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.