Hypertherm HT4001 User Manual

HT4001

®

Plasma Arc
Cutting System

Instruction Manual
802000 – Revision 18

EN60974-1
EN50199

1

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

2

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

3

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

4

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

5

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)

[e-mail] (Main Office Email)

800-643-9878 Tel (Technical Service)

[e-mail] (Technical Service Email)

800-737-2978 Tel (Customer Service)

[e-mail] (Customer Service Email)

Hypertherm Automation, LLC

5 Technology Drive, Suite 300

West Lebanon, NH 03755 USA

603-298-7970 Tel

603-298-7977 Fax

Hypertherm Plasmatechnik, GmbH

Technologiepark Hanau

Rodenbacher Chaussee 6

63457 Hanau-Wolfgang, Deutschland

49 6181 58 2100 Tel

49 6181 58 2134 Fax

49 6181 58 2123 (Technical Service)

Hypertherm (S) Pte Ltd.

No. 19 Kaki Bukit Road 2

K.B. Warehouse Complex

Singapore 417847, Republic of Singapore

65 6 841 2489 Tel

65 6 841 2490 Fax

65 6 841 2489 (Technical Service)

Hypertherm UK, Ltd.

9 Berkeley Court, Manor Park

Runcorn, Cheshire, England WA7 1TQ

44 1928 579 074 Tel

44 1928 579 604 Fax

France

15 Impasse des Rosiers

95610 Eragny, France

00 800 3324 9737 Tel

00 800 4973 7329 Fax

Hypertherm S.r.l.

Via Torino 2

20123 Milano, Italia

39 02 725 46 312 Tel

39 02 725 46 400 Fax

39 02 725 46 314 (Technical Service)

Hypertherm Europe B.V.

Vaartveld 9

4704 SE Roosendaal, Nederland

31 165 596907 Tel

31 165 596901 Fax

31 165 596908 Tel (Marketing)

31 165 596900 Tel (ETSO – Technical Service)

00 800 49 73 7843 Tel (ETSO – Technical Service

toll-free in Europe)

Japan

1952-14 Yata-Natsumegi

Mishima City, Shizuoka Pref.

411-0801 Japan

81 0 559 75 7387 Tel

81 0 559 75 7376 Fax

Hypertherm Brasil Ltda.

Rua Visconde de Santa Isabel, 20 – Sala 611

Vila Isabel, RJ

Brasil CEP 20560-120

55 21 2278 6162 Tel

55 21 2578 0947 Fax

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.

1-98

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

11-96

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

1-98

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

1-98

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

1-98

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

0°

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.