HT4100
Plasma Arc
Cutting System
- Operation -
Instruction Manual
801660 - Rev. 4
®
HT4100
Plasma Arc Cutting System
- Operation -
Instruction Manual
IM-166
(P/N 801660)
for Serial Numbers
beginning with
4100-000001
Revision 4 June, 1996
HYPERTHERM, Inc.
P.O. Box 5010
Hanover, New Hampshire 03755-5010
Tel.: (603) 643-3441
Fax: (603) 643-5352
© Copyright 1996 Hypertherm, Inc.
All Rights Reserved
HYPERTHERM HT and MAX are trademarks of Hypertherm, Inc. and may be
registered in the United States and/or other countries
WARRANTY
ATTENTION
Genuine Hypertherm parts are the factory-recommended replacement parts
for your Hypertherm system. Any damage caused by the use of other than
genuine Hypertherm parts is not covered by the Hypertherm warranty.
HT4100 Instruction Manual: Operation
i
WARRANTY AND DISCLAIMERS
GENERAL
HYPERTHERM, Inc. warrants that Products shall be free from defects in materials and workmanship, under proper and normal
use for which such Equipment is recommended, for a period of two (2) years, except only with respect to the Torch, for which
the warranty period shall be one (1) year, from the date of its delivery to you
HYPERTHERM, at its sole option, shall repair, replace, or adjust, free of charge, any 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, all costs, insurance and freight prepaid, and which examination proves not to be free from defects in materials and workmanship. HYPERTHERM shall not be liable for any repairs,
replacements, or adjustments of Products covered by this warranty, except those made pursuant to this paragraph or with
HYPERTHERM's written consent. This warranty shall not apply to any Product which has been mishandled, incorrectly
installed, modified or assembled by you or any other person. HYPERTHERM shall be liable for breach of this warranty only if it
receives written notice of such breach within the applicable warranty period specified herein above. THE FOREGOING SHALL
CONSTITUTE THE SOLE REMEDY TO DISTRIBUTORS OR THEIR CUSTOMERS FOR ANY BREACH BY HYPERTHERM
OF ITS WARRANTY.
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 agrees to indemnify, protect and hold harmless
Distributors and their customers against any and all liability or claims in any manner imposed upon or accruing against
Distributors and their customers because of the use in or about the construction or operation of Equipment or any design,
system, formula, combination, article or material which infringes or alleges to infringe on any patent or other right. Distributors
shall notify HYPERTHERM promptly upon learning of any action or threatened action in connection with any such alleged
infringement, and each party may appoint its own counsel for any such action or threatened action.
.
DISCLAIMER OF OTHER WARRANTIES
HYPERTHERM MAKES NO WARRANTIES REGARDING PRODUCTS MANUFACTURED BY IT OR OTHERS (INCLUDING
WITHOUT IMPLIED LIMITATION WARRANTIES AS TO MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE), EITHER EXPRESS OR IMPLIED, EXCEPT AS PROVIDED HEREIN. This warranty is in lieu of any and all warranties,
express or implied, by law or otherwise; and Distributors are not authorized to give any other warranty purporting to be binding
upon HYPERTHERM upon resale of Products to their customers. IN NO EVENT shall HYPER-THERM be liable for incidental
or consequential damages or injury to the person or property of anyone by reason of any defect in any Equipment sold
hereunder.
PLUMBING AND ELECTRICAL 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 incidental or consequential injury to persons or property damage by
reason of any code violation or poor work practices.
ii
HT4100 Instruction Manual: Operation
7-99
TABLE OF CONTENTS
Section 1 SAFETY ..............................................................................................1-1
Introduction ............................................................................................................1-2
Notes, Cautions & Warnings ..................................................................................1-2
Safety Instructions..................................................................................................1-4
Burn Prevention ................................................................................................1-4
Toxic Fume Prevention .....................................................................................1-5
Fire Prevention ................................................................................................. 1-5
Electric Shock Prevention .................................................................................1-6
Explosion Prevention ........................................................................................1-7
Grounding .........................................................................................................1-8
Safety Reminders...................................................................................................1-9
Standards Index .....................................................................................................1-9
Section 2 INTRODUCTION & SPECIFICATIONS ..............................................2-1
Introduction ............................................................................................................2-2
General .............................................................................................................2-3
HT4100 Master Power Supply ..........................................................................2-3
HT4100 Slave Power Supply ............................................................................2-3
High Frequency (HF) Console ..........................................................................2-3
Remote Voltage/Current (V/C) Control .............................................................2-4
Gas Console .....................................................................................................2-4
Motor Valve Console ........................................................................................ 2-4
Timer/Counter ...................................................................................................2-4
Water Chiller .....................................................................................................2-5
Initial Height Sensing (IHS)...............................................................................2-5
Specifications .........................................................................................................2-6
System Requirements ...................................................................................... 2-6
HT4100 Power Supplies (Master & Slave) .......................................................2-6
PAC610 Machine Torch....................................................................................2-7
High Frequency Console ..................................................................................2-7
Switch Remote (SR) V/C Control......................................................................2-7
Digital Remote (DR) V/C Control ......................................................................2-8
Programmable Remote (PR) V/C Control.........................................................2-8
Gas Console .....................................................................................................2-9
Water Chiller .....................................................................................................2-9
Motor Valve Console ........................................................................................ 2-9
Initial Height Sensing ........................................................................................2-9
Timer/Counter ...................................................................................................2-9
HT4100 Instruction Manual: Operation
iii
12-14-92
TABLE OF CONTENTS
Section 3 OPERATION .......................................................................................3-1
Front Panel Controls and Indicators.......................................................................3-2
HT4100 Master Power Supply ..........................................................................3-2
HT4100 Slave Power Supply ............................................................................ 3-2
Gas Console ..................................................................................................... 3-4
Digital Remote (DR) V/C Module ...................................................................... 3-6
Programmable Remote (PR) V/C Module ........................................................ 3-6
Timer/Counter ................................................................................................... 3-8
Daily Start-Up ......................................................................................................... 3-9
Common Cutting Faults ....................................................................................... 3-10
Technical Questions ..............................................................................................3-11
Cut Charts .............................................................................................................3-11
Changing Consumable Parts ............................................................................... 3-14
Removal and Inspection ................................................................................. 3-14
Replacement................................................................................................... 3-14
Changing the Water Tube ............................................................................... 3-15
Routine Inspection and Cleaning ......................................................................... 3-16
Power Supplies ............................................................................................... 3-16
Water Chiller ................................................................................................... 3-16
Interconnections ............................................................................................. 3-16
Section 4 STANDARDS INDEX ..........................................................................4-1
Standards Index .....................................................................................................4-2
APPENDIX .............................................................................................................a-1
IEC Symbols Used .................................................................................................a-1
GLOSSARY ...........................................................................................................g-1
iv
HT4100 Instruction Manual: Operation
12-14-92
TABLE OF CONTENTS
ILLUSTRATIONS
Figure 3-1 Master Power Supply Front Panel Controls and Indicators ............... 3-3
Figure 3-2 Slave Power Supply Front Panel Indicators ....................................... 3-3
Figure 3-3 Gas Console Front Panel Controls and Indicators ............................ 3-5
Figure 3-4 Digital Remote (DR) V/C Front Panel Controls and Indicators .......... 3-7
Figure 3-5 Programmable Remote (DR) V/C Front Panel Indicators.................. 3-7
Figure 3-5ASwitch Remote (SR) V/C Front Panel Controls and Indicators ........ 3-7A
Figure 3-6 Timer/Counter Front Panel Controls and Indicators .......................... 3-8
Figure 3-7 Changing Consumable Parts........................................................... 3-15
Figure 3-8 Changing the Water Tube ................................................................ 3-16
HT4100 Instruction Manual: Operation
v
12-14-92
Section 1 SAFETY
In this section:
Introduction ......................................................................................... 1-2
Notes, Cautions & Warnings ............................................................... 1-2
Safety Instructions............................................................................... 1-4
Burn Prevention .............................................................................. 1-4
Toxic Fume Prevention ................................................................... 1-5
Fire Prevention ............................................................................... 1-5
Electric Shock Prevention............................................................... 1-6
Explosion Prevention ...................................................................... 1-7
Grounding ....................................................................................... 1-8
Safety Reminders................................................................................ 1-9
Standards Index .................................................................................. 1-9
HT4100 Instruction Manual: Operation
1-1
SAFETY
INTRODUCTION
Abbreviated safety precautions are printed on the power supply.
Before using the plasma arc cutting equipment (including compressed gas),
each person operating, maintaining or supervising the use of this equipment
must read the following safety instructions.
NOTES, CAUTIONS & WARNINGS
Throughout this manual, notes, cautions, and warnings are used to describe situations that require additional information. The following formats are used for each:
Notes: A note offers additional information, such as an operating tip, that aids the
user in operating the plasma system.
Caution: A caution describes a situation that may cause damage to the plasma
system and offers advice to avoid or rectify the situation.
WARNING
A warning describes a situation that presents a physical danger to the
operator, and offers advice to avoid or rectify the situation. Each type of
warning displays an applicable danger symbol, ie. fire, explosion, electrical shock, etc.
1-2
HT4100 Instruction Manual: Operation
SAFETY
WARNING
ELECTRIC SHOCK CAN KILL.
• Do not touch live electrical parts.
• Keep all panels and covers in place when the machine is connected to a
power source.
• Insulate yourself from work and ground: wear insulating gloves, shoes and
clothing.
• Keep gloves, shoes, clothing, work area, torch, and this machinery dry.
EXPLOSION WILL RESULT IF PRESSURIZED CONTAINERS ARE CUT.
ARC RAYS CAN INJURE EYES AND BURN SKIN.
• Wear correct eye and body protection.
NOISE CAN DAMAGE HEARING.
• Wear correct ear protection.
FUMES AND GASES CAN INJURE YOUR HEALTH.
• Keep your head out of the fumes.
• Provide ventilation, exhaust at the arc, or both to keep the fumes and
gases from your breathing zone and the general area.
• If ventilation is inadequate, use an approved respirator.
HEAT, SPLATTER AND SPARKS CAUSE FIRE AND BURNS.
• Do not cut near combustible material.
• Do not cut containers that have held combustibles.
• Do not have on your person any combustibles such as a butane lighter or
matches.
• Pilot arc can cause burns. Keep the torch nozzle away from yourself and
others when the switch is depressed.
• Wear correct eye and body protection.
HT4100 Instruction Manual: Operation
1-3
SAFETY
SAFETY INSTRUCTIONS
Burn Prevention
Eye
Safety
To protect eyes against burns caused by high-intensity ultraviolet light, sparks and
hot metal:
• Wear dark safety glasses/goggles with side shields or a welding helmet. Refer to
the chart below for recommended lens shades:
Arc Current Shield Shade
Up to 100 Amps Shade No. 8
100 - 200 Amps Shade No. 10
200 - 400 Amps Shade No. 12
Over 400 Amps Shade No. 14
• Replace the glasses/goggles or helmet when the shield becomes pitted or
broken.
• Warn other people in the area not to look directly at the arc unless they wear a
glasses/goggles or helmet.
• Prepare the cutting area in a manner that reduces the reflection and transmission
of ultraviolet light:
- Paint walls and other surfaces with dark colors to reduce reflection.
Skin
Safety
1-4
- Install protective screens or curtains to reduce ultraviolet transmission.
To protect skin against burns caused by high-intensity ultraviolet light, sparks and hot
metal:
• Wear protective clothing:
- Gauntlet gloves, safety shoes and hat.
- Flame-retardant clothing which covers all exposed areas.
- Cuffless trousers to prevent entry of sparks and slag.
• Hold any hand torch away from your body when pressing the start button because
the pilot arc may come on immediately.
HT4100 Instruction Manual: Operation
• Do not touch the front of the torch when starting it. After cutting, allow time for the
front of the torch to cool.
Toxic Fume Prevention
To protect against the danger of toxic fumes which may be produced during cutting:
• Keep the cutting area well-ventilated.
• Remove all chlorinated solvents from the cutting area before cutting. Certain
chlorinated solvents decompose when exposed to ultraviolet radiation to form
phosgene gas.
• Wear proper breathing mask when cutting galvanized metal and use proper
ventilation.
• Do not cut containers with toxic materials inside or containers that have held toxic
materials. Clean such containers thoroughly before cutting.
SAFETY
Fire Prevention
Cutting with a plasma system produces hot metal, sparks and slag. Take the following precautions against fire:
• Make fire extinguishers available in the cutting area.
• Remove combustible material from the immediate cutting area to a distance of at
• Quench freshly cut metal or allow metal to cool before handling it or bringing it into
• Never use a plasma system to cut containers with potentially flammable materials
WARNING
Do not cut metal or painted metals containing zinc, lead, cadmium or beryllium unless the operator, or anyone else subjected to the fumes, is wearing
respiratory equipment or an air-supplied helmet.
least 35 feet (10 meters).
contact with combustible materials.
inside. Such containers must be thoroughly cleaned prior to cutting.
HT4100 Instruction Manual: Operation
1-5
SAFETY
• Ventilate potentially flammable atmospheres before cutting with a plasma system.
Never operate the plasma system in an atmosphere which contains heavy concentrations of dust, flammable gas or combustible liquid vapors.
Electric Shock Prevention
All Hypertherm plasma systems use high voltage (up to 280 VDC) to initiate the
plasma arc. Take the following precautions when operating the plasma system:
• Keep your body and clothing dry.
• Do not stand in, sit on or lie on any wet surface when using the plasma system.
• Maintain proper insulation against electrical shock. If you must work in or near a
damp area, use extreme caution. Wear insulated gloves and boots.
• Provide a wall-mounted disconnect switch with proper size fuses close to the
power supply. This switch allows the operator to turn the power supply off quickly
in an emergency situation.
• Conform to all local electrical codes for primary wiring sizes and types.
• Inspect the primary power cord frequently for damage or cracking of the cover.
Bare wiring can kill. Do not use the system with a damaged power cord. If a
power cord is damaged, replace it immediately.
• Inspect the torch leads. Replace if frayed or damaged.
• Never operate the plasma system unless the power supply unit covers are in
place. Exposed power supply connections present a severe electrical hazard.
• 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 at all times.
• Before changing the torch parts, disconnect the main power or unplug the power
supply. After changing the torch parts and returning the retaining cap to its
operating position, plug the power supply in again.
• Never bypass or shortcut the safety interlocks.
• Before removing a power supply cover for maintenance, disconnect the main
power at the wall disconnect switch or unplug the power supply. To avoid exposer
to severe electrical hazard, wait five minutes after disconnecting the main power
to allow capacitor discharge to occur.
1-6
HT4100 Instruction Manual: Operation
Explosion Prevention
The plasma system uses compressed gas. Proper precautions must be
observed when handling and using compressed gas equipment and cylinders. Refer to the Standards Index in this manual.
When cutting with the plasma system:
• Do not cut in atmospheres containing explosive dust or vapors.
• Do not cut pressurized cylinders or any closed container.
SAFETY
WARNING
Pressure
Regulators
Compressed
Gas
Cylinders
• Maintain all pressure regulators in proper working condition. Faulty regulators can
cause damage or operator injury and must be serviced by trained repair technicians.
• Never use a regulator for any gas other than that for which it is intended.
• Never use a regulator that leaks, creeps excessively or is physically damaged in
any way.
• Never attempt to lubricate a regulator with oil or grease.
• Handle and use compressed gas cylinders in accordance with safety standards
published by the Compressed Gas Association (CGA ), American Welding Society
(AWS) and Canadian Standards Association (CSA).
• Never use a cylinder that leaks or is physically damaged.
• Never use a cylinder that is not upright and secured in place.
• Never move or transport a cylinder without the protective valve cover in place.
• Never use a gas cylinder or its contents for any purpose other than that for which
it is intended.
• Never lubricate cylinder valves with oil or grease.
HT4100 Instruction Manual: Operation
1-7
SAFETY
• Never allow electrical contact between the plasma arc and a cylinder.
• Never expose cylinders to excessive heat, sparks, slag or open flame.
• Never use hammers, wrenches or other tools to open stuck cylinder valves.
Hoses
Grounding
Input
Power
Label and color-code all gas hoses in order to clearly identify the type of gas in each
hose. Consult applicable national or local codes.
• Never use the oxygen hose for any gas other than oxygen.
• Replace hose that is damaged by physical abuse or by sparks, heat or open
flame.
• Lay hose out straight to prevent kinks.
• Coil excess hose and place it out of the way to prevent damage and to eliminate
tripping danger.
• Examine hoses at regular intervals for leaks, wear, loose connections or other
hazard.
• Keep hose lengths to a minimum to prevent damage, reduce pressure drop and to
prevent possible volume flow restriction.
Before operating the plasma system:
• Be sure the power cord is plugged into a properly grounded outlet or that the
power cord ground wire is properly connected to the ground in the disconnect box.
Work
Table
Work
Table
1-8
• If installation of the plasma system involves connecting the power cord to the
power supply, ensure that the power cord ground wire is properly connected.
Conform to CSA standards by placing the power cord ground wire on the stud
first; then place the other wires on top of the power cord ground. Fasten the
retaining nut tightly.
• Make sure that all electrical connections are tight to avoid excessive heating.
• Clamp the work cable with good metal-to-metal contact to the workpiece (not the
portion that will fall away) or to the work table.
• Connect the work table to a good earth ground. Consult the U.S. National Electrical Code, Article 250, Section H
ate national or local codes.
For additional information, refer to the
Grounding Electrode System
Standards Index
in this manual.
, or other appropri-
HT4100 Instruction Manual: Operation
SAFETY REMINDERS
• All Hypertherm torches are designed with a safety interlock, which turns off the
power supply when the retaining cap is loosened.
• Never bypass or shortcut the safety interlocks on any of the plasma system units.
• Never operate the plasma system with any of its covers not in place. This would
be hazardous to the operator and other people in the area, and prevents the
proper cooling of the equipment.
• 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 potentially dangerous situation to the operator and any personnel in the
area.
STANDARDS INDEX
The
Standards Index
equipment safety practices. For additional information, refer to this
SAFETY
contains a list of publications dealing with plasma arc cutting
Standards Index
.
HT4100 Instruction Manual: Operation
1-9
Section 2 INTRODUCTION & SPECIFICATIONS
In this section:
Introduction ......................................................................................... 2-2
General ........................................................................................... 2-3
HT4100 Master Power Supply........................................................ 2-3
HT4100 Slave Power Supply.......................................................... 2-3
High Frequency (HF) Console ........................................................ 2-3
Remote Voltage/Current (V/C) Control ........................................... 2-4
Gas Console ................................................................................... 2-4
Motor Valve Console ...................................................................... 2-4
Timer/Counter................................................................................. 2-5
Water Chiller ................................................................................... 2-5
Initial Height Sensing (IHS) ............................................................ 2-5
Specifications ...................................................................................... 2-6
System Requirements .................................................................... 2-6
HT4100 Power Supplies (Master & Slave) ..................................... 2-6
PAC610 Machine Torch .................................................................. 2-7
High Frequency Console ................................................................ 2-7
Switch Remote (SR) V/C Control ................................................... 2-7
Digital Remote (DR) V/C Control .................................................... 2-8
Programmable Remote (PR) V/C Control ...................................... 2-8
Gas Console ................................................................................... 2-9
Water Chiller ................................................................................... 2-9
Motor Valve Console ...................................................................... 2-9
Initial Height Sensing ...................................................................... 2-9
Timer/Counter................................................................................. 2-9
HT4100 Instruction Manual: Operation
2-1
INTRODUCTION & SPECIFICATIONS
INTRODUCTION
The instructions to install, operate and maintain the HT4100 system have been separated
into three manuals. The following is a list of the manual titles, part numbers, and contents:
HT4100 Instruction Manual: Installation (#801650)
This manual gives pertinent information for the pre-installation supply requirements,
installation, and post-installation requirements for the HT4100 system.
Also included in this manual are specifications of the components of the HT4100 system,
system interconnect diagrams, and accompanying drawings.
HT4100 Instruction Manual: Operation (#801660)
This manual describes the controls and indicators for the system units, explains how to
start-up and operate the HT4100 system, contains cut chart tables, gives instructions to
remove and replace consumable parts, and provides routine inspection and cleaning
information.
HT4100 Instruction Manual: Maintenance (#801670)
This manual contains basic troubleshooting tips, and a parts list.
It is our hope that this manual set will aid and answer most questions on installing,
operating, and ordering parts for your HT4100 system.
If any questions do arise, please call our Customer Service at 1-800-643-0030 or Field
Service group at 1-800-643-9878.
.
2-2
HT4100 Instruction Manual: Operation
INTRODUCTION & SPECIFICATIONS
General
Hypertherm’s HT4100 is designed as a machine-mounted plasma cutting system for
cutting mild steel from gauge to one and one-half inch (38 mm) thick using oxygen as
the plasma gas. A micro-controller on the Master power supply control board helps to
provide extended life for the torch consumable parts. To achieve consumable long
life, all cuts must begin and end on the plate surface; this allows for the proper
ramping of gases and DC current to extend the life of the torch nozzle and electrode.
The HT4100 system provides the user with capability of locating the power supply
and the torch apart by a maximum of 300 feet (91 m). This is accomplished by
adding a remote High Frequency (HF) Console.
Maximum DC output for clean, dross-free cuts using oxygen with the HT4100 system, is 300 amps (See
descriptions briefly describe the purpose and configuration of the major units which
comprise the HT4100 System.
HT4100 Master Power Supply
This unit houses two 100-amp, 15kHz 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 HF console, IHS, computer interface, remote V/
C, gas console, the HT4100 Slave power supply, and the workpiece.
Cut Charts
in the Operation section of IM166). The following
HT4100 Slave Power Supply
This unit also houses two 100-amp, 15kHz chopper power supplies. When interconnected with the HT4100 Master power supply, up to 400 amps is made
available to the cutting system. The Slave interfaces with the Master supply, and
the Timer/Counter unit.
High Frequency (HF) Console
This unit houses the high frequency starting circuit which permits more effective RF
shielding and allows the power supplies to be installed at a distance of up to 300 feet
(91 m) from the torch. Also located in the console are two door interlock switches,
and a cooling water flow switch.
HT4100 Instruction Manual: Operation
2-3
8-96
INTRODUCTION & SPECIFICATIONS
Remote Voltage/Current (V/C) Control
This unit provides accurate operator control of the arc voltage and current. It includes high intensity LED displays which indicate the setpoints for volts and amperes
prior to starting the arc. After the arc is initiated, the displays automatically switch to
show the actual values of the voltage and current reached. This unit interfaces with
the Master power supply. Three different types of remote V/C controls are
available:
Switch Remote - Includes the voltage and current displays and two potentiometers
used to select the desired values. Also included are start and stop switches for the
power supply, switches for activating the torch height control (THC), and initial height
sensing (IHS) circuits. This unit is for use on guidance machinery that does not
include switches to control the initial height sensing and torch height functions.
Digital Remote - Includes the voltage and current displays and two potentiometers
used to select the desired values. It is used with guidance machinery that already
includes plasma control switches.
Programmable Remote - Includes the voltage and current displays. No switches or
potentiometers are included. All functions are controlled by the guidance machinery
computer. This unit also interconnects with the computer interface.
Gas Console
This unit houses solenoid valves for plasma and shield gas flow control as well as
flowmeters for plasma and shield gas flow, metering valves for plasma and shield gas
preflow, metering valves for shield gas operating flow, and three switches: one to
choose between oxygen or nitrogen, another to select either test preflow, test operate
flow, or run modes, and a third to adjust plasma operate flows during operate mode.
The gas console interfaces with the gas supplies, the motor valve console and the
Master power supply.
Motor Valve Console
This unit houses a motor-driven plasma gas metering valve as well as solenoid
valves to switch the plasma gas and shield gas from preflow to operate modes.
Plasma preflow and operate gas lines as well as shield preflow and operate
lines and interface cable connect the motor valve console to the gas console. The
motor valve console also interfaces with the torch via a lead set consisting of a
plasma gas hose, shield gas hose and a plasma-off valve control cable.
Note: The motor valve console must be mounted 10 feet (3 m) from the torch.
2-4
1-93
HT4100 Instruction Manual: Operation
INTRODUCTION & SPECIFICATIONS
Timer/Counter
The timer/counter is provided so that the number of arc starts and arc-on time can
be monitored. This unit is interfaced to the HT4100 Slave power supply.
Water Chiller
The water chiller for the HT4100 system is a refrigeration unit that is capable of
reducing the water coolant temperature well below ambient air and water supply
temperature. Having this capabililty greatly increases the life of the nozzle and
electrode. The water chiller is a three-phase power system that directly interfaces
with the HF console. See
section of this manual.
Initial Height Sensing (IHS) - Optional
This unit, used with two inductive probes, is designed to automatically detect the
workpiece surface and index the torch to the pierce position. This system can be
used for underwater, at the water line, or above-water applications. This unit interconnects with the Master power supply and the inductive probes, and requires an air
supply to operate.
Water Supply Requirements
in the Pre-Installation
HT4100 Instruction Manual: Operation
2-5
INTRODUCTION & SPECIFICATIONS
SPECIFICATIONS
System Requirements
Power Requirements:
Refer to HT4100 power supply specifications below:
Gas Requirements:
Plasma Gas Type .........................................Oxygen (O2), *Nitrogen (N2)
Shield Gas Types .........................................Oxygen (O2), and Nitrogen (N2) mixture
Gas Quality
Oxygen .................................................. 99.5% pure (liquid gas recommended)
Nitrogen .................................................99.995% pure (liquid gas recommended)
Oxygen Gas Inlet Pressure ..........................120 psi (8.3 bar)
Nitrogen Gas Inlet Pressure .........................120 psi (8.3 bar)
Oxygen Gas Inlet Flowrate...........................127 scfh (60 l/min) at fullscale
Nitrogen Gas Inlet Flowrate .........................338 scfh (160 l/min) at fullscale
* Nitrogen is used for plasma gas preflow
HT4100 Power Supplies (Master & Slave)
Maximum OCV (U0) ......................................275 VDC
Maximum Output Current (I2) .......................400 amps
Output Voltage (U2) ......................................150 VDC
Duty Cycle Rating (X)...................................100%
Ambient Temperatures/Duty Cycle ...............Power supplies will operate between
+14° and 104°F (-10° and +40°C).
Power supplies operated in an ambient
temperature above 86°F (30C) may
show some decrease in duty cycle.
Cooling .........................................................Forced Air (Class F)
Input Power: (U1 - Input Voltage ; I1 - Input Current):
#073086 (Master)/ #073087 (Slave) ............200 VAC (U1), 3PH, 50 Hz @ 108A (I1)
#073089 (Master)/ #073090 (Slave) ............240 VAC (U1), 3PH, 60 Hz @ 90A (I1)
480 VAC (U1), 3PH, 60 Hz @ 45A (I1)
#073095 (Master)/ #073096 (Slave) ............220 VAC (U1), 3PH, 50 Hz @ 101 A (I1)
380 VAC (U1), 3PH, 50 Hz @ 58A (I1)
415 VAC (U1), 3PH, 50 Hz @ 54A (I1)
#073070 (Master)/ #073071 (Slave) ............440 VAC (U1), 3PH, 60 Hz @ 49A (I1)
460 VAC (U1), 3PH, 60 Hz @ 47A (I1)
#073100 (Master)/ #073101 (Slave) ............600 VAC (U1), 3PH, 60 Hz @ 36A (I1)
2-6
7-94
HT4100 Instruction Manual: Operation
INTRODUCTION & SPECIFICATIONS
Dimensions and Weight:
Width ............................................................28-1/4" (71 cm)
Height ...........................................................35-1/2" (90 cm)
Depth............................................................41-1/4" (104 cm)
Weight ..........................................................760 pounds (345 kg)
PAC610 Machine Torch #028601
Maximum cutting thickness ..........................1-1/2 inch (38 mm)
Maximum current at 100% duty cycle ..........260 amps for O2 cutting
Plasma and Shield Gas Flow .......................Refer to the
Electrode coolant flow rate ...........................1.4 gpm (5.3 l/min)
Weight ..........................................................3-1/2 pounds (1.59 kg)
High Frequency Console #073077
Dimensions and Weight:
Width ............................................................16" ( 41 cm)
Height ...........................................................16-3/4" ( 42 cm)
Depth............................................................13-3/4" ( 35 cm)
Weight ..........................................................75 pounds (34 kg)
Switch Remote (SR) V/C Control (073053)
Controls ........................................................Start button:
Cut Charts
section of the HT4100 Instruction
Manual: Operation (IM166) for specific
gas requirements.
Activates IHS (if on) and initializes
pilot arc.
Stop button:
Deactivates main contactor in
power supplies.
IHS On/Off switch:
Turns IHS system on or off.
Auto Height On/Off switch:
Activates THC in Master power
supply.
Voltage adjust pot:
Adjusts arc cutting voltage and
displays value on LEDs.
Current adjust pot:
Adjusts arc cutting current and
displays value on LEDs.
in the Operation
HT4100 Instruction Manual: Operation
2-7
12-14-92
INTRODUCTION & SPECIFICATIONS
Control Range ..............................................Current: 100 to 400 Amps
Voltage: 100 to 200 Volts
Control Resolution........................................Current: 20 Amps
Voltage: 5 Volts
Dimensions and Weight:
Width ............................................................11-1/2" ( 29 cm)
Height ...........................................................5" (13 cm)
Depth............................................................13-1/4" (34 cm)
Weight ..........................................................6 pounds (2.7 kg)
Digital Remote (DR) V/C Control #055003
Controls ........................................................Voltage adjust pot:
Adjusts arc cutting voltage and
displays value on LEDs.
Current adjust pot:
Adjusts arc cutting current and
displays value on LEDs.
Control Range ..............................................Current: 100 to 400 Amps
Voltage: 100 to 200 Volts
Control Resolution........................................Current: 10 Amps
Voltage: 5 Volts
Dimensions and Weight:
Width ............................................................11-1/2" (29 cm)
Height ...........................................................3" (7.6 cm)
Depth............................................................13-3/8" (34 cm)
Weight ..........................................................5 pounds-5 oz. (2.4 kg)
Programmable Remote (PR) V/C Control #055004
Controls ........................................................None. Controlled through guidance
machinery computer.
Control Range ..............................................Current: 100 to 400 Amps
Voltage: 100 to 200 Volts
Control Resolution........................................Current: 10 Amps
Voltage: 5 Volts
Dimensions and Weight:
Width ............................................................11-1/2" (29 cm)
Height ...........................................................3" (7.6 cm)
Depth............................................................12-1/2" (31.8 cm)
Weight ..........................................................5 pounds-5 oz. (2.4 kg)
2-8
HT4100 Instruction Manual: Operation
INTRODUCTION & SPECIFICATIONS
Gas Console #073078
Dimensions and Weight:
Width ............................................................11-1/2 " (29 cm)
Height ...........................................................14-5/8 " (37 cm)
Depth............................................................4 " (10 cm)
Weight ..........................................................23 pounds (10.4 kg)
Water Chiller
Refer to Water Chiller Model C Instruction Manual (#802410).
Motor Valve Console #073079
Dimensions and Weight:
Width ............................................................11-1/2 " (29 cm)
Height ...........................................................6" (15.8 cm)
Depth............................................................8" (20 cm)
Weight ..........................................................18 pounds (8.2 kg)
Initial Height Sensing #053016
Input Power ..................................................120 VAC from power supply
Air Pressure .................................................20 psi (1.4 bar) regulated shop air input
to solenoid.
Dimensions and Weight:
Width ............................................................9" (23 cm)
Height ...........................................................4.5" (11 cm)
Depth............................................................11-1/2" (29 cm)
Weight ..........................................................13 pounds (6 kg)
Timer/Counter #073057
Dimensions and Weight:
Width ............................................................6-1/2" (16.5 cm)
Height ...........................................................2-1/2" (6.4 cm)
Depth............................................................8-5/8" (22 cm)
Weight ..........................................................3 lbs (1 kg)
HT4100 Instruction Manual: Operation
2-9
1-96
Section 3 OPERATION
In this section:
Front Panel Controls and Indicators.................................................... 3-2
HT4100 Master Power Supply........................................................ 3-2
HT4100 Slave Power Supply.......................................................... 3-2
Gas Console ................................................................................... 3-4
Digital Remote (DR) V/C Module.................................................... 3-6
Programmable Remote (PR) V/C Module ...................................... 3-6
Switch Remote (SR) V/C Module .................................................3-6A
Timer/Counter................................................................................. 3-8
Daily Start-Up ...................................................................................... 3-9
Common Cutting Faults .................................................................... 3-10
Technical Questions .......................................................................... 3-11
Cut Chart ........................................................................................... 3-11
Changing Consumable Parts ............................................................ 3-14
Removal and Inspection ............................................................... 3-14
Replacement ................................................................................ 3-14
Changing the Water Tube............................................................. 3-15
Routine Inspection and Cleaning ...................................................... 3-16
Power Supplies............................................................................. 3-16
Water Chiller ................................................................................. 3-16
Interconnections ........................................................................... 3-16
HT4100 Instruction Manual: Operation
3-1
6-96
OPERATION
FRONT PANEL CONTROLS AND INDICATORS
HT4100 Master Power Supply (Fig. 3-1)
POWER
• ON (1) Pushbutton/indicator switch (PB1/LT1)
Activates the power supply and its control circuits. Indicator lights when power up is
complete.
• OFF (0) Pushbutton switch (PB2)
Shuts the power supply down.
• DC POWER ON Indicator (LT2)
Lights when main contactor closes, indicating DC power is being supplied to the torch.
STATUS
• Slave Transformer LED
When off, indicates that the slave power supply main transformer has overheated.
• Master Transformer LED
When off, indicates that the master power supply main transformer has overheated.
• RHF Interlock LED
When off, indicates that either or both remote HF console door interlock(s) is disengaged.
• Slave Interlock LED
When off, indicates that the slave power supply microprocessor has malfunctioned.
• Plasma Gas LED
When off, indicates that the plasma gas pressure is too low.
• Spare LED
Spare indicator.
• Coolant Flow LED
When off, indicates that the coolant flow to the electrode is inadequate.
HT4100 Slave Power Supply (Fig. 3-2)
• AC ON Indicator (LT1)
Lights when the power supply and control circuits are activated.
• DC POWER ON Indicator (LT2)
Lights when main contactor closes, indicating DC power is being supplied to the torch.
3-2
HT4100 Instruction Manual: Operation
Slave Transformer
Master Transformer
RHF Interlock
Slave Interlock
Plasma Gas
Spare
Coolant Flow
OPERATION
(LT2)
Figure 3-1 Master Power Supply Front Panel Controls and Indicators
(PB2)
(PB1/LT1)
HT4100 Instruction Manual: Operation
AC ON
Figure 3-2 Slave Power Supply Front Panel Indicators
(LT2)
(LT1)
3-3
OPERATION
FRONT PANEL CONTROLS AND INDICATORS (Cont.)
Gas Console (Fig. 3-3)
• PLASMA N2/O 2 Toggle Switch (S1)
The O2 position selects oxygen as the plasma cutting gas. The N2 position is for the
future availability of nitrogen as the plasma cutting gas.
• Test Preflow/Run/Test Cut Flow Toggle Switch (S2)
Test Preflow - This test position is used when setting the plasma and shield gas preflow
flow rates on the flowmeters for plasma oxygen cutting as specified in the
pages 3-12 to 3-13. A nitrogen and oxygen mixture is used as the preflow gas in order to
promote easier starts and longer electrode life when using oxygen. In this position the
contactor is disabled, so that current is not delivered to the electrode and the arc cannot
be fired.
Cut Charts
on
• PLASMA O2 (FM1) and N
nitrogen and oxygen required for the preflow gas mixture for oxygen cutting.
• PLASMA Preflow O2 (MV1) and N
• SHIELD O2 (FM2) and N2 (FM4) flowmeters - In test preflow, indicate the percentage of
nitrogen and oxygen required for the shield preflow gas mixture.
• SHIELD Preflow O2 (MV3) and N
Test Cut Flow - This test position is used when setting the plasma and shield gas flow
rates on the flowmeters for cutting conditions as specified in the
3-12 to 3-13. In this position the contactor is disabled, so that current is not delivered to
the electrode and the arc cannot be fired.
• PLASMA O2 flowmeter (FM1) - In test cut flow, indicates the percentage of plasma
(oxygen) gas flow required for cutting conditions.
• PLASMA Cut Flow Toggle switch (S3) - This switch controls a motor-driven metering
valve in the motor valve console which adjusts the plasma gas (oxygen) in test cut flow.
• SHIELD O2 (FM2) and N2 (FM4) flowmeters - In test operate, indicate the percentage of
nitrogen and oxygen required for cutting conditions.
• SHIELD Cut Flow O2 (MV2) and N
flow.
(FM3) flowmeters - In test preflow, indicate the percentage of
2
(MV4) metering valves - Adjusts plasma gas preflow.
2
(MV6) metering valves - Adjusts shield gas preflow.
2
Cut Charts
(MV5) metering valves - Adjusts shield gas test cut
2
on pages
3-4
Run - This position enables the contactor and the subsequent firing of the arc after the
gas flow rates have been set in the Test Preflow and Test Cut Flow positions.
HT4100 Instruction Manual: Operation
OPERATION
(FM4)
(FM2)
(S3)
(MV5)
(S1)
(S2)
(MV2)
(FM3)
(FM1)
(MV6)
(MV3)
Figure 3-3 Gas Console Front Panel Controls and Indicators
HT4100 Instruction Manual: Operation
(MV4)
(MV1)
3-5
OPERATION
FRONT PANEL CONTROLS and INDICATORS (Cont.)
Digital Remote (DR) V/C Module (Fig. 3-4)
• VOLTAGE Adjust Pot
Adjusts the cutting arc voltage from 100 to 200 volts. Values are chosen from the
Charts
• VOLTAGE LEDs
Displays cutting voltage.
• CURRENT Adjust Pot
Adjusts the cutting arc current from 100 amps to 400 amps. Values are chosen from the
Cut Charts
• CURRENT LEDs
Displays cutting current during cut sequence.
• UP/DOWN LEDs
Indicates that torch height is being adjusted up or down.
and depend on the type of metal to cut, and metal thickness.
and depend on the type of metal to cut, and metal thickness.
Cut
Programmable Remote (PR) V/C Module (Fig. 3-5)
• VOLTAGE LEDs
Displays cutting voltage during cut sequence.
• CURRENT LEDs
Displays cutting current during cut sequence.
• UP/DOWN LEDs
Indicates that torch height is being adjusted up or down.
3-6
HT4100 Instruction Manual: Operation
OPERATION
FRONT PANEL CONTROLS AND INDICATORS (Cont.)
Switch Remote (SR) V/C Module (Fig. 3-5A)
• INITIAL HEIGHT ON/OFF Toggle Switch
Activates the IHS system when ON. When START button is pushed, the IHS system
moves the torch down to the preset starting position above the workpiece.
• AUTO HEIGHT ON/OFF Toggle Switch
When in ON position, automatically maintains torch height at preset distance from
workpiece as cut is being made.
• UP/DOWN LEDs
Indicates that torch height is being adjusted up or down. Works when Auto Height switch
is in ON position.
• START Button
Activates the IHS system (if on) and after a five-second delay, initializes the pilot arc,
followed by cutting arc transfer.
• STOP Button
Deactivates the main contactor, shutting off DC power to the torch which shuts off the
cutting arc.
• VOLTAGE Adjust Pot
Adjusts the cutting arc voltage from 100 to 200 volts. Values are chosen from the
Charts
, and depend on the type of metal to cut, and metal thickness. The Torch Height
Control constantly monitors the set voltage with the actual cutting voltage and adjusts
torch up or down to maintain the set voltage.
• VOLTAGE LEDs
Displays cutting voltage.
• CURRENT Adjust Pot
Adjusts the cutting arc current from 100 amps to 400 amps. Values are chosen from the
Cut Charts
• CURRENT LEDs
Displays cutting current.
and depend on the type of metal to cut, and metal thickness.
Cut
HT4100 Instruction Manual: Operation
3-6A
12-14-92
OPERATION
Voltage Adjust Pot Current Adjust Pot
Figure 3-4 Digital Remote (DR) V/C Front Panel Controls and Indicators
Figure 3-5 Programmable Remote (PR) V/C Front Panel Indicators
3-7
HT4100 Instruction Manual: Operation
OPERATION
Voltage Adjust Pot Current Adjust Pot
INITIAL HEIGHT AUTO HEIGHT PLASMA
ON ON RUN
OFF OFF TEST
Figure 3-5A Switch Remote (SR) V/C Front Panel Controls and Indicators
HT4100 Instruction Manual: Operation
START STOP
START STOP
3-7A
12-14-92
OPERATION
FRONT PANEL CONTROLS and INDICATORS (Cont.)
Timer/Counter (Fig. 3-6)
Each LCD counter is self-powered by a three-volt lithium battery.
• STARTS LCD Counter (w/Reset)
Indicates the number of arc starts.
• ARC TIME LCD Counter
Indicates the cumulative time that the arc is on in hours.
• ERRORS LCD Counter (w/Reset)
Indicates the number of times that the arc cut cycle ended before the programmed
current ramp down time had elapsed. This reading provides a direct correlation to the
long-life operation of the electrode; the higher the reading, the shorter the electrode life.
Reset
STARTS
Figure 3-6 Timer/Counter Front Panel Indicators
ARC TIME
Reset
ERRORS
3-8
HT4100 Instruction Manual: Operation
DAILY START-UP
Prior to start-up, ensure that your cutting environment and that your clothing meet the safety
requirements outlined in the
refer to the HT4100 Instruction Manual: Installation (#801650) for the post-installation
system checkout requirements.
1. Remove the consumables from the torch and check for worn or damaged parts. Always
place the consumables on a clean, dry, oil free surface after removing. Dirty
consumables can cause the torch to malfunction.
• Check the pit depth of the electrode using the electrode gauge assembly. The
electrode should be replaced when the depth exceeds .050 inch (1.3mm).
• Wipe the current ring in the torch with a clean paper towel or Q-tip (see Figure 3-7).
Safety
OPERATION
section of this manual. If problems occur during start-up,
• Refer to the
cutting needs.
2. Replace consumable parts. Refer to the
manual for detailed information on replacing consumables.
3. Ensure that the torch is squared to the material. Refer to the HT4100 Instruction Manual:
Installation (P/N 801650) for the torch alignment procedure.
4. Set Test Preflow/Run/Test Cut Flow toggle switch (S2) on the gas console to Run.
5. Set the main disconnect switches for the master and slave power supplies and the water
chiller to On.
6. Turn the required oxygen and nitrogen gas supplies gases On. Both gases should be
supplied to the gas console at pressures of 120 psi (8.3 bar).
7. Check the water level in the water chiller.
8. Turn on the water chiller by depressing the START switch.
9. Set the PLASMA N2/O2 toggle switch (S1) on the gas console to O2.
10. Turn on the power supplies by depressing the POWER ON (1) button (PB1) on the
master power supply and holding down for five seconds. Ensure the green POWER ON
indicator (LT1) and all seven green LEDs on the master power supply and the white AC
ON indicator (LT1) on the slave power supply are lit. If the seven green LEDs do not
light, see
(#801670).
Cut Chart
on page 3-12 to choose the correct consumables for your
Changing Consumable Parts
STATUS LED Troubleshooting
in Section 3 of the Maintenance manual IM167
section later in this
11. Set the VOLTAGE and CURRENT on the Digital Remote V/C module if installed. The
Programmable Remote V/C module, if installed, is computer controlled and does not
HT4100 Instruction Manual: Operation
3-9
6-96
OPERATION
require manual control by the operator. Select the arc current, arc voltage and pierce
delay time from the
cut.
12. Set the switch (S2) on the gas console to Test Preflow. Test preflow uses a nitrogen
and oxygen mixture as the preflow gas. The plasma and shield preflow rates are set on
the PLASMA (FM1 and FM3) and SHIELD (FM2 and FM4) flowmeters using the
PLASMA (MV1 and MV4) and SHIELD (MV3 and MV6) metering valves and are specified in the
Cut Chart
13. Set the switch to Test Cut Flow. This position allows the plasma and shield test cut flow
rates to be set on the PLASMA O2 flowmeter (FM1) using PLASMA Cut Flow switch
(S3) and on the SHIELD O2 and N2 flowmeters using the SHIELD Cut Flow metering
valves (MV2 and MV5). Test cut flow rates are specified in the
14. Set switch (S2) to Run after the test preflow and test cut flow rates have been set.
15. The system is now ready for operation.
COMMON CUTTING FAULTS
Cut Chart
on page 3-12.
on pages 3-12 for the type and thickness of metal to be
Cut Chart
on page 3-12.
• Torch pilot arc will initiate, but will not transfer. Cause can be:
1. Work cable connection on cutting table not making good contact.
2. Malfunction in HT4100 system. See HT4100 Instruction Manual: Maintenance (#801670).
3. The torch initial height is set too high.
• The workpiece is not totally penetrated, and there is excessive sparking on top of the workpiece.
Causes can be:
1. Current is set too low (check
2. Cut speed is too high (check
3. Torch parts are worn (see
4. Metal being cut is too thick.
• Dross forms on the bottom of the cut. Causes can be:
1. Cutting speed is too slow or too fast (check
2. Arc current set too low (check
3. Torch parts are worn (see
Cut Chart
Cut Chart
Changing Consumable Parts
Cut Chart
Changing Consumable Parts
information).
information).
Cut Chart
information).
).
information).
).
3-10
6-96
HT4100 Instruction Manual: Operation
• Cut angle not square. Causes can be:
1. Wrong direction of machine travel.
High quality side is on the
right with respect to the forward motion of the torch.
OPERATION
2. Torch standoff (torch-to-work distance) is not correct (check
3. Cutting speed is not correct (check
4. Arc current is not correct (check
5. Damaged consumable parts (see
• Short consumable life. Causes can be:
1. Arc current, arc voltage, travel speed, pierce delay time, gas flow rates, or initial torch
height not set as specified in
2. Attempting to cut highly magnetic metal plate (some metals such as armor plate with a high
nickel content) will shorten consumable life. Long consumable life is difficult to achieve when
cutting plate that is magnetized or becomes magnetized easily. Call Hypertherm's Technical
Service department (1-800-643-9878) if you suspect the type of metal you are cutting is
causing shortened consumable life.
TECHNICAL QUESTIONS
Claims for defective merchandise -- All units shipped from Hypertherm undergo rigorous quality
control testing. However, if your system does not function correctly:
1. Recheck all pre-installation and installation requirements and connections in HT4100
Instruction Manual: Installation (P/N 801650).
Cut Chart
Cut Chart
information).
information).
Changing Consumable Parts
Cut Charts
.
Cut Chart
).
information).
2. If you are unable to solve the problem, call your distributor. They will be able to help you, or
refer you to an authorized Hypertherm repair facility.
3. If you need assistance, call our Customer Service or Field Service group at 1-800-643-9878.
CUT CHART
The
Cut Chart
the HT4100 system to be successful in plasma arc cutting. The HT4100 provides a wide travel
speed operating window: usually ± 10 ipm (± 254mm/min) on most materials. The
are for making drop cuts with minimal dross.
on the following page provides the necessary information for the operator using
Caution: Before cutting, check all settings and adjustments and check for
damaged torch parts and worn consumable parts.
Note: Plasma arc may extinguish if material intended to be cut is thinner than the minimum plate
thickness listed in the cut chart tables.
HT4100 Instruction Manual: Operation
Cut Chart
data
3-11
6-96
HT4100 Operating Data (Cut) Charts
Mild Steel - 300 Amp Cutting
O2 Plasma / O2 & N2 Shield
3-12
Material
Thickness
(in) (mm)
1/4 6
3/8 10
1/2 12.5
5/8 16
3/4 19
7/8 22
125
Shield
% Full Scale
N
O
2 &
30 0
30 0
30 0
30 0
30 0
30 0
30 0
Nozzle Retaining Cap
120103
Preflow
Plasma
% Full Scale
N
O
2
2 &
28 7
28 7
28 7
28 7
28 7
28 7
28 7
2
14 9
Nozzle
120096 (cw)
120116 (ccw)
Shield
% Full Scale
N
O
2 &
2
14 9
14 9
14 11
14 11
14 11
14 11
Cut Flow
Plasma
% Full Scale
N
0 70
060
060
060
060
060
060
or O
2
Swirl Ring
120108 (cw)
120115 (ccw)
Arc
Current
(amps)
2
200
260
260
280
300
300
300
Electrode
020721
Arc
Voltage
(volts)
125
130
135
145
150
150
155
Torch
Standoff
(in) (mm)
.06 1.5
1/8 3
1/8 3
3/16 5
3/16 5
3/16 5
3/16 5
PAC610 Torch
120107
Travel
Speed
(ipm) (mm/min)
160 4065
145 3680
105 2650
90 2280
80 2030
70 1780
55 1400
Pierce
Delay
Time
(sec)
0.3
0.5
0.7
0.9
1.1
1.3
1.5
Initial
Pierce
Height
(in) (mm)
3/16 4.7
3/16 4.7
3/16 4.7
1/4 6.3
1/4 6.3
3/8 9.5
3/8 9.5
1-1/8 28.5
1-1/4 32
1-3/8 35
1-1/2 38
30 0
30 0
30 0
30 0
28 7
28 7
28 7
28 7
14 11
14 11
14 11
14 11
060
060
060
060
300
300
300
300
155
155
155
155
Notes: O2 and N2 gas inlet pressures remain at one setting of 120 psi (8.3 bar) for all material thickness.
O2 flowrate at full scale is 127 scfh (60 l/min) @ 120 psi (8.3 bar) inlet pressure.
Shield N2 flowrate at full scale is 338 scfh (160 l/min) @ 120 psi (8.3 bar) inlet pressure.
Plasma N2 flowrate at full scale is 135 scfh (64 l/min) @ 120 psi (8.3 bar) inlet pressure.
Torch standoff tolerances are ± 0.020 inch /± 0.5mm. When using a THC, the tolerances are ± 2.5 volt.
* Piercing is not recommended.
3/16 5
3/16 5
3/16 5
3/16 5
50 1270
45 1145
40 1015
35 890
*
*
*
*
*
*
*
*
9-98
OPERATION
CHANGING CONSUMABLE PARTS
WARNING
Always disconnect the power supply from the main power source before
inspecting or changing the torch parts.
Inspect the consumable parts before cutting for wear, and replaced when needed. Follow t
the instructions below to inspect and replace the consumables and refer to Figure 3-7.
Removal and Inspection
1. Unscrew the retaining cap.
2. Remove the nozzle from the torch using the 1-1/4" (32 mm) tool (004574) in the Spare
Parts Kit (028554). Check the orifices of the nozzle for signs of wear and arcing.
3. Remove the electrode by unscrewing it from the torch head using the 7/16" (11mm) socket
wrench (027001) supplied in the Spare Parts Kit. Inspect and replace the electrode if the
crater in the center of the insert exceeds .050 inch (1.3 mm).
4. Remove the swirl ring from the electrode and inspect it for plugged holes or other damage.
Replacement
Before replacing the consumable parts, clean the current ring in the torch. Use a clean paper
towel or cotton swab to remove any dirt, grease, etc., from the current ring. If the water tube
appears damaged or loose, see
1. Replace the electrode by screwing it back into the torch head. Use the electrode socket
wrench to tighten down the electrode. Do not overtighten.
2. Prior to installing the swirl ring, apply a light coating of silicone grease to both outside
O-rings. As a guideline, you should be able to feel the grease on your fingers, but not see
it. Do not use an excessive amount of grease. The swirl ring ports can easily be
plugged by grease, causing improper gas flow during operation. When installing the swirl
ring, make sure to place the smaller diameter end into the torch.
3. When replacing the nozzle, apply a light coat of silicone grease to the O-ring on the O.D. of
the copper portion of the nozzle (as a guideline for amount of silicone, see step 2 above).
Insert the nozzle into the torch and tighten by hand. Use the nozzle wrench to tighten the
nozzle snugly. Do not overtighten.
Changing the Water Tube
on page 3-15.
3-14
3-94
HT4100 Instruction Manual: Operation
OPERATION
4. Replace the retaining cap by tightening it snugly by hand to insure there are no
water or gas leaks between the nozzle and the cap.
If the cap does not go on easily, clean the threads on the torch body and the retaining cap
and apply a small amount (see step 2 above) of silicone grease to both O-rings located just
below the threads of the torch body.
Note: Failure to tighten the retaining cap snugly (or to keep the threads and current ring
clean) will result in coolant water and gas leaks around the upper nozzle O-ring,
impairing cut quality. However, the retaining cap should be tightened by hand
only.
Nozzle
Retaining Cap
120103
Figure 3-7 Changing Consumable Parts
Changing the Water Tube
Problems and causes you may find with a defective or improperly installed water tube:
• Short electrode life: Water tube not screwed in tightly
Nozzle
120096
(O2)
Swirl Ring
120108
(O2)
Electrode
020721
(O2)
Water Tube
Current Ring
Torch Main
Body
120107
• Flow switch interlock shutting down the system: Water flow restricted due to loose
water tube
• Humming or rattling sound coming from the torch: Water tube bent or loose
If you suspect a problem with the water tube, you may need to replace it.
1. Disconnect power supply from power source.
2. Remove all consumables from torch (see
HT4100 Instruction Manual: Operation
Changing Consumable Parts
- pg. 3-14).
3-15
6-96
OPERATION
3. Look for any damage or bends in the water tube.
4. Remove and replace the water tube by using the water tube wrench (027347) supplied by
Hypertherm - Fig. 3-8. When installing water tube, do not over tighten! Snug down
by hand only.
Always disconnect the power supply
from the main power source before
inspecting or changing the torch parts.
WARNING
Figure 3-8 Changing the Water Tube
ROUTINE INSPECTION AND CLEANING
Power Supplies
The only routine inspection and cleaning necessary on the master and slave power supplies
is to keep dust and foreign matter from inside the units. This can be done by removing the
covers and blowing out the units with compressed air. Periodically, inspect the units for
cleanliness and clean as required. In an excessively dirty environment, perform this procedure on a weekly basis.
Water Chiller
Refer to the Water Chiller instruction manual IM-88 (P/N 802410),
and monthly inspection and cleaning procedures.
Interconnections
Check for plumbing leaks. Repair any leaks in the water recirculation plumbing.
Maintenance
for weekly
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1-96
HT4100 Instruction Manual: Operation
Section 4 STANDARDS INDEX
In this section:
Standards Index ..................................................................................4-2
HT4100 Instruction Manual: Operation
4-1
STANDARDS INDEX
For further information concerning safety practices to be exercised with plasma arc cutting equipment, please refer to the following publications:
1. ANSI Standard Z49.1,
Society, 550 LeJeune Road, P.O. Box 351020, Miami, FL 33135.
2. NIOSH,
Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402.
3. OSHA,
Printing Office, Washington, D.C. 20402.
4. ANSI Standard Z87.1,
obtainable from the American National Standards Institute, 1430 Broadway, New York, NY
10018.
5. ANSI Standard Z41.1, S
National Standards Institute, 1430 Broadway, New York, NY 10018.
6. ANSI Standard Z49.2,
from the American National Standards Institute, 1430 Broadway, New York, NY 10018.
7. AWS Standard A6.0,
able from the American Welding Society, 550 LeJeune Road, P.O. Box 351040, Miami, FL
33135.
8. NFPA Standard 51,
National Fire Protection Association, 470 Atlantic Avenue, Boston, MA 02210.
Safety and Health in Arc Welding and Gas Welding and Cutting
Safety and Health Standards
Safety in Welding and Cutting
, 29FR 1910, obtainable from the U.S. Government
, obtainable from the American Welding
, obtainable from the
Safe Practices for Occupation and Educational Eye and Face Protection
tandard for Men's Safety-Toe Footwear
, obtainable from the American
Fire Prevention in the Use of Cutting and Welding Processes
Welding and Cutting Containers Which Have Held Combustibles
Oxygen — Fuel Gas Systems for Welding and Cutting
, obtainable from the
,
, obtainable
, obtain-
9. NFPA Standard 70-1978,
Association, 470 Atlantic Avenue, Boston, MA 02210.
10. NFPA Standard 51B,
tion Association, 470 Atlantic Avenue, Boston, MA 02210.
11. CGA Pamphlet P-1,
Compressed Gas Association, 1235 Jefferson Davis Highway, Arlington, VA 22202.
12. CSA Standard W117.2,
Standards Association Standard Sales, 178 Rexdale Boulevard, Rexdale, Ontario M9W 1R3,
Canada.
13. NWSA booklet,
Association, 1900 Arch Street, Philadelphia, PA 19103.
14. American Welding Society Standard AWS F4.1,
Welding Safety Bibliography
National Electrical Code
Cutting and Welding Processes
Safe Handling of Compressed Gases in Cylinders
Code for Safety in Welding and Cutting
, obtainable from the National Fire Protection
, obtainable from the National Fire Protec-
, obtainable from the
, obtainable from the Canadian
, obtainable from the National Welding Supply
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances
Miami, FL 33135.
4-2
, obtainable from the American Welding Society, 550 LeJeune Road, P.O. Box 351040,
HT4100 Instruction Manual: Operation
STANDARDS INDEX
15. ANSI Standard Z88.2,
National Standards Institute, 1430 Broadway, New York, NY 10018.
16. Canadian Electrical Code Part 1,
the Canadian Standards Association, 178 Rexdale Boulevard, Rexdale, Ontario, Canada
M9W1R3.
Practices for Respiratory Protection
Safety Standards for Electrical Installations
, obtainable from the American
, obtainable from
HT4100 Instruction Manual: Operation
4-3
IEC SYMBOLS USED
Direct Current (DC).
Alternating current (AC).
Plasma cutting torch.
AC input power connection.
The terminal for the external protective (earthed) conductor.
A chopper-based power source.
APPENDIX
I
O
Anode (+) work clamp.
Temperature switch.
Pressure switch.
Plasma torch in the TEST position (cooling and cutting gas exiting nozzle).
The power is on.
The power is off.
Volt/amp curve.
HT4100 Instruction Manual: Operation
a-1
GLOSSARY
AC Alternating Current. Motion of current alternately in one direction, then the other.
The number of times per second the direction changes (the "frequency") is measured
in hertz.
amp Amperes. Measurement of the electron flow (the number of electrons per second) in
an electrical circuit.
anode The "positive" (+) side of a DC power source. Electrons leave the cathode and move
toward the anode; ions move in the opposite direction. Plasma cutting requires the
work and the nozzle to be the anode, and the electrode to be the cathode.
arc Motion of electricity in a gas.
AWG American Wire Gauge. Defines the diameter of wires.
bar A unit of pressure equal to one million dynes per square centimeter.
breaker A device which interrupts an electrical current if the current exceeds a preset
amperage setting. Breakers can be returned to their conducting (non-interrupting)
state by some mechanical action, such as flipping a switch.
cap Nozzle retaining cap. Holds the swirl ring, electrode and nozzle inside the torch.
capacitor A device that stores electric energy in the form of voltage.
cathode The "negative" (-) side of a DC power source. (See anode)
consumable Electrode, nozzle, swirl ring and retaining cap.
CSA Canadian Standards Association. A product standards and testing agency.
current Movement of electricity, measured in amperes. Current is said to move in a direction
opposite that of electron flow.
DC Direct Current. Motion of current in one direction only, from anode (+) to cathode (-).
dross Globs of metal hanging around the kerf, usually on the bottom side.
duty cycle Percentage of on-time (measured in minutes) in a 10 minute period in which a device
can be operated.
electricity Fundamental property of atoms that atoms can have their electrons pulled away
("ionized") and then the electrons can move about in metals or gases. An atom
missing one or more electrons is called an ion. Both electrons and ions can move
about in gases.
HT4100 Instruction Manual: Operation
g-1
GLOSSARY
electrode A part inside the torch connected to the cathode (-) of the power supply. Electrons
come out of the electrode.
ferrule A ring of metal surrounding the end of a cable or wire to strengthen a connection.
fuse A protective device which melts when the current running through it exceeds the
usage rating.
ground An electrical connection buried in the earth to establish a voltage of zero (0) volts.
Hertz (Hz) Measurement of "frequency" of an AC voltage or current in cycles per second.
IEC International Electrotechnical Commission. An international standards organization.
interlock A safety device which must be activated before another device can be activated.
ion An atom which has an excess or shortage of electrons.
IP International Protection. An IEC designator, describing the degree of protection an
enclosure offers against entry of objects and water.
I
1
I
2
kerf Slit made in a workpiece by a cutting torch.
kilowatt Thousand (kilo) watts. Measurement of electrical power.
LED Light Emitting Diode. An electronic indicator lamp.
line As in "line voltage." Utility voltage from a branch circuit (wall outlet).
liters/minute A measure of gas flow.
nozzle Tip of the plasma torch, made from copper, out of which the plasma arc comes. The
OCV Open Circuit Voltage. U0. The highest voltage from a electrical power supply. It
pilot arc A plasma arc that attaches to the torch nozzle rather than the work.
plasma An electrically charged gas is said to be "ionized". A cloud of ionized gas together
Rated supply current. The supply current to the power source at a rated cutting
condition (given U1, U2 and I2).
Rated output cutting current.
nozzle pinches the plasma arc. It is usually an anode (+).
occurs when the power supply is on and active but not producing a plasma arc.
with its electrons is called "plasma."
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HT4100 Instruction Manual: Operation
GLOSSARY
plasma arc Movement of electric current in a plasma (ionized gas). An intensely hot and bright
arc which exists between the cathode (-) (electrode) and the anode (+) (either the
nozzle or the work).
pressure Force per unit area.
psi Pounds per Square Inch. Measurement of gas pressure.
quench Put in water to cool.
regulator A mechanical device to control the outlet pressure of a gas supply.
ripple Unwanted variations in current or voltage from an electrical power supply.
scfm Standard cubic feet per minute. A measurement of gas flow.
single phase An alternating current carried by only two wires. In the U.S. the "hot" carries the AC
voltage and the "neutral" is at approximately "ground" voltage. The "ground" wire
carries current only in fault conditions.
swirl ring An insulating ring that separates the electrode from the nozzle and causes the air
inside the plasma torch to swirl and aid in squeezing the arc.
transfer A pilot arc
and attaches to the work.
U
0
U
1
U
2
VAC Volts Alternating Current.
VDC Volts Direct Current.
volt Measurement of electrical force required to move an electric current through an
watt Measurement of electrical power. The ability to heat the work equivalent to a current
work(piece) The object to be cut.
X Duty cycle at a given U1, U2 and I2.
Rated Open Circuit Voltage occuring at the rated input voltage (U1).
Rated Supply Voltage. The supply voltage for which the power source is
constructed.
Conventional load voltage. The output load voltage at which rated input current (I1),
rated output current (I2) and duty cycle (X) are measured.
electrical circuit.
of one ampere times an electrical force of one volt.
transfers
to the work when the plasma arc leaves the surface of the nozzle
HT4100 Instruction Manual: Operation
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