3. Un choc électrique causé par la torche ou les câbles peut être fatal. Se protéger contre les risques de chocs électriques.
3.1 Porter des gants isolants. Ne pas porter de gants mouillés ou abîmés.
3.2 S’isoler de la surface de travail et du sol.
3.3 Débrancher la prise ou la source de courant avant de manipuler l’équipement.
4. L’inhalation des vapeurs produites par le coupage peut être dangereuse pour la santé.
4.1 Garder le visage à l’écart des vapeurs.
4.2 Utiliser un système de ventilation par aspiration ou d’échappement localisé pour dissiper les vapeurs.
4.3 Utiliser un ventilateur pour dissiper les vapeurs.
5. Les rayons de l’arc peuvent brûler les yeux et provoquer des lésions de la peau.
5.1 Porter un casque et des lunettes de sécurité. Se protéger les oreilles et porter une chemise dont le col peut être déboutonné. Porter un casque de soudure dont la protection filtrante est suffisante. Porter des vêtements protecteurs couvrant la totalité du corps.
6. Se former à la technique du coupage et lire les instructions avant de manipuler l’équipement ou de procéder au coupage.
7. Ne pas retirer ou peindre (recouvrir) les étiquettes de sécurité.
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HT4001 Instruction Manual 2-1
Section 2
SPECIFICATIONS
In this section:
Description................................................................................................................................................................2-2
HT4001 Power supply......................................................................................................................................2-2
Remote High Frequency (RHF) Console .........................................................................................................2-2
Gas Console ....................................................................................................................................................2-3
Motor Valve Console ........................................................................................................................................2-3
Remote Voltage/Current (V/C) Control – Optional ...........................................................................................2-3
Timer/Counter – Optional.................................................................................................................................2-4
Water Chiller – Optional ...................................................................................................................................2-4
Initial Height Sensing (IHS) – Optional.............................................................................................................2-4
H401 Slave Power Supply – Optional..............................................................................................................2-4
Water Muffler – Optional ..................................................................................................................................2-4
Specifications............................................................................................................................................................2-5
System Requirements......................................................................................................................................2-5
HT4001 Power Supply .....................................................................................................................................2-5
HT4001 Power Supply with Slave....................................................................................................................2-5
PAC620 Machine Torches ................................................................................................................................2-7
Remote High Frequency Console ....................................................................................................................2-8
Digital Remote (DR) V/C Control .....................................................................................................................2-9
Programmable Remote (PR) V/C Control ........................................................................................................2-9
Gas Console ..................................................................................................................................................2-10
Motor Valve Console ......................................................................................................................................2-10
Initial Height Sensing......................................................................................................................................2-11
Timer/Counter.................................................................................................................................................2-11
Water Chiller...................................................................................................................................................2-12
H401 Power Supply .......................................................................................................................................2-12
Water Muffler..................................................................................................................................................2-12
IEC Symbols Used..................................................................................................................................................2-13
SPECIFICATIONS
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2-2 HT4001 Instruction Manual
Description
Hypertherm’s HT4001 is a machine-mounted plasma cutting system for cutting most metals from gauge to three­inch (76 mm) thick (when used with the optional slave configuration). A micro-controller on the power supply control board helps to provide extended life for the oxygen consumable parts. To achieve consumable long life, all cuts must begin and end on the plate surface when cutting with oxygen as the plasma gas; this allows for the proper ramping of gases and DC current to extend the life of the torch nozzle and electrode. See also How to get Longer Consumable Life in Section 5.
The HT4001 power supply provides continuously variable output current of up to 400 amps for optimum cutting on all thicknesses of metal up to two-inches thick. When configured with a slave power supply, the HT4001 system provides continuously variable output current of up to 760 amps for cutting metal up to three-inches thick. This allows the operator wide variations in cutting speeds on the same thickness of metal. Five nozzle sizes produce high-quality cuts throughout the range of cut thicknesses.
The plasma gases used with the HT4001 system are oxygen, for cutting mild steel, and nitrogen, for cutting stainless steel, aluminum and other non-ferrous materials.
The following descriptions briefly describe the purpose and configuration of the HT4001 System components.
HT4001 Power Supply
This unit houses four 100-amp, 15 kHz chopper power supplies to produce constant current DC output. Also located in this unit is the torch height control (THC). The power supply interconnects with the remote high frequency console, initial height sensing, computer interface, remote voltage/current, water muffler, gas console, the timer-counter, the workpiece, other HT4001 supplies (for multi-torch use) and optional slave unit (to output up to 750 Amps).
Remote High Frequency (RHF) Console
This unit houses the high-frequency starting circuit that initializes the plasma arc at the torch. Having the high­frequency circuit in its own enclosure permits more effective RF shielding and allows the power supply to be installed at a distance of up to 300 feet (91.5 m) from the torch. Also located in the console are two door interlock switches, a cooling water flow switch, injection water flow switch, the pilot arc relay and injection water valve. The RHF console interfaces with the power supply, gas console, water chiller, and the torch.
SPECIFICATIONS
HT4001 Instruction Manual 2-3
Gas Console
This unit houses control components for plasma gas and injection water flow. The gas console interfaces with the gas supplies, the RHF console, the motor valve console, the power supply and the torch.
Motor Valve Console
This unit houses a plasma gas metering valve and a preflow/operate solenoid valve. These valves allow the flow of gases to be unaffected by the length of the torch leads. Plasma gas lines and an interface cable connect the motor valve console to the gas console. The motor valve console also interfaces with the torch.
Note: The motor valve console must be mounted within 10 feet (3 m) of the torch.
Remote Voltage/Current (V/C) Control – Optional
The digital and programmable remotes provide accurate operator control of the arc voltage and current. High intensity LED displays indicate the setpoints for volts and amperes prior to starting the arc. After the arc is initiated, the displays automatically indicate the actual values of the voltage and current reached. The current remote does not come with LED displays: a thumbwheel switch is provided to set current only. These units interface with the power supply.
Digital Remote – Includes:
• Voltage and current displays and two potentiometers to select the desired values.
This unit is designed for use with guidance machinery that already includes plasma control switches.
Programmable Remote – Includes:
• Voltage and current displays.
No switches or potentiometers included. All functions controlled by the guidance machinery computer.
Current Remote – Used with HT4001 systems without THC. Includes:
• Thumbwheel switch for setting cutting current.
Note: See IM191 RCC Installation for more information on the Current Remote.
SPECIFICATIONS
11-96
2-4 HT4001 Instruction Manual
Timer/Counter – Optional
The timer/counter monitors the number of arc starts and arc time on. This unit interfaces with the power supply.
Water Chiller – Optional
The water chiller for the HT4001 system is a refrigeration unit capable of reducing the water supply temperature and increasing the water pressure to the RHF console. Reducing the water temperature greatly increases the life of the nozzle and electrode. The water chiller requires a water supply and may also require a water softener. See Water Supply Requirements in the Pre-Installation section of this manual. This three-phase power system interfaces with the RHF console.
Refer also to Water Chiller Model D Instruction Manual (802410).
Initial Height Sensing (IHS) – Optional
This unit, used with two inductive probes, automatically detects the workpiece surface and indexes the torch to the pierce position. This system is used for underwater, at the water line, or above-water applications. This unit interfaces with the power supply and requires an air supply to operate.
H401 Slave Power Supply – Optional
This unit can function as a “slave” when paralleled with the HT4001 power supply, providing up to 750 amps of current for the HT4001 system.
Refer also to H401 & H601 Instruction Manual IM41 (800410).
Water Muffler – Optional
The water muffler for the HT4001 system reduces radiated light, noise, and captures fumes and particles generated during the cut process. The water muffler is used to cut both at water and below water levels. The water muffler requires an air supply and a water supply.
Refer to the Water Muffler Instruction Manual (801730) for more detailed information.
SPECIFICATIONS
1-98
HT4001 Instruction Manual 2-5
Specifications
System Requirements
Power Requirements:
Refer to HT4001 Power Supply specifications below:
Gas Requirements:
Plasma Gas Types ..............................................Oxygen (O2), Nitrogen (N2)
Gas Quality
Oxygen.............................................................99.5%
Nitrogen............................................................99.995%
Oxygen Gas Inlet Pressure .................................120 psi +/- 10 psi (8.3 bar +/- 0.7 bar)
Nitrogen Gas Inlet Pressure ................................150 psi +/- 10 psi (10.3 bar +/- 0.7 bar)
Air Gas Inlet Pressure (for Wtr Muffler and IHS)..120 psi (8.3 bar)
Water Requirements:
Water Flow ...........................................................0.5 gpm (1.9 l/m) to water chiller
2.5 gpm (9.5 l/m) to RHF console
Water Inlet Pressure ............................................35 psi (2.4 bar) to water chiller
150 psi (10.3 bar) to RHF console
HT4001 Power Supply – with Slave
Maximum OCV (U0)..............................................400 VDC
Maximum Output Current (I
2
) ...............................760 A
Output Voltage (U2) .............................................80-200 VDC
Duty Cycle Rating (X) ..........................................100% @ 40°C at 760 A and 200 V
Ambient Temperatures/Duty Cycle.......................Power supplies will operate between +14° and
104°F (-10° and +40°C). Power supplies operated in an ambient temperature above 86°F (30°C) may show some decrease in duty cycle.
Cooling .................................................................Forced Air (Class F)
See instruction manual 800410: H401 & H601 for further specifications on the H401 slave power supply.
HT4001 Power Supply
Maximum OCV (U0)..............................................361 VDC
Maximum Output Current (I2) ...............................400 A
Output Voltage (U2) .............................................80-200 VDC
Duty Cycle Rating (X) ..........................................100% @ 40°C at 400 A and 200 V
Ambient Temperatures/Duty Cycle.......................Power supplies will operate between +14° and
104°F (-10° and +40°C). Power supplies operated in an ambient temperature above 86°F (30°C) may show some decrease in
duty cycle.
Power Factor (cosϕ).............................................0.94
Cooling .................................................................Forced Air (Class F)
SPECIFICATIONS
11-97
2-6 HT4001 Instruction Manual
HT4001 Power Supply Input Power: (U1- Input voltage; I1- Input current)
077002 with THC / 077016 without THC..............200 VAC (U1), 3Ø, 50-60 Hz @ 257A (I1)
220 VAC (U1), 3Ø, 50-60 Hz @ 234A (I1)
077003 with THC / 077017 without THC..............380 VAC (U1), 3Ø, 50-60 Hz @ 135A (I1)
400 VAC (U1), 3Ø, 50-60 Hz @ 128A (I1) 415 VAC (U1), 3Ø, 50-60 Hz @ 124A (I1)
077022 with THC / 077023 without THC..............400 VAC (U1), CE, 3Ø, 50-60 Hz @ 128A (I1)
077031 with THC / 077030 without THC..............440 VAC (U1), 3Ø, 50 Hz @ 117A (I1)
480 VAC (U1), 3Ø, 50 Hz @ 107A (I1)
077004 with THC / 077018 without THC..............240 VAC (U1), 3Ø, 60 Hz @ 214A (I1)
480 VAC (U1), 3Ø, 60 Hz @ 107A (I1)
077005 with THC / 077019 without THC..............575 VAC (U1), 3Ø, 60 Hz @ 89A (I1)
600 VAC (U1), 3Ø, 60 Hz @ 86A (I1)
Dimensions and Weight:
Width ....................................................................34" (863 mm)
Maximum Height ..................................................51" (1295 mm); 63" (1600 mm) on CE units
and 200/220V units
Maximum Depth ...................................................48-11/16" (1236 mm)
Weight ..................................................................1800 lbs (817 kg); 1850 lbs (840 kg) on CE units
Figure 2-1 Overall Dimensions – HT4001 Power Supply
2.5" (64 mm)
1.88"
(48 mm)
0.4"
(10 mm)
0.62"
(16 mm)
1.2"
(30 mm)
6.02" (153 mm)
9.35" (238 mm)
15.37" (390 mm)
17.15" (435 mm)
2"
(51 mm)
1.98"
(50 mm)
2"
(51 mm)
1.98"
(50 mm)
1.88" (48 mm)
0.87"
(22 mm)
1.77"
(45 mm)
11.75" (298 mm)
5.4" (137 mm)
SPECIFICATIONS
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HT4001 Instruction Manual 2-7
PAC620 Machine Torches (028507 – Standard / 028741 – Bevel)
Figure 2-2 PAC620 Standard Torch Assembly with Dimensions
Figure 2-3 PAC620 Bevel Torch Assembly with Dimensions
Maximum cutting thickness ..................................See Cut Charts for details.
Maximum current at 100% duty cycle ..................760 A
Plasma Gas Flow .................................................Oxygen – 114 scfh (54 l/min)
Nitrogen – 223 scfh (105 l/min)
Injection Water Flow Rate ....................................0.38 to 0.48 gpm (1.4 to 1.8 l/min)
Water coolant flow rate (max.) .............................1.7 gpm (6.4 l/min)
Dimensions and Weight:
Diameter...............................................................2" (50 mm)
Length ..................................................................17.15" (435 mm) standard;
15.37" (390 mm) bevel
Weight ..................................................................3-1/2 lbs (1.58 kg)
WARNING
CE countries must operate the PAC620 machine torch using a special CE retaining cap in order to comply with CE regulations. Part numbers for the CE retaining caps are indicated in the cut charts (Section 5).
SPECIFICATIONS
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2-8 HT4001 Instruction Manual
Remote High Frequency Console (077010)
Dimensions and Weight:
Width (Max.).........................................................14.63" (372 mm)
Height...................................................................16.75" (425 mm)
Depth....................................................................16.00" (406 mm)
Weight ..................................................................75 lbs (34 kg)
Figure 2-4 Mounting Dimensions (bottom view) – RHF Console
5/16"
dia. (4)
12.38" (314.5 mm)
16.00" (406 mm)
14.63"
(370 mm)
13.63"
(346 mm)
SPECIFICATIONS
01/22/98
HT4001 Instruction Manual 2-9
Figure 2-5 Mounting Dimensions (bottom view) – Remote V/C Control
.45"
(11.4 mm)
11.65"
(296 mm)
6.50"
(165 mm)
1.20"
(30.5 mm)
(Programmable Remote V/C Control Shown)
11.40" (290 mm)
7/32" dia. (4)
Digital Remote (DR) V/C Control (077012)
Controls................................................................Voltage adjust pot:
Adjusts arc cutting voltage and displays value on LEDs.
Current adjust pot:
Adjusts arc cutting current and displays value on LEDs.
Control Range ......................................................Current: 100 to 760 A
Voltage: 100 to 200 V
Control Resolution................................................Current: 20 A
Voltage: 5 V
Dimensions and Weight:
Width ....................................................................11.40" (290 mm)
Height...................................................................3" (76 mm)
Depth (Max.) ........................................................13.38" (340 mm)
Weight ..................................................................5 lbs – 5 oz. (2.4 kg)
Programmable Remote (PR) V/C Control (077013)
Controls................................................................None. Controlled through guidance machinery computer.
Control Range ......................................................Current: 100 to 760 A
Voltage: 100 to 200 V
Control Resolution................................................Current: 20 A
Voltage: 5 V
Dimensions and Weight:
Width ....................................................................11.40" (290 mm)
Height...................................................................3" (76 mm)
Depth (Max,) ........................................................12.50" (318 mm)
Weight ..................................................................5 lbs – 5 oz. (2.4 kg)
10.50" (266.7 mm)
5"
(127 mm)
SPECIFICATIONS
1-98
2-10 HT4001 Instruction Manual
Gas Console (073216)
Dimensions and Weight:
Width ....................................................................11.50 " (290 mm)
Height...................................................................14.60 " (370 mm)
Depth....................................................................4 " (100 mm)
Weight ..................................................................16 lbs (7.3 kg)
Figure 2-6 Mounting Dimensions (bottom view) – Gas Console
Motor Valve Console (073214)
Dimensions and Weight:
Width ....................................................................11.50 " (290 mm)
Height...................................................................4.25" (110 mm)
Depth....................................................................8" (200 mm)
Weight..........................................................................14 lbs (6.3 kg)
Figure 2-7 Mounting Dimensions (bottom view) – Motor Valve Console
8"
(200 mm)
7"
(180 mm)
6"
(152.4
mm)
5/16"
dia. (4)
2"
(50 mm)
2"
(50 mm)
3"
(75 mm)
1/2" (12,7 mm)
1/4-20 PEM – Use 1/4-20 screws that do not enter more than 1/2" into enclosure.
ooo
ooo
4"
(100 mm)
3-3/4"
(95 mm)
3-3/4"
(95 mm)
11.50" (290 mm)
10.75" (273 mm)
10.25" (260 mm)
SPECIFICATIONS
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HT4001 Instruction Manual 2-11
Initial Height Sensing (053016)
Input Power ..........................................................120 VAC from power supply
Air Pressure .........................................................20 psi (1.4 bar) regulated shop air input to solenoid.
Dimensions and Weight:
Width (Max.).........................................................9" (230 mm)
Height...................................................................4.50" (110 mm)
Depth (Max.) ........................................................11.5" (290 mm)
Weight ..................................................................13 lbs (6 kg)
Figure 2-8 Mounting Dimensions – Initial Height Sensing
Timer/Counter (073057)
Dimensions and Weight:
Width ....................................................................6.50" (165 mm)
Height...................................................................2.50" (64 mm)
Depth....................................................................8.50" (220 mm)
Weight ..................................................................3 lbs (1 kg)
Figure 2-9 Mounting Dimensions (bottom view) – Timer/Counter
8.50" (220 mm)
.50" (12.7 mm)
6.25" (158.8 mm)
3.38" (85.9
mm)
1.70" (43.2
mm)
5/32" dia. (4)
8" (200 mm)
6" (154.2 mm)
5/16" dia. (4)
11.50"
(290 mm)
10.75"
(273 mm)
6.50"
(170 mm)
SPECIFICATIONS
4-00
2-12 HT4001 Instruction Manual
Water Chiller
Dimensions and Weight:
Width ....................................................................30.25" (770 mm)
Height...................................................................42.25" (1075 mm)
Depth....................................................................46" (1170 mm)
Weight ..................................................................700 lbs (320 kg), 600A – 1-Torch
745 lbs (340 kg), 600A – 2-Torch 745 lbs (340 kg), 1000A – 1-Torch
Refer also to Water Chiller Model D Instruction Manual (802410).
Water Muffler
Air Control Dimensions and Weight:
Width ....................................................................6.25" (160 mm)
Height...................................................................6.25" (160 mm)
Depth....................................................................4.25" (110 mm)
Weight ..................................................................6 lbs (2.7 kg)
Pump Dimensions and Weight:
Width ....................................................................11" (280 mm)
Height...................................................................19" (480 mm)
Depth....................................................................17" (430 mm)
Weight ..................................................................85 lbs (38.6 kg)
Refer also to Water Muffler Instruction Manual (801730).
H401 Power Supply
H401 Dimensions and Weight:
Width ....................................................................40" (1025 mm)
Height...................................................................53" (1345 mm)
Depth....................................................................50" (1270 mm)
Weight ..................................................................2250 lbs (1022 kg)
Refer also to H401 & H601 Instruction Manual IM41 (800410).
SPECIFICATIONS
1-98
HT4001 Instruction Manual 2-13
IEC Symbols Used
Direct Current (DC)
Alternating current (AC)
Plasma cutting torch
AC input power connection
The terminal for the external protective (earthed) conductor
A chopper-based power source
Anode (+) work clamp
Temperature switch
Pressure switch
Plasma torch in the TEST position (cooling and cutting gas exiting nozzle)
The power is on
The power is off
Volt/amp curve
15
HT4001 Instruction Manual 3-1
Section 3
PRE-INSTALLATION
In this section:
Introduction ...............................................................................................................................................................3-2
Gas Requirements....................................................................................................................................................3-2
Water Supply Requirements.....................................................................................................................................3-3
Grounding Requirements..........................................................................................................................................3-4
Power Requirements ................................................................................................................................................3-4
Line Disconnect Switch ....................................................................................................................................3-5
Power Cables...................................................................................................................................................3-5
Positioning the Power Supplies........................................................................................................................3-6
Transformer Configurations ......................................................................................................................................3-7
Connecting the Power.............................................................................................................................................3-11
Torch Lifter Requirement ........................................................................................................................................3-12
Optional Equipment ................................................................................................................................................3-12
Water Muffler..................................................................................................................................................3-12
Initial Height Sensing (IHS) ............................................................................................................................3-13
7-99
PRE-INSTALLATION
3-2 HT4001 Instruction Manual
Introduction
Prior to the installation of the HT4001 plasma cutting system, please read the following requirements. Their purpose is to both aid you in the installation of your plasma cutting system and to maximize performance of the system.
Installation and service of the electrical and plumbing systems must conform to national or local electrical and plumbing codes. Have this work performed only by qualified, licensed personnel.
If questions arise at any time, call Technical Service listed in the front of this manual or your authorized Hypertherm distributor.
WARNING
Cutting with oxygen as the plasma gas can cause a potential fire hazard due to the oxygen-enriched atmosphere that it creates. As a precaution, Hypertherm recommends the installation of an exhaust ventilation system if the customer will be cutting with oxygen.
Gas Requirements
The HT4001 system requires a supply gas purity of 99.995% for nitrogen and 99.5% for oxygen. The customer must supply the source gas. Hypertherm recommends using liquid gas containers.
Note: If the purity level of the gas is too low or if there are leaks in the supply hoses or
connections, cut speeds can decrease, cut quality can deteriorate, cutting thickness capability can decrease, and parts life can shorten.
If making hard plumbing connections, avoid using iron pipe. Never use PTFE tape on any joint preparation. After installation, pressurize the entire system and check for leaks.
From Source Supply to Gas Console
The customer must provide a regulator capable of delivering the following:
Oxygen: 120 psi +/- 10 psi (8.3 bar +/- 0.7 bar) to the gas console Nitrogen: 150 psi +/- 10 psi (10.3 bar +/- 0.7 bar) to the gas console.
Caution: Gas supply pressures not within the above parameters can cause poor cut quality,
poor consumable life, and operational problems.
We recommend filtering nitrogen gas with an oil absorbing or coalescing filter and using liquid nitrogen to reduce the risk of gas contamination.
If you are not using hard plumbing from the supply gas to the gas console, we recommend using standard oxygen and nitrogen hose with the system. Hypertherm can provide oxygen or nitrogen hose. See page 4-26 for detail.
4-96
PRE-INSTALLATION
HT4001 Instruction Manual 3-3
Water Supply Requirements
The customer must supply a clean water source to the RHF console that will deliver 2.5 gpm (9.5 lpm) at a minimum pressure of 150 psi (10.3 bar). To maximize consumable life, water temperature to the RHF console must also be under 70°F (21°C). An effective way to meet these requirements is to include a water chiller in the HT4001 system.
From Source Supply to Water Chiller
The customer must provide a clean water source capable of delivering the following:
35 psi (2.4 bar) at 0.5 gpm (1.9 l/m) to the water chiller
(The water chiller then increases the pressure to a maximum of 185 psi (12.8 bar) and recirculates cooling water to the electrode at a flow of 1.7 gpm (6.4 l/m).) To ensure water purity, use type K hard copper tubing for all plumbing both before and after the water softener (or deionizer), including plumbing from the outlet of the water chiller to the power track or festoon system. We suggest using copper tubing of 1/2 inch I.D. to the pump inlet.
Hypertherm recommends filtering the inlet line. Purchase filters locally or from Hypertherm.
Refer to water chiller instruction manual (802410 Model D) for additional information on the water chiller. Refer also to Routine Maintenance in Section 6 for instructions on how to protect copper surfaces in the water chiller loop.
Water Quality
A low level of calcium carbonate (measured in water hardness) is critical for proper performance of the nozzle in the torch. Excessive deposits of calcium carbonate on the nozzle will alter water flow and produce an unstable arc.
Hardness of the water at the torch must be between .206 and 8.5 ppm.
If using a conductivity meter to measure water purity, the recommended level is:
between .5 and 18 µSiemens/cm at 77° F (25° C).
Source water may require a water softener, reverse osmosis system or other de-ionizing equipment to obtain this low level of hardness. Consult a water specialist for detailed advice in this area.
Water in the Water Table
A corrosion inhibitor can be added to the water in the water table to extend the life of the table and the workpiece. When using the water muffler system with the HT4001, special filtering of the water table water is necessary. See Optional Equipment – Water Muffler on page 3-12 for details.
6-98
PRE-INSTALLATION
3-4 HT4001 Instruction Manual
Grounding Requirements
Properly ground the HT4001 system for personal safety and to prevent emission of high-frequency interference. See Appendix F for system grounding requirements.
Connect the worktable to a high-quality earth ground from within 20 feet (6 m) of the table. A suitable ground consists of a solid copper rod of at least 3/4-inch (19 mm) diameter driven to a depth of at least 15 feet (4.5 m) into the earth. This will allow ample grounding only if you reach a permanent moisture level. If soil conditions provide no permanent moisture level, drill a 6-inch (152 mm) hole to a depth of 15 feet (4.5 m) and place a 3/4-inch (19 mm) copper coated steel rod within the 6-inch hole. Pack down the hole with wet rock-salt. For additional information consult the National Electric Code, Article 250, Section H Grounding Electrode System, or other appropriate code.
All switches, slow-blow fuses and power cables are customer supplied and must be chosen as directed by applicable national and/or local electrical codes.
Use a separate primary line disconnect switch for each HT4001 power supply and slave.
Note: Input voltage must not drop below 15% of the values listed below. The power supply will go
into an idle mode and display an error on the control board if the input voltage is too low. See also Error Codes in Section 6.
Size the disconnect box(es) to the following requirements for the HT4001 power supply:
Rated Input
Input Current @ Recommended
V
oltage Phase 89 kVA Output Slow-Blow Fuse Size
200 VAC 3 257 amps 350 amps 220 VAC 3 234 amps 300 amps 240 VAC 3 214 amps 300 amps 380 VAC 3 135 amps 175 amps 400 VAC 3 128 amps 175 amps 415 VAC 3 124 amps 175 amps 440 VAC 3 117 amps 175 amps 480 VAC 3 107 amps 150 amps 575 VAC 3 89 amps 125 amps 600 VAC 3 86 amps 125 amps
WARNING
Electrical installation must be performed by qualified personnel only.
Power Requirements
12-99
PRE-INSTALLATION
HT4001 Instruction Manual 3-5
Line Disconnect Switch
The line disconnect switch serves as the supply voltage disconnecting (isolating) device. Install this switch on a wall near the power supply for easy accessibility by the operator. The line disconnect switch must be installed
by qualified personnel following all applicable local and national codes. The switch should:
• Isolate the electrical equipment and disconnect all live conductors from the supply voltage when in “OFF” position
• Have one “OFF” and one “ON” position clearly marked with “O” (OFF) and “I” (ON)
• Have an external operating handle capable of being locked in the “OFF” position
• Contain a power operated mechanism that serves as an emergency stop
• Have slow-blow fuses installed for the proper breaking capacity (see table on pg.3-4)
Power Cables
Wire sizes vary based on the distance of the receptacle from the main box.
HT4001 Power Supplies
The wire sizes listed below are taken from the National Electric Code 1990 handbook, table 310.16. Use a 4-conductor (3 conductor w/ground) input power cable with a conductor temperature rating of 60° C (140° F) or 90° C (194° F) according to the following requirements:
Water Chiller
For information on cable sizes for the water chiller, refer to its instruction manual (802410 Model D).
H401 Slave
For information on cable sizes for the H401 slave, refer to its instruction manual (800410).
tupnI
egatloVegatloV
egatloV
egatloVegatloV
)GWAroMCM(eziSelbaCdednemmoceR
)F°041(C°06rofdetar)F°041(C°06rofdetar
)F°041(C°06rofdetar
)F°041(C°06rofdetar)F°041(C°06rofdetar
)GWA(eziSelbaCdednemmoceR
)F°491(C°09rofdetar)F°491(C°09rofdetar
)F°491(C°09rofdetar
)F°491(C°09rofdetar)F°491(C°09rofdetar
tnerruC
gnitaRgnitaR
gnitaR
gnitaRgnitaR
CAV002
etoNeeS*
GWA0/4spma062
CAV022
etoNeeS*
0/4GWAspma042 CAV042MCM0520/3GWAspma512 CAV083GWA0/21GWAspma541 CAV004GWA0/21GWAspma541 CAV514GWA0/12GWAspma521 CAV044GWA0/12GWAspma521 CAV084GWA13GWAspma011 CAV575GWA24GWAspma59 CAV006GWA24GWAspma59
Note: Use the smaller diameter 4/0 AWG
cable (1.6"/40.6 mm) rated for 90° C (194° F) rather than an equivalent larger diameter cable (350 MCM, 2.05"/52 mm) rated for 60° C (140° F) to accommodate the bend radius necessary to connect incoming power cable to the power supply.
PRE-INSTALLATION
3-6 HT4001 Instruction Manual
Positioning the Power Supplies
Note: Use a forklift with forks long enough to extend the entire length of the power supply base. If
forks are too short they can damage the underside of the power supply.
A lifting eye is also provided for moving the power supplies with a crane or hoist. Take
extra care when moving by hoist or crane! The lifting eye may not be the balanced center of the power supply.
1. Place the power supplies in an area that is free of excessive moisture, has proper ventilation, and is relatively clean. Allow room for accessing the sides of the power supplies for servicing.
2. Place the power supplies so that air flow is not blocked in any way. (Cooling air is drawn in through the front panel grating, and is exhausted through the rear of the unit by cooling fans.)
3. Do not place any filter device over the air intake locations. This reduces cooling efficiency and VOIDS THE WARRANTY.
WARNING
Remove all electrical connections to power supplies before moving or positioning. Transporting the unit can cause personal injury and equipment damage.
PRE-INSTALLATION
HT4001 Instruction Manual 3-7
Transformer Configurations
Three-phase input
Three-phase input
Figure 3-2 480V Transformer
Figure 3-1 240V Transformer
ØA ØB ØC
ØA ØB ØC
10-95
PRE-INSTALLATION
3-8 HT4001 Instruction Manual
Transformer Configurations (cont.)
Figure 3-3 200V Transformer
Figure 3-4 380V Transformer
ØA
ØB
ØC
ØA
ØB
ØC
11-97
PRE-INSTALLATION
HT4001 Instruction Manual 3-9
Transformer Configurations (cont.)
Figure 3-6 415V Transformer
ØA
ØB
ØCØA
ØB
ØC
Figure 3-5 400V Transformer
ØA
ØB
ØC
Figure 3-6a 440V Transformer
PRE-INSTALLATION
3-10 HT4001 Instruction Manual
Transformer Configurations (cont.)
Figure 3-7 575V Transformer
Figure 3-8 600V Transformer
ØA ØB ØC
ØA ØB ØC
Ground (PE)
L1
L2
L3
CON1
Power Cable
Strain Relief
Power Cable to HT4001 Power Supply
To connect the power cable to the 400V CE power supplies (077022 and 077023), refer to Appendix C. To connect the power cable to the 200/220V power supplies (077002 and
077016), refer to Appendix D. For all other power supplies, use the procedure below.
1. Insert the Power Cable through the Strain Relief located in the rear of the power supply.
2. Connect the power leads to the L1, L2, and L3 terminals of CON1. See Fig. 3-9.
3. Connect the Ground (PE) lead to the stud as shown in Fig. 3-9.
Connecting the Power
16
PRE-INSTALLATION
HT4001 Instruction Manual 3-11
Figure 3-9 Power Cable Connections
WARNING
There is line voltage at the contactors after the line disconnect switch is ON, even if the circuit breaker on the HT4001 power supply is OFF. As a common safety practice,
ALWAYS verify that the line disconnect switch is in the OFF position before installing, disconnecting or servicing in these areas.
WARNING
The line disconnect switch must be in the OFF position before making the power cable connections! In the U.S., use a “lock-out/tag-out” procedure until installation is complete. In other countries, follow appropriate local or national safety procedures.
PRE-INSTALLATION
3-12 HT4001 Instruction Manual
Power Cable from HT4001 Power Supplies to Power Source
1. The line disconnect switch must be in the OFF position!
2. Connect the power cable leads to the line disconnect switch following local and applicable electrical codes.
Optional Equipment
Water Muffler
The water table provides the supply of water for the water-muffler pump. This water must be filtered for the water-muffler system. Hypertherm provides a filter (027009) with all water-muffler systems.
Important: Place the pump as close as possible to the water table. Longer distances result in pump priming and
water lag problems during start up. This results in excessive noise and smoke during the initial starting.
Plumbing Requirements
Attach the filter to the pump with approximately four feet of 3/4 inch I.D. #12 hose. The customer may supply his/her own water pump and water hose or purchase a pump with or without hose through Hypertherm. Please refer to water muffler system part numbers listed on the following page, and water muffler instruction manual 801730 for further information.
Torch Lifter Requirement
The HT4001 system requires a high-quality, motorized torch lifter with sufficient travel to cover all cutting thickness requirements. The lifter must provide at least 10 inches (254 mm) of vertical travel. The unit must have a constant speed of at least 20 ipm (508 mm/min) with positive braking. A unit which drifts through the stop point is not acceptable.
WARNING
The line disconnect switch must remain in the OFF position during the rest of the pre-installation and installation of the HT4001 system!
4-96
PRE-INSTALLATION
HT4001 Instruction Manual 3-13
Power Requirements
The customer must provide the power cable for the water-muffler pump. The pumps provided by Hypertherm take a three-phase input. Part numbers and corresponding voltages are listed below. Input current information is provided on the motor data plate. Present pump systems all draw less than 20 amps. Select cable sizes accordingly.
Water Muffler System Water Pump
Part Number Part Number
Input Voltages
034126 (w/hoses) 028042 230-460 Volt/3Ø/60 Hz 034128 (w/hoses) 028299 380-415 Volt/3Ø/50 Hz 034130 (w/hoses) 028308 575 Volt/3Ø/60 Hz 034127 (wo/hoses) 028042 230-460 Volt/3Ø/60 Hz 034129 (wo/hoses) 028299 380-415 Volt/3Ø/50 Hz 034131 (wo/hoses) 028308 575 Volt/3Ø/60 Hz
Air Requirements
Provide a clean, dry, oil-free source of air with a delivery pressure between 80 and 120 psi (5.5 and 8.3 bar) with a minimum flow rate of 20 scfm.
For further information, please refer to Hypertherm water muffler instruction manual (801730).
Initial Height Sensing (IHS)
The customer must provide a source of compressed air to the Initial Height Sensing system.
Air Requirements
Use a clean, dry, oil-free source of air to prevent possible problems created by moisture and water in the line. Reduce shop air pressure to 20 psi (1.4 bar) with a regulator. Use a 1/4 inch I.D. hose between the regulator and the inductive height control module.
An option to the IHS system is an upper-limit switch and cable. Please refer to Initial Height Sensing Connections in the Installation section of this manual for further information.
HT4001 Instruction Manual 4-1
15
Section 4
INSTALLATION
In this section:
Upon Receipt ............................................................................................................................................................4-2
Claims.......................................................................................................................................................................4-2
Module Grounding and Grounding Checks ..............................................................................................................4-3
Noise Levels (Decibels) ............................................................................................................................................4-3
System Units Placement...........................................................................................................................................4-4
HT4001 Interconnection Reference Map..................................................................................................................4-5
Power Supply Connections.......................................................................................................................................4-6
RHF Console Connections .....................................................................................................................................4-22
Gas Console Connections ......................................................................................................................................4-26
Motor Valve Console Connections..........................................................................................................................4-30
Initial Height Sensing Connections .........................................................................................................................4-32
Optional Power Supply Connections ......................................................................................................................4-36
Mounting the Machine Torch...................................................................................................................................4-38
Torch Alignment..............................................................................................................................................4-38
INSTALLATION
8-97
4-2 HT4001 Instruction Manual
Upon Receipt
The HT4001 system is shipped mounted on skid(s) and protected by heavy carton covers. Before unpacking, inspect the cartons for evidence of damage during shipment. If there is evidence of damage, refer to Claims for damage during shipment below for details.
1. Remove all packing material and discard. Remove the units and items from the shipping skid.
2. Verify that the components of the HT4001 system, optional units, cables and hoses, and items listed below are included.
Alert your distributor or Hypertherm if any of the items are damaged or missing. All communications regarding this equipment must include the model number and serial number (located on the back of the HT4001 power supply). Refer to Claims for defective or missing merchandise below for details.
Claims
Claims for damage during shipment — If your unit was damaged during shipment, you must file a claim with the
carrier. Hypertherm will furnish you with a copy of the bill of lading upon request. If you need additional assistance, call our Customer Service group at 1-800-737-2978.
Claims for defective or missing merchandise — All units shipped from Hypertherm undergo rigorous quality control inspections for defects. If any of the merchandise is defective or missing, call your distributor for help. If you need additional assistance, call our Customer Service group at 1-800-737-2978.
HT4001 System Components
• HT4001 Power Supply
• Remote High Frequency Console
• Remote Voltage/Current Control
• Gas Console
• Motor Valve Console
• Cable
• Hoses
• Torch lead set to Motor Valve Console
• Shielded torch lead set to RHF Console
• Machine Torch
• Consumable spare parts kit
Optional Units
• Initial Height Sensing
• Water Muffler System
• Timer/Counter
• H-401 Slave
• Water Chiller
INSTALLATION
6-98
HT4001 Instruction Manual 4-3
Module Grounding and Grounding Checks
Please refer to Grounding Requirements in the Pre-Installation section of this manual for earth ground specifications.
See Appendix F for system grounding requirements.
Before operating the HT4001, perform the following grounding checks to ensure proper operation, personal safety, and to reduce emission of radio-frequency interference:
• Ensure the power cord ground wire is properly connected to the ground in the line disconnect box.
• Ensure the power cord ground wire is properly connected to the HT4001 power supply chassis. Refer to Connecting the Power in the Pre-Installation section of this manual.
• Ensure that all electrical connections are tight to avoid excessive heating.
Figure 4-1 Noise Levels (Decibels)
Noise Levels (Decibels)
Figure 4-1 presents the noise levels in decibels experienced by an operator standing 10 feet (3 m) from the torch in a confined area under varied conditions while cutting mild steel.
Without Water Muffler – 102 dbs
With Water Muffler using
oxygen at 260 Amps – 85 dbs
With Water Muffler using
nitrogen at 400 Amps – 89 dbs
Water 3" over plate with
Water Muffler using oxygen or nitrogen – less than 85 dbs
INSTALLATION
11-97
4-4 HT4001 Instruction Manual
System Units Placement
• Position all required units prior to making electrical, gas, and interface connections.
• See Section 2 for mounting dimensions of all units.
• Ground all external modules in the HT4001 system to earth.
• To prevent leaks in the system, tighten all gas and water connections to the following specifications:
* System shown includes H401 slave, IHS, and water muffler options
Air
Air
Torch
Machine Interface
Motor Valve Console
Water Muffler
IHS Probe
Air Regulator
Gas Console (mount near operator) RHF Console
IHS Console
Timer/Counter
Water Chiller
HT4001
Remote V/C Control
(mount near operator)
Water
Power
H401 Slave
(optional)
Water Muffler Pump
Power
Power
Figure 4-2 Typical HT4001 System* Component Placement for Gantry Cutter
Gas or water Torch Specification hose size lbf-in lbf-ft kgf-cm
Up to 3/8" (9.5 mm) 75-85 6.25-7 86-98 1/2" (12.7 mm) 360-480 30-40 415-550
H2O
in
20
IHS
Console
Machine
Computer
Interface
INSTALLATION
HT4001 Instruction Manual 4-5
HT4001 Interconnection Reference Map
Figure 4-3 HT4001 Interconnect System Diagram with IHS, Water Muffler and Slave
Key
Plasma gas hose Water hose Air hose Shielded torch leads Cables Slave requirements Reference to
installation steps
RHF
Console
HT4001
Power
Supply
400 Amp
Remote
V/C
Timer/
Counter
H401 or H601
Slave
W-M
Air Control
Work table
Air in
H
2
O in
N2in
3-Phase
Power
To Second
HT4001 System
H2O
in
3-Phase
Power
Water
Chiller
15
5
4
2
1
34
25
24
17
27
Motor Valve
Console
28
28
26
J
B
3-Phase
Power
W-M
Supply
K
Air in
K
L
13
14
33
8
7
3
23
22
21
16
D
Gas
Console
C
18
19
6
12
F
A
G
H
3-Phase
Power
10
30
31
32
11
9
E
, etc.
19
5
Off Valve
INSTALLATION
4-97
4-6 HT4001 Instruction Manual
Part No. Length
023136 20 ft (6 m) 023078 25 ft (7.5 m) 023101 30 ft (9 m) 023135 40 ft (12 m) 023079 50 ft (15 m)
Part No. Length
023124 75 ft (23 m) 023080 100 ft (30.5 m) 023081 150 ft (46 m) 023316 180 ft (55 m) 023188 200 ft (61 m)
Nozzle Lead – PS to RHF Console
Pass the fork terminal end of the nozzle lead through the small bushing in the lower rear of the HT4001 power supply and connect to the start circuit assembly as shown in Figure 4-4. Connect the ring terminal end of the nozzle lead to the inductor coil in the RHF console. See pages 4-8 and 4-22 through 4-25 for remaining RHF console connections.
Power Supply Connections
The circled numbers on the right-hand pages represent connection points for the corresponding numbered cables and hoses on the left-hand pages. Any special instructions for installation are also explained on the left-hand pages. The cable and hose part numbers in this section represent the most commonly used lengths. For
additional lengths, see Section 7 or call Hypertherm.
Part No. Length
123009 25 ft (7.5 m) 123010 50 ft (15 m) 123011 75 ft (23 m)
Part No. Length
123012 100 ft (30.5 m) 123013 150 ft (46 m) 123014 200 ft (61 m)
1
2
3
4
Fork Terminal Ring Terminal
Power Cables – Power Supply (PS) to Power Source
See Connecting the Power in the Pre-Installation section of this manual.
Negative Lead – PS to Remote High Frequency (RHF) Console
Pass the negative 2 lead through one of the 2" bushings in the lower rear of the HT4001 power supply and connect to the lower bar (-) on the center bail rear as shown in Fig. 4-4. Connect the other end of the negative lead securely to the cathode block in the RHF console. See part number information below under Positive
Lead – PS to Work Table
Positive Lead – PS to Work Table
Pass the positive 3 lead through one of the 2" bushings in the lower rear of the HT4001 power supply and connect to the upper bar (+) on the center bail rear as shown in Fig. 4-4. Connect the other end of the lead securely to the grounded work table.
Note: Two positive and two negative leads needed when cutting with from 400-750 amps. See
Appendix A to connect H401 Slave to HT4001 power supply.
WARNING
All power must be turned OFF before performing installation!!
INSTALLATION
5-00
HT4001 Instruction Manual 4-7
Figure 4-4 Negative Lead and Nozzle Lead Connections – PS to RHF Console
Positive Lead Connection – PS to Work Table
RHF Console RHF Console
Inductor Coil
Power Supply
3
2
4
3
2
Work Table
Cathode Block
Center Bail Rear
4
Start Circuit Assembly – (on Center Bail Front)
INSTALLATION
1-98
4-8 HT4001 Instruction Manual
Power Supply Connections (cont.)
PS/RHF Cable – PS to RHF Console
See pages 4-6 and 4-22 through 4-25 for remaining RHF console connections.
RUN LIST – PS/RHF CABLE
SIGNAL PLUG 1X1 COLOR PLUG 2X1
HF XFMR 1 BLACK 12 HF XFMR 2 RED 15 Gnd 3 SHIELD CUT SV6/Inj. H2O 4 BLACK 2 SV6/Inj. H2O 8 WHITE 5 Gnd 9 SHIELD CUT FS2/Flow SW 10 BLACK 10 FS2/Flow SW 11 GREEN 13 Gnd 12 SHIELD CUT FS1/Flow SW 23 BLACK 7 PS1/Pressure SW 24 BLUE 8 Gnd 25 SHIELD CUT S1,S2/Door Intlk 34 BLACK 1 S1,S2/Door Intlk 35 YELLOW 4 Gnd 36 SHIELD CUT CR1 28 BROWN 9 Pilot Arc Relay 21 BLACK 11 Gnd 26 SHIELD CUT CR2 5 ORANGE 3
6 BLACK 6
Gnd 7 SHIELD CUT
5
PS End
1X1 2X1
RHF End
Part No. Length
023764 50 ft (15 m) 023765 75 ft (23 m) 023766 100 ft (30.5 m)
Part No. Length
023767 150 ft (46 m) 023768 200 ft (61 m) 023769 300 ft (91.5 m)
INSTALLATION
6-96
HT4001 Instruction Manual 4-9
Figure 4-5 RHF Cable Connections – PS to RHF Console
Power Supply
5
RHF Console
5
2X1
INSTALLATION
1-98
4-10 HT4001 Instruction Manual
Power Supply Connections (cont.)
Gas Console Cable – PS to Gas Console
See pages 4-26 through 4-29 for remaining gas console connections.
RUN LIST PS/GAS CONSOLE CABLE SIGNAL PLUG 1X2 COLOR PLUG 3X1 SV5/Plasma OFF 29 BLACK 29
SV5/Plasma OFF 30 RED 30 Gnd 34 SHIELD 34 S1/O
2,N2
Select 5 BLACK 5
S1/O
2,N2
Select 6 WHITE 6 Gnd 1 SHIELD 1 S2/Test Preflow 2 BLACK 2 S2/Test Preflow 3 GREEN 3 Gnd 7 SHIELD 7 S2/Test Cut Flow 8 BLACK 8 S2/Test Cut Flow 9 BLUE 9 Gnd 4 SHIELD 4 SV4A/Preflow-Cut 16 BLACK 16 SV4A/Preflow-Cut 17 YELLOW 17 Gnd 10 SHIELD 10 SV4B/Preflow-Cut 23 RED 23 SV4B/Preflow-Cut 24 YELLOW 24 Gnd 25 SHIELD 25 SV2, SV3/O2 N2 Preflow 11 BLACK 11 SV2, SV3/O2 N2 Preflow 12 BROWN 12 Gnd 18 SHIELD 18 SV1A/Plasma O2-N2 35 RED 35 SV1A/Plasma O2-N2 36 GREEN 36 Gnd 31 SHIELD 31 SV1B/Plasma O2-N2 19 BLACK 19 SV1B/Plasma O2-N2 20 ORANGE 20 Gnd 13 SHIELD 13 PS1, PS2/Plasma Pressure 14 RED 14 PS1, PS2/Plasma Pressure 15 WHITE 15 Gnd 21 SHIELD 21 S3, Increase/Decrease 26 RED 26 S3. Increase/Decrease 27 BROWN 27 Gnd 28 SHIELD 28 Spare 32 RED 32 Spare 33 BLUE 33 Gnd 37 SHIELD 37
6
1X2 3X1
PS End GC End
Part No. Length
023496 50 ft (15 m) 023497 75 ft (23 m) 023498 100 ft (30.5 m) 023499 150 ft (46 m)
Part No. Length
023500 200 ft (61 m) 023812 250 ft (76 m) 023819 300 ft (92 m) 023576 350 ft (107 m)
INSTALLATION
12-96
HT4001 Instruction Manual 4-11
Figure 4-6 Gas Console Cable Connection – PS to Gas Console
Power Supply
6
Gas Console
6
3X1
INSTALLATION
5-00
4-12 HT4001 Instruction Manual
Power Supply Connections (cont.)
Machine Interface I/O Cable – PS to Machine Interface
PS END MACH. END SCKT COLOR LUG DESCRIPTION AND COMMENTS
1 Wht 87 Hold (12VDC) Signal. Synchronizes starting of 2 or more systems. Closed=ON; Open=OFF 5 Blk 86 Hold - Common
10 Shield Cut Hold - Shield
2 Yel 173 Initial Height (12VDC) Signal. Closed=OFF ; Open=ON 6 Blk 174 Initial Height - Common
11 Shield Cut Initial Height - Shield.
3 Brn 171 Auto Height (12VDC) Signal. Closed=OFF; Open=ON or Corner (12VDC) 7 Blk 172 Auto Height - Common
12 Shield Cut Auto Height - Shield
4 Orange 135 Remote On/Off - See note on next page 8 Black 136 Remote On/Off - See note on next page
13 Shield Cut Remote On/Off - Shield
9 Blu 82 Plasma Start (24VAC) - Signal. Close=Start 15 Blk 83 Plasma Start - Signal. 14 Shield Cut Plasma Start - Shield. 22 Red 77 Upper Limit Switch, Hot. Normally closed. Open when fully retracted. 21 Wht 76 Upper Limit Switch, Neutral. 20 Shield Cut Upper Limit Switch, Shield. 28 Yel 80 Plasma Emergency Stop (24VAC) Signal. Closed =stop. 33 Red 81 Plasma Emergency Stop - Signal 27 Shield Cut Plasma Emergency Stop - Shld 34 Red 169 †Down Relay, Load (Solid state, rated to switch 24 to 120VAC, 1amp. DC relay optional) Closed=Down 29 Blk 170 Down Relay, Line 23 Shield Cut Down Relay, Shield 35 Grn 167 †Up Relay, Load (Solid state, rated to switch 24 to 120VAC, 1amp. DC relay optional) Closed=Up 30 Blk 168 Up Relay, Line 24 Shield Cut Up Relay, Shield 36 Red 84 †*Arc Xfer Output - Signal Contact closes after arc transfer and time delay. Dry contact relay. 31 Blu 85 *Arc Xfer Output - Signal 25 Shield Cut *Arc Xfer Output - Shield 37 Red 79 **Arc Voltage Isolated + Divided (1/100) Signal 32 Grn 78 **Arc Voltage Isolated + Divided (1/100) Sig 26 Shield **Arc Voltage Isolated + Divided (1/100),Shld
7
PS End
Notes: * Note on the µP PCB that resistor R150 and capacitor C78 are connected in series across the contacts. In some cases one lead of
R150 must be cut from the control PC board as the R-C circuit may provide enough current flow to maintain machine motion input to cutting machine.
** Note on the µP PCB that resistor R155 and capacitor C79 are connected in series across the contacts. In some cases one lead of
R155 must be cut from the control PC board as the R-C circuit may provide enough current flow to maintain machine motion input to cutting machine.
Signals are AC relays. DC relays are available as an option from Hypertherm by ordering kit: 128404
1X6
WARNING
When installing or servicing the HT4001, AC or DC line voltages may be present on the UP, DOWN and TRANSFER signals even if the power supply line disconnect switch is OFF. Make certain that all line disconnect switches relating to the HT4001 system are OFF during installation and when servicing.
Part No. Length
023892 25 ft (7.5 m) 023893 50 ft (15 m) 023894 75 ft (23 m)
Part No. Length
023895 100 ft (30.5 m) 023896 150 ft (46 m) 023897 200 ft (61 m)
INSTALLATION
5-00
HT4001 Instruction Manual 4-13
Figure 4-7 Machine Interface I/O Cable Connection – PS to Computer Interface
Power Supply
7
7
Machine
Computer
Interface
**Move jumper to TB4
terminals 2&3 to enable
a remote ON/OFF switch
24 VAC
AUXILIARY
(INTER-
LOCKED
WITH AUTO
STOP)
INSTALLATION
10-99
4-14 HT4001 Instruction Manual
Power Supply Connections (cont.)
Machine Interface V/C Cable – PS to Machine Interface
Note: If HT4001 system uses the digital remote V/C unit to set voltage and current, skip this step. The
machine interface V/C cable is used only with the programmable remote.
Before connecting the machine V/C interface cable, see the wiring diagrams in this manual and verify that the correct plug is attached to the µP control PCB REC6 receptacle.
PS END SCKT COLOR DESCRIPTION
1 Black Current 5 2 Wht Current 10 3 Red Current 20 4 Green Current 40 5 Orange Current 80 6 Blue Current 100 7 White/Black Current 200 8 Red/Black Current 400 9 Green/Black Current 800 10 Shield Shield 11 Blue/Black Current ICom 12 Black/White spare 13 Red/White spare 14 Green/White Voltage V1.25 15 Blue/White Voltage V2.5 16 Black/Red Voltage V5 17 White/Red Voltage V10 18 Orange/Red Voltage V20 19 Blue/Red Voltage V40 20 Red/Green Voltage V80 21 Orange/Green Voltage V100 22 Black/White/Red Voltage V200 23 White/Black/Red Voltage VCom
8
PS End
1X7
Part No. Length
023851 15 ft (4.5 m) 023852 25 ft (7.5 m) 023853 35 ft (10.6 m) 023854 50 ft (15 m)
Part No. Length
023855 75 ft (23 m) 023856 100 ft (30.5 m) 023903 125 ft (38 m) 023857 150 ft (46 m) 023858 200 ft (61 m)
INSTALLATION
HT4001 Instruction Manual 4-15
Power Supply
8
8
Machine
Computer
Interface
Figure 4-8 Machine Interface V/C Cable Connection – PS to Computer Interface
INSTALLATION
10-95
4-16 HT4001 Instruction Manual
Power Supply Connections (cont.)
See IM191 RCC Installation for installation of Remote Current Control to HT4001.
Remote Serial Cable – PS to Remote V/C
Connect this cable from the power supply to either the digital or programmable remote.
RUN LIST – REMOTE SERIAL CABLE SIGNAL PS END COLOR V/C END SID DATA 4 GREEN 1
SID COMMON 8 BLACK 2 SOD DATA 9 RED 3 SOD COMMON 15 BLACK 6 SHIELD 13 GRN/BLACK SHIELD 14 RED/BLACK SHIELD-(AC) 31 WHT/BLK AC POWER 35 WHITE 7 AC POWER 36 BLACK 8
KEY 5
Remote V/C Cable – PS to Remote V/C
Connect this cable from the power supply to the programmable remote.
SIGNAL PS END COLOR V/C END Current 20 1 Black 1
Current 40 2 Blue 2 Current 80 3 Green 3 Current 100 4 White 4 Current 200 5 Orange 5 Current 400 6 Red 6 Common 7 Black/White 7
SIGNAL PS END COLOR V/C END Voltage 5 8 Blue/White 8
Voltage 10 9 Blue/Black 9 Voltage 20 10 Green/Black 10 Voltage 40 11 Orange/Black 11 Voltage 80 12 Red/Black 12 Voltage 100 13 Green/White 13 Voltage 200 14 Red/White 14 Spare 15 White/Black 15 Shield 16 Shld 16
9
10
1X4
5X1
PS End V/C End
1X5 5X2
PS End V/C End
Part No. Length
023911 15 ft (4.5 m) 023878 25 ft (7.6 m) 023879 50 ft (15 m) 023880 75 ft (23 m) 023881 100 ft (30.5 m) 023882 125 ft (38 m)
Part No. Length
023883 150 ft (46 m) 023884 200 ft (61 m) 023885 250 ft (76 m) 023886 275 ft (84 m) 023887 300 ft (92 m)
Part No. Length
023834 15 ft (4.5 m) 023835 25 ft (7.6 m) 023836 50 ft (15 m) 023837 75 ft (23 m) 023838 100 ft (30.5 m) 023898 125 ft (38 m)
Part No. Length
023839 150 ft (46 m) 023840 200 ft (61 m) 023899 250 ft (76 m) 023900 275 ft (84 m) 023901 300 ft (92 m)
INSTALLATION
HT4001 Instruction Manual 4-17
Power Supply
9
10
Figure 4-9 Remote Serial and V/C Cables – PS to Remote V/C
Digital Remote
Programmable Remote
9
9
10
INSTALLATION
4-18 HT4001 Instruction Manual
Power Supply Connections (cont.)
Timer/Counter Cable – PS to Timer/Counter
Pass the timer/counter cable through one of the 2" bushings in the lower rear of the HT4001 power supply and connect to TB3. TB3 is located on the inside rear wall of the power supply.
PS TB3 TIMER/CNTR END COLOR END DESCRIPTION
53 Wht 1 Starts & Arc Time 52 Black 2 Starts & Arc Time 8 Drain 3 Drain 50 Red 15 Error Counter 51 Black 16 Error Counter 3 Drain 12 Drain
IHS Interface Cable – PS to IHS
See pages 4-32 through 4-35 for remaining IHS connections.
PS IHS MODULE END COLOR END DESCRIPTION
1 Red 1 IHS Complete Signal 4 Black 4 IHS Complete Common 8 Shield Drain 2 Green 2 Upper Limit Switch Signal 5 Black 3 Upper Limit Switch Common 9 Shield 5 Drain 11 Blk 9 AC Power 14 White 8 AC Power 7 Shield AC Drain
7 Key
11
PS End
12
1X9 8X1
IHS EndPS End
Tmr/Cntr End
11X1
Part No. Length
023789 10 ft (3 m) 023790 25 ft (7.5 m) 023791 50 ft (15 m)
Part No. Length
023792 75 ft (23 m) 023793 100 ft (30.5 m) 023794 150 ft (46 m)
Part No. Length
023859 25 ft (7.5 m) 023860 50 ft (15 m) 023861 75 ft (23 m)
Part No. Length
023862 100 ft (30.5 m) 023863 150 ft (46 m) 023864 200 ft (61 m)
INSTALLATION
10-98
HT4001 Instruction Manual 4-19
Figure 4-10 Timer/Counter Cable and IHS Cable Connections – PS to T/C
PS to IHS
Power Supply
12
11
Timer/Counter
TB3 – Power Supply
IHS Module
11 X 1
12
11
INSTALLATION
1-98
4-20 HT4001 Instruction Manual
Power Supply Connections (cont.)
Water Muffler Air Control Cable – PS to Water Muffler Air Control Box
See water muffler instruction manual IM173 for remaining connections to water muffler, and detailed information on the water muffler system.
PS WM AIR CNTRL END (1X11) COLOR END (10X1) SIGNAL
11 Wht 1 Water Muffler Hot 12 Black 2 AC Neutral 13 Red 3 Contactor Coil 14 Brown 4 Water Muffler Coil 6 Green 5 Ground
Water Muffler Pump Cable – PS to Water Muffler Pump
See water muffler instruction manual IM173 for remaining connections to water muffler, and detailed information on the water muffler system.
PS END (1X10) COLOR SIGNAL
2 Black Water Muffler Coil 4 White AC Neutral 3 Green Ground
13
14
1x11 10x1
PS End Air Control Box End
PS End Water Muffler
Pump End
1X10
Part No. Length
023866 50 ft (15 m) 023867 75 ft (23 m) 023868 100 ft (31 m)
Part No. Length
023905 25 ft (7.5 m) 023906 50 ft (15 m) 023907 75 ft (23 m)
Part No. Length
023908 100 ft (30.5 m) 023909 150 ft (46 m) 023910 200 ft (61 m)
INSTALLATION
HT4001 Instruction Manual 4-21
Figure 4-11 Water Muffler Connections – PS to Water Muffler
Power Supply
14
13
INSTALLATION
1-96
4-22 HT4001 Instruction Manual
RHF Console Connections
See page 4-6 for power supply connections to RHF console.
Cooling Hose Set – RHF Console to Water Chiller
There are two hoses in the hose set. For two-torch systems, double the hose order.
Caution Connect WATER OUT of the RHF console to RETURN of the water chiller, and
connect WATER IN of the RHF console to DISCHARGE of the water chiller.
Injection Water Hose – RHF Console to Gas Console
Note that the water injection hose is left-hand threaded. Turn counterclockwise to tighten. See pages 4-26 through 4-29 for remaining gas console connections.
15
See instruction manual IM241 (802410) for more information on the water chiller.
16
RED RED
GRN GRN
RED RED
Part No. Length
024335 26 in (.6 m) 024315 5 ft (1.5 m) 024046 6 ft (1.8 m) 024032 10 ft (3 m) 024261 11.5 ft (3.5 m) 024130 12 ft (3.6 m) 024132 14 ft (4.2 m)
Part No. Length
024033 15 ft (4.5 m) 024018 20 ft (6 m) 024034 25 ft (7.5 m) 024035 30 ft (9 m) 024036 35 ft (10.5 m) 024037 40 ft (12.2 m)
Part No. Length
024208 45 ft (13.7 m) 024258 50 ft (15 m) 024179 53 ft (16 m) 024128 60 ft (18 m) 024345 75 ft (23 m) 024346 100 ft (30.5 m)
Part No. Length
028652 10 ft (3 m) 028440 15 ft (4.5 m) 028653 20 ft (6 m) 028441 25 ft (7.5 m) 028442 50 ft (15 m)
Part No. Length
028443 75 ft (23 m) 028444 100 ft (30.5 m) 028445 150 ft (46 m) 028637 200 ft (61 m)
INSTALLATION
12-96
HT4001 Instruction Manual 4-23
Figure 4-12 RHF Connections to Water Chiller and Gas Console
Water Chiller
Gas Console
WATER OUT
WATER IN
15
15
16
16
DISCHARGE
RETURN
15
15
RHF Console
RHF Console
NEGATIVE (-)
NOZZLE
2X1
WATER
TORCH
INSTALLATION
6-96
4-24 HT4001 Instruction Manual
RHF Console Connections (cont.)
Shielded Torch Leads – RHF Console to Torch
Routing the Torch Leads
The leads must be routed between the RHF console and the torch before making connections. You will usually need to route the leads through a festoon or a power track. Do not have the torch connected when
routing leads.
Connecting the Torch Leads to the RHF Console
Pass the torch leads through the brass ring of the RHF console and make connections as shown in Figure 4-13. The fittings on the cathode block are color-coded to correspond with the bands on the torch leads. Match color to color. Connect pilot arc lead as shown.
Connecting the Torch Leads to the Torch
1. Slide the insulating sleeve over the torch leads with the threaded end pointing towards the unconnected torch. (The insulating sleeve will screw onto the torch later.)
2. Using a 9/16" open-end wrench on the two largest torch fittings and a 1/2" open-end wrench on the two largest lead fittings, connect the leads to the torch. Note color code on torch and torch leads.
3. Attach and hand tighten the white pilot arc lead from the torch leads to the corresponding connector on the torch body.
See page 4-26 to connect injection water hose to torch, and 4-30 to connect plasma gas lead to torch. See also page 4-38 to mount the torch to the torch mounting bracket.
17
Part No. Length
028508 10 ft (3 m) 028509 15 ft (4.5 m) 028510 20 ft (6 m) 028511 25 ft (7.5 m) 028512 30 ft (9 m)
Part No. Length
028513 35 ft (10.5 m) 028514 40 ft (12 m) 028515 45 ft (13.5 m) 028516 50 ft (15 m)
INSTALLATION
7-96
HT4001 Instruction Manual 4-25
Figure 4-13 RHF Connections to Torch – Shielded Leads
RHF Console RHF Console
Pilot Arc Lead – Pass through opening
Pilot Arc Lead – Connection
THREADED END
Torch
Green
Red
17
17
INSULATING SLEEVE
17
Green to Green
Red to Red
White to White
Cathode Block
Brass Ring
INSTALLATION
11-97
4-26 HT4001 Instruction Manual
Gas Console Connections
See page 4-10 for power supply connections to gas console, page 4-22 for RHF console connections to gas console and page 4-4 for torque specifications.
Oxygen Supply Hose – Gas Console to Oxygen Supply
Nitrogen Supply Hose – Gas Console to Nitrogen Supply
Injection Water Hose – Gas Console to Torch
1. Slide the injection water hose through the torch insulating sleeve.
2. Using a 7/16" open-end wrench on the left-handed torch fitting and a 7/16" open-end wrench on the left­handed injection water hose fitting, turn the water-hose fitting in a counterclockwise direction to tighten.
3. Make injection water hose connection at gas console (Fig. 4-14).
See page 4-30 to connect plasma gas lead to torch.
18
19
20
RED RED
Left-hand fitting
Note: If cutting with nitrogen as the
plasma gas, the oxygen hose does not need to be connected to the gas console.
Note: If cutting with oxygen as the
plasma gas, nitrogen must also be connected to the gas console to achieve the proper oxygen­nitrogen mixtures in the preflow and cut flow conditions.
Part No. Length
024335 26 in (.6 m) 024315 5 ft (1.5 m) 024046 6 ft (1.8 m) 024032 10 ft (3 m) 024261 11.5 ft (3.5 m) 024130 12 ft (3.6 m) 024132 14 ft (4.2 m)
Part No. Length
024033 15 ft (4.5 m) 024018 20 ft (6 m) 024034 25 ft (7.5 m) 024035 30 ft (9 m) 024036 35 ft (10.5 m) 024037 40 ft (12.2 m)
Part No. Length
024208 45 ft (13.7 m) 024258 50 ft (15 m) 024179 53 ft (16 m) 024128 60 ft (18 m) 024345 75 ft (23 m) 024346 100 ft (30.5 m)
Part No. Length
024204 15 ft (4.5 m) 024205 25 ft (7.5 m) 024155 50 ft (15 m)
Part No. Length
024206 100 ft (30.5 m) 024159 150 ft (46 m) 024333 200 ft (61 m)
Part No. Length
024210 10 ft (3 m) 024203 15 ft (4.5 m) 024232 20 ft (6 m) 024134 25 ft (7.5 m) 024211 35 ft (10.5 m) 024112 50 ft (15 m)
Part No. Length
024148 75 ft (23 m) 024116 100 ft (30.5 m) 024120 150 ft (46 m) 024185 180 ft (55 m) 024124 200 ft (61 m)
INSTALLATION
12-96
HT4001 Instruction Manual 4-27
Figure 4-14 Gas Console Connections – Gas Console to Gas Supplies
Gas Console to Torch
Gas Console
Gas supplies
20
18
19
18 19
Torch
INSULATING SLEEVE
20
Left-hand fitting to left-hand fitting
g
y
e
x
n
O
g
o
r
e
t
i
n
N
INSTALLATION
12-96
4-28 HT4001 Instruction Manual
Gas Console Connections (cont.)
Preflow Gas Hose – Gas Console to Motor Valve Console
Note that this hose is left-hand threaded and is tightened in a counterclockwise direction.
Cut Flow Gas Hose – Gas Console to Motor Valve Console
Gas Console/Motor Valve Console Cable – Gas Console to Motor Valve Console
See page 4-30 for remaining motor valve console connections.
SIGNAL GC END COLOR MVC END SV4A Preflow/Cutflow 16 Black 16
SV4A Preflow/Cutflow 17 Yellow 17 Ground 10 Shield 10 SV4B Preflow/Cutflow 23 Red 23 SV4B Preflow/Cutflow 24 Yellow 24 Ground 25 Shield 25 SV5 Plasma Off 29 Black 29 SV5 Plasma Off 30 Red 30 Ground 34 Shield 34 MV1 Decrease 11 Black 11 120VAC Neut. 12 Brown 12 Ground 18 Shield 18 MV1 Increase 14 Red 14 Ground 21 Shield 21
21
22
23
GRN
GRN GRN
GRN
Left-hand fitting
3X2
4X1
GC End MVC End
Part No. Length
024316 5 ft (1.5 m) 024307 10 ft (3 m) 024320 15 ft (4.5 m) 024308 20 ft (6 m) 024321 25 ft (7.5 m) 024309 30 ft (9 m) 024322 35 ft (10.5 m)
Part No. Length
024310 40 ft (12 m) 024323 45 ft (13.5 m) 024311 50 ft (15 m) 024420 56 ft (17 m) 024367 60 ft (18 m) 024357 75 ft (23 m)
Part No. Length
024317 5 ft (1.5 m) 024026 10 ft (3 m) 024027 15 ft (4.5 m) 024017 20 ft (6 m) 024028 25 ft (7.5 m) 024029 30 ft (9 m) 024030 35 ft (10.5 m)
Part No. Length
024031 40 ft (12 m) 024207 45 ft (13.5 m) 024340 50 ft (15 m) 024419 56 ft (17 m) 024127 60 ft (18 m) 024343 75 ft (23 m)
Part No. Length
023619 5 ft (1.5 m) 023646 15 ft (4.5 m) 023647 20 ft (6 m) 023583 25 ft (7.5 m) 023648 30 ft (9 m) 023649 35 ft (10.5 m)
Part No. Length
023650 40 ft (12 m) 023651 45 ft (13.5 m) 023584 50 ft (15 m) 023811 56 ft (17 m) 023691 60 ft (18 m ) 023654 75 ft (23 m)
INSTALLATION
12-96
HT4001 Instruction Manual 4-29
Figure 4-15 Gas Console Connections – Gas Console to Motor Valve Console
Gas Console
22
21
23
Motor Valve Console
22
21
23
3X2
INSTALLATION
11-97
4-30 HT4001 Instruction Manual
Motor Valve Console Connections
See page 4-28 for motor valve console connections to gas console. Make torch connections on pgs 4-24 and 4-26 before making these motor valve console to torch connections. See page 4-4 for torque specifications.
Motor Valve Console Lead Assembly – Motor Valve Console to Torch
1. Disconnect the plasma off-valve lead from the off valve.
2. Connect one end of the plasma off-valve lead to the remaining lead fitting of the torch. Use 7/16" open-end wrenches to tighten this connection (Fig. 4-16).
3. Slide the Insulating sleeve back over the torch body and screw together.
4. Reconnect the plasma off-valve lead to the off valve.
5. Make plasma-off cable and plasma lead connections at the motor valve console (Fig. 4-16).
6. Attach the torch to the torch mounting bracket. See Mounting the Machine Torch on page 4-38.
MOTOR VALVE OFF-VALVE
FUNCTION 4 X 2 WIRE COLOR CONN. Plasma Off & Vent 1 Black 1
2 Red 2 Drain 3 N/A Cut Ground 4 Clear
Part No. Length
129158 14 ft (4 m)
24
Plasma off-valve lead
Off Valve
Plasma-Off cable
Plasma lead
INSTALLATION
12-95
HT4001 Instruction Manual 4-31
Figure 4-16 Motor Valve Console to Torch Connections
TORCH BODY
INSULATING SLEEVE
24
Plasma off-valve lead connections
24
24
Motor Valve Console
INSTALLATION
2-95
4-32 HT4001 Instruction Manual
Initial Height Sensing Connections
See page 4-18 for IHS connection to power supply.
Air Supply Hose – IHS Module to Air Supply
The customer must supply the 20 psig regulated shop air and the air hose. A #4 swivel fitting (015259) comes with the IHS console assembly.
Air Hose Assembly – IHS Module to Inductive Sensor Air Cylinder
The 40-foot air hose is a component of the IHS leads packages – see page 7-47.
Inductive IHS Torch Mounting Assembly
The two inductive probes come as part of the IHS torch mounting subassembly – see page 7-47.
IHS Sensor Cables - IHS Module to IHS Probes
The 40-foot sensor cables are components of the IHS leads packages – see page 7-47.
FUNCTION PIN COLOR Power (+15 VDC) A Brown
Common B Blue Signal C Black
Part No.
005074
FUNCTION IHS END COLOR PROBE END Power (+15 VDC) 4 Red A
Common 2 Black B Signal 1 Clear C Shield 3 Braid
25
26
27
28
1
32
4
B
AC
1
32
4
B
AC
Part No. Length
024144 40 ft (12 m)
Part No. Length
023888 2 ft (.6 m) 023869 40 ft (12 m)
Part No. Length
023889 2 ft (.6 m) 023870 40 ft (12 m)
8X2 8X4
8X3 8X5
INSTALLATION
HT4001 Instruction Manual 4-33
Figure 4-17 Initial Height Sensing Connections
IHS CONTROL MODULE
SWIVEL FITTING
TORCH LIFTER
INDUCTIVE PROBES
TORCH MOUNTING BRACKET
TORCH (TYPICAL)
20 PSI REGULATED SHOP AIR
AIR CYLINDER
26
25
27
28
INSTALLATION
4-34 HT4001 Instruction Manual
Initial Height Sensing Connections (cont.)
Upper Limit Switch and Cable – Upper Limit Switch to IHS Module
Note: The customer must supply the upper limit switch option.
Switch specifications: +12 VDC @ 1.2 ma. Gold-type contacts preferred. Select a normally closed switch that opens when the lever is up (when the torch fully retracts). Install the upper limit switch behind the torch lifter as in figure 4-18.
Caution: Follow the cable installation procedure below to avoid electromagnetic
interference problems with the torch lead set.
1. Use a shielded, twisted pair of 22-24 gauge wire (stranded). Use Belden #8761.
2. At the upper limit switch, connect the common wire (black) and signal wire (clear) to the upper limit switch. Cut the shield drain wire (uninsulated). Wrap the cut end with electrician's tape.
3. At the IHS control module, loosen the two (2) latches and open the front cover.
4. Route the cable through the strain relief to connect the cable wires to 1TB.
5. Connect the shield drain wire (uninsulated) to 1TB-10 (#S). This connects the cable shield to the HT4001 frame. The shield drain must not touch the IHS module case.
6. Connect the common wire (black) to 1TB-11 (#4).
7. Connect the signal wire (clear) to 1TB-12 (#67).
Note: If the upper limit switch signal comes from an interface on the cutting machine, the shield
must be electrically isolated from other shields in other cables. Using a separate cable will avoid ground-loop problems.
INSTALLATION
HT4001 Instruction Manual 4-35
Figure 4-18 Initial Height Sensing Upper Limit Switch Connections
IHS CONTROL MODULE
TORCH LIFTER
UPPER LIMIT SWITCH AND CABLE
67 4
S
1TB
INSTALLATION
4-98
4-36 HT4001 Instruction Manual
Optional Power Supply Connections
Hold cable – PS to Second HT4001 Power Supply
When using a multi-torch system, the hold cable interfaces the two HT4001 power supplies. Make connections at TB3 on both supplies. TB3 is located on the inside rear wall of the HT4001 power supply.
PS1 PS2 END COLOR END FUNCTION
86 Black 86 Hold signal 87 Red 87 Hold common PE Shield GND Hold shield
Slave Cable – PS to H401 or H601 Power Supply
Positive Lead – PS to H401 or H601 Power Supply
Negative Lead – PS to H401 or H601 Power Supply
Positive Lead – PS to Work Table (Additional lead needed when using slave)
Negative Lead – PS to RHF Console (Additional lead needed when using slave)
When using more than 400 amps of cutting current, a slave power supply must be used with the HT4001 power supply. See Appendix A for details.
29
30
31
32
33
34
Black
Red
GND
Black
Red
GND
Part No. Length
023340 15 ft (4.5 m) 023341 25 ft (7.5 m) 023342 50 ft (15 m)
Part No. Length
023343 100 ft (30.5 m) 023344 150 ft (46 m)
INSTALLATION
HT4001 Instruction Manual 4-37
24 VAC
AUXILIARY
(INTER-
LOCKED
WITH AUTO
STOP)
Figure 4-19 Hold Cable Connections to TB3
29
INSTALLATION
4-38 HT4001 Instruction Manual
Mounting the Machine Torch
1. Install the machine torch (with torch leads attached) in the torch mounting bracket without IHS probes (Fig. 4-21) or the alternate torch mounting bracket (Fig. 4-20) if IHS is used.
2. Position the torch until the torch body extends all the way through the bracket, so that the bracket is now around the plastic torch sleeve and not touching the stainless steel torch body. Position the torch approximately .25 " (6 mm) from the workpiece.
3. Tighten the securing screw(s). See Pre-Operation in Section 5 for final adjustment of torch.
Torch Alignment
To guarantee the torch is at right angles to the workpiece, align the torch with a square at 0° and 90°. See figure 4-21.
Figure 4-21 Torch Alignment (without IHS probes)Figure 4-20 Mounting the Machine Torch
(with IHS probes)
Torch leads (typical)
Torch sleeve
Torch mounting bracket
Workpiece
90°
Securing screw
Securing screws
Torch sleeve
Torch mounting bracket
.25" 6 mm
HT4001 Instruction Manual 5-1
15
Section 5
OPERATION
In this section:
Controls and Indicators.............................................................................................................................................5-2
HT4001 Power Supply Front Panel..................................................................................................................5-2
HT4001 Power Supply Rear Panel Control......................................................................................................5-2
Gas Console ....................................................................................................................................................5-4
Digital Remote (DR) V/C Module .....................................................................................................................5-6
Programmable Remote (PR) V/C Module........................................................................................................5-7
Timer/Counter ..................................................................................................................................................5-7
Pre-Operation System Checkout ..............................................................................................................................5-8
Final Torch Adjustment ...................................................................................................................................5-11
Daily Start-Up .........................................................................................................................................................5-13
How to Optimize Cut Quality...................................................................................................................................5-15
Tips for Table and Torch .................................................................................................................................5-15
Plasma Set-up Tips........................................................................................................................................5-15
Maximize the Life of Consumable Parts.........................................................................................................5-15
Additional Factors of Cut Quality....................................................................................................................5-16
Additional Improvements................................................................................................................................5-17
Common Cutting Faults ..........................................................................................................................................5-18
Technical Questions................................................................................................................................................5-19
Cut Charts...............................................................................................................................................................5-19
Cut Chart and Consumable Parts Index .................................................................................................................5-20
Changing Consumable Parts..................................................................................................................................5-33
Removal and Inspection.................................................................................................................................5-33
Replacement ..................................................................................................................................................5-33
Changing the Water Tube ..............................................................................................................................5-35
OPERATION
11-96
5-2 HT4001 Instruction Manual
Controls and Indicators
HT4001 Power Supply Front Panel (Fig. 5-1)
POWER
AC Indicator Indicator illuminates when power up is complete.
• DC Indicator Illuminates when main contactor closes, indicating DC power is being supplied to the torch.
STATUS
• RHF DOOR LED
When illuminated, indicates that one of the door interlock switches in the RHF console is disengaged. (RHF console door is open)
• TRANSFORMER LED When illuminated, indicates that either the power supply main transformer or one of the choppers is operating in an unacceptable temperature range.
• COOLING WATER LED When illuminated, indicates that the coolant flow to the electrode is inadequate.
• PLASMA GAS LED When illuminated, indicates that the plasma gas pressure is inadequate.
HT4001 Power Supply Rear Panel Control (Fig. 5-2)
POWER
•UPPosition (I)
In this position, AC is sent to the control transformer, turning the power supply on.
• DOWN Position (O) In this position, AC is cut off to the control transformer, turning the power supply off.
OPERATION
HT4001 Instruction Manual 5-3
Figure 5-1 Power Supply Front Panel Indicators
Figure 5-2 Power Supply Rear Panel Circuit Breaker
STATUS
-RHF DOOR
-TRANSFORMER
-COOLING WATER
-PLASMA GAS
OPERATION
5-4 HT4001 Instruction Manual
Controls and Indicators (cont.)
Gas Console (Fig. 5-3)
PLASMA N2/O2Toggle Switch (S1)
Selects the use of either nitrogen or oxygen as the plasma cutting gas.
Test Preflow / Run / Test Cut Flow Toggle Switch (S2)
Test Preflow – Used when setting the plasma gas preflow flow rates on the flow meters as specified in the
Cut Charts. In this position the contactor is disabled.
N2 (FM1) and O2(FM2) flow meters - In test preflow, indicate the percentage of plasma gas flow, nitrogen
or oxygen/nitrogen mix, required for pre-cut conditions.
N2 Preflow (MV2) and O2 Preflow (MV3) metering valves - Adjusts plasma gas preflow.
Test Cut Flow – Used when setting the plasma gas cut flow rate on the N2 or O2 flow meter for cutting
conditions as specified in the Cut Charts. In this position the contactor is disabled.
N2 (FM1) or O2(FM2) flow meter – In test cut flow, indicates the percentage of plasma gas flow, oxygen or
nitrogen, required for cutting conditions.
PLASMA Cut Flow motor valve (MV1) (Activated by momentary switch) – Adjusts plasma gas test cut flow.
Run – Enables the contactor and the subsequent firing of the arc after the gas flow rates have been set in the Test Preflow and Test Cut Flow positions and the H2O Injection (torch water injection) as described below has been set.
H2O Injection flow meter (FM3) – Indicates the percentage of injection water flow as indicated in the Cut Charts.
• H2O Injection metering valve (MV4) – Adjusts injection water flow as indicated in the Cut Charts.
OPERATION
6-95
HT4001 Instruction Manual 5-5
Figure 5-3 Gas Console Front Panel Controls and Indicators
(FM1)
(S1)
(FM2) (FM3)
(PG1)
(PG2)
(PG3)
(MV2)
(MV1) (S2)
(MV3) (MV4)
HT4001
HYPERTHERM
OPERATION
5-6 HT4001 Instruction Manual
Controls and Indicators (cont.)
Digital Remote (DR) V/C Module (Fig. 5-4)
VOLTAGE Adjust Pot
Adjusts the cutting arc voltage from 90 to 205 volts. Values are chosen from the Cut Charts and depend on the type of metal to cut, and metal thickness.
VOLTAGE LEDs
Displays cutting voltage.
CURRENT Adjust Pot
Adjusts the cutting arc current from 90 to 800 amps. Values are chosen from the Cut Charts and depend on the type of metal to cut, and metal thickness.
CURRENT LEDs
Displays cutting current.
UP / DOWN LEDs
Indicates that torch height is being adjusted up or down.
Figure 5-4 Digital Remote (DR) V/C Front Panel Controls and Indicators
Voltage Adjust Pot Current Adjust Pot
OPERATION
HT4001 Instruction Manual 5-7
Programmable Remote (PR) V/C Module (Fig. 5-5)
VOLTAGE LEDs
Displays cutting voltage during cut sequence.
CURRENT LEDs
Displays cutting current during cut sequence.
UP / DOWN LEDs
Indicates that torch height is being adjusted up or down.
Timer/Counter (Fig. 5-6)
Each LCD counter is self-powered by a three-volt lithium battery.
STARTS LCD Counter (w/Reset) Indicates the number of arc starts.
ARC TIME LCD Counter Indicates the cumulative time that the arc is on in hours.
ERRORS LCD Counter (w/Reset) Indicates the number of times that the arc cut cycle ends before the programmed current ramp down time has elapsed. This reading provides a direct correlation to the long-life operation of the electrode; the higher the reading, the shorter the electrode life.
Figure 5-5 Programmable Remote (PR) V/C Front Panel Indicators
Figure 5-6 Timer / Counter Front Panel Indicators
Reset Reset
OPERATION
6-95
5-8 HT4001 Instruction Manual
Pre-Operation System Checkout
Figure 5-7 Gas Console Reference – Pre-Operation
N2Flow meter
S1
MV2 MV1 MV3 S2 MV4
O2Flow meter
N2Press. Gauge
Water Flow meter
O
2
Press.
Gauge
The following procedure is for an HT4001 system with a water chiller, an IHS system with upper limit switch, and a Digital Remote (DR) V/C control module.
1. Set the main disconnect switches for the power supply and the water chiller to OFF.
2. Set the S2 toggle switch on the gas console to Run.
WARNING
Before operating this system, you must read the Safety section thoroughly! Wear proper clothing. Your cutting environment must meet requirements outlined in the Safety section. Turn main disconnect switches to the HT4001 power supply and water chiller OFF before proceeding.
HYPERTHERM
HT4001
OPERATION
3-97
HT4001 Instruction Manual 5-9
3. Verify that the proper consumables are installed in the torch. Refer to the Cut Charts to choose the correct consumables for your cutting needs. See also Changing Consumable Parts later in this section.
4. Turn the required supply gas ON.
Set the pressure on the nitrogen supply to read 150 psi +/- 10 psi (10.3 bar +/- 0.7 bar) at the N2 pressure gauge on the gas console.
Set the pressure on the oxygen supply to read 120 psi +/- 10 psi (8.3 bar +/- 0.7 bar) at the O2 pressure gauge on the gas console.
5. Turn the water supply to the water chiller ON.
6. Set the main disconnect switch for the water chiller to the ON position and depress the START switch on the water chiller. Outlet water pressure should read between 175-185 psi (12-12.8 bar) on the water chiller gauge. See IM241 Water Chiller Model D instruction manual for adjustment procedure, if necessary.
7. Set S1 on the gas console to plasma gas N2or O2.
8. Set the main disconnect switch for the power supply to ON and throw the POWER circuit breaker on the rear of the power supply to the UP position. Verify that the POWER AC indicator illuminates.
9. Set the VOLTAGE and CURRENT on the DR V/C module. Select the arc current and voltage from the Cut Charts for the type and thickness of metal to test cut.
Notes: If using the H-401 power supply as a slave and you need to reduce the existing arc
current level, lower the current to below 360A on the remote V/C before resetting to the desired value.
If using the H-401 power supply as a slave, note that the current control adjust knob on the front of the H-401 supply will have no effect on setting current for the slave.
10. Set the S2 toggle switch to Test Preflow. Set the preflow flow rate(s) on the O2 and/or N2flow meters using the MV2 and MV3 metering valve. Select the test preflow rates from the Cut Charts.
11. Set S2 to Test Cut Flow. Set the cut flow rate on the O2 or N2flow meters using the MV1 metering valve.
Select the test cut flow rates from the Cut Charts.
12. Check the water flow rate at the water flow meter and adjust with MV4, if necessary. Water flow rates are specified in the Cut Charts.
13. Verify that there is a uniform conical water pattern at the front of the torch. If the pattern is irregular, shut the power supply down at the main disconnect switch and check the nozzle and swirl ring. Replace with new parts, if worn or damaged.
14. Set S2 to Run after setting the preflow and cut flow rates.
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