Hypertherm HT4100 User Manual
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
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