Hypertherm HySpeed HT2000 Preventive Maintenance Procedures

®

HySpeed® HT2000

Preventive Maintenance Program

Instruction Manual

809020|Revision0|English

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HySpeed HT2000

Preventive Maintenance Program

Instruction Manual

809020

Revision 0

English

September 2015

Hypertherm Inc.

Hanover, NH 03755 USA

www.hypertherm.com

Hypertherm Inc.

Etna Road, P.O. Box 5010
Hanover, NH 03755 USA
603-643-3441 Tel (Main Office)
603-643-5352 Fax (All Departments)
[e-mail] (Main Office Email)

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Hypertherm Plasmatechnik GmbH

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WARNING!

Before operating any Hypertherm equipment, read the safety instructions in
your product’s manual and in the Safety and Compliance Manual (80669C).
Failure to follow safety instructions can result in personal injury or in
damage to equipment.

Copies of the manuals may accompany the product in electronic and printed
formats. You can also obtain copies of the manuals, in all languages
available for each manual, from the “Downloads library” at

www.hypertherm.com

.

Preventive Maintenance Program 11

Overview ......................................................................................................................................................................................... 11

Cleaning and inspection schedule ........................................................................................................................................... 12

Daily ......................................................................................................................................................................................... 13

Do a check of the gas flow settings ......................................................................................................................... 13

Examine the torch and consumables ........................................................................................................................ 13

Examine the torch leads .............................................................................................................................................. 15

Examine all of the hoses and hose fittings .............................................................................................................. 15

Weekly ..................................................................................................................................................................................... 16

Clean inside of the power supply .............................................................................................................................. 16

Clean the torch threads and the ring inside of the torch main body ................................................................. 16

Do a check of the cooling fans .................................................................................................................................. 17

Do a check of the coolant level ................................................................................................................................. 17

Bi-monthly ............................................................................................................................................................................... 18

Examine the air filter inside of the power supply .................................................................................................... 18

Monthly .................................................................................................................................................................................... 19

Make sure that the system is correctly grounded ................................................................................................. 19

Examine the exterior of the power supply ................................................................................................................ 20

Examine and clean the interior of the power supply ............................................................................................. 20

Examine the coolant filter in the power supply ....................................................................................................... 22

Test the rate of coolant flow to the torch ................................................................................................................ 22

Test the rate of coolant return from the torch ........................................................................................................ 23

Look for coolant leaks .................................................................................................................................................. 24

Clean the torch threads and the rings inside of the torch main body .............................................................. 25

Examine and lubricate all of the O-rings .................................................................................................................. 25

Examine the optional water tube (if applicable) and the torch main body ....................................................... 25

Examine the torch insulator for cracks ..................................................................................................................... 25

Examine the retaining cap and shield ....................................................................................................................... 26

Contents

HySpeed HT2000 Instruction Manual 809020 7

Contents

Examine all of the hoses and hose fittings .............................................................................................................. 26

Examine all of the torch leads .................................................................................................................................... 26

Examine all of the cables and cable connections .................................................................................................. 26

Examine the gas line connections ............................................................................................................................. 26

Do tests for gas leaks .................................................................................................................................................. 27

Examine the air filter in the power supply ................................................................................................................ 28

Examine the remote high-frequency console (if applicable) ............................................................................... 28

Examine the motor valve console .............................................................................................................................. 29

Examine the gas console ............................................................................................................................................ 30

Bi-yearly .................................................................................................................................................................................. 31

Replace the coolant and the coolant filter .............................................................................................................. 31

Clean the coolant pump strainer ............................................................................................................................... 32

Do all maintenance tasks ............................................................................................................................................ 33

Replace all service parts ............................................................................................................................................. 33

Yearly ....................................................................................................................................................................................... 33

Do all maintenance tasks ............................................................................................................................................ 33

Replace all service parts ............................................................................................................................................. 33

Component replacement schedule .................................................................................................................................. 34

HT2000 preventive maintenance kits .............................................................................................................................. 35

Cutting area and operation effects ................................................................................................................................... 36

External cutting area ..................................................................................................................................................... 36

Incoming air supply quality .......................................................................................................................................... 38

Metal dust inside of the power supply cabinet ...................................................................................................... 38

Consumable use ........................................................................................................................................................... 39

Cut cycle time ................................................................................................................................................................ 40

Part numbers for hoses, leads, and cables ............................................................................................................................ 41

Hoses ...................................................................................................................................................................................... 41

Oxygen supply hoses (oxygen supply to gas console) ........................................................................................ 41

Nitrogen supply hoses (nitrogen supply to gas console) .................................................................................... 41

Plasmas preflow gas hoses (gas console to motor valve console) .................................................................. 41

Plasma cut flow gas hoses (gas console to motor valve console) .................................................................... 41

Shield gas hoses (shield gas supply to gas console) .......................................................................................... 42

Shield gas hoses (gas console to remote high-frequency console) ................................................................ 42

Shield gas hoses (gas console to remote high-frequency console) ................................................................ 42

Argon/hydrogen gas hoses (argon/hydrogen console to torch) ....................................................................... 42

Cooling system hoses (sets of 2: 1 red, 1 green) (power supply to remote high-frequency console) .... 43

Remote high frequency console hoses (remote high-frequency console to gas console) ......................... 43

Gas console hoses (gas console to motor valve) ................................................................................................. 43

8 HySpeed HT2000 Instruction Manual 809020

Contents

Leads ....................................................................................................................................................................................... 43

Shielded torch leads .................................................................................................................................................... 43

Negative lead and work cable (power supply to remote high-frequency console) ....................................... 44

Power supply leads (power supply to remote high-frequency console) .......................................................... 44

Cables ..................................................................................................................................................................................... 44

Pilot arc cables (power supply to remote high-frequency console) ................................................................. 44

HT2000 remote high frequency (RHF) console leads (power supply to remote high-frequency console) ...
44

Gas console cables (power supply to gas console) ............................................................................................ 45

Motor valve console cables (power supply to motor valve console) ................................................................ 45

Machine interface cables (power supply to machine I/O) ................................................................................... 45

Machine interface V/C cables (power supply to machine computer) .............................................................. 45

Remote V/C cables (power supply to digital (DR)/Programmable (PR) V/C) ................................................ 45

Power supply/programmable remote (PR) cables (power supply to PR V/C) ............................................... 46

Argon/hydrogen console cables (power supply to argon/hydrogen console) ............................................... 46

Time/counter cables (power supply to timer/counter) ......................................................................................... 46

Hold cables (power supply to power supply) ........................................................................................................ 46

Water muffler pump cables (power supply to water muffler) ............................................................................. 46

Initial height sensing cables (power supply to initial height sensor) ................................................................. 46

Initial height sensing cables (initial height sensor to sensors) ........................................................................... 46

System information ....................................................................................................................................................................... 47

Model number ........................................................................................................................................................................ 47

Serial number ......................................................................................................................................................................... 47

System voltage ...................................................................................................................................................................... 47

Coolant requirements .......................................................................................................................................................... 47

Notes ............................................................................................................................................................................................... 48

Maintenance log for the HySpeed HT2000 (page 1 of 3) ................................................................................................. 49

HySpeed HT2000 Instruction Manual 809020 9

Contents

10 HySpeed HT2000 Instruction Manual 809020

Preventive Maintenance Program

Overview

Hypertherm plasma systems can operate in harsh conditions for many years. To maintain system performance, minimize
operating costs, and lengthen system life, follow the maintenance procedures given in this Preventative Maintenance
Program (PMP).

Hypertherm made this PMP specifically for your plasma system. The PMP has two parts: a cleaning and inspection
schedule and a component replacement schedule.

If you have questions about how to maintain your plasma system, contact your OEM or regional Hypertherm Technical
Service team. You can find contact information for each regional office at www.hypertherm.com
page.

This document refers to your system’s instruction manual. If you do not have your instruction manual, you can find it in the
Hypertherm downloads library:

on the “Contact us”

1. Go to www.hypertherm.com

2. Click Downloads library.

3. Enter your instruction manual’s part number in the Part number field.

 HySpeed HT2000 Plasma Arc Cutting System Instruction Manual: 802070

.

HySpeed HT2000 Instruction Manual 809020 11

Preventive Maintenance Program

Cleaning and inspection schedule

This is a schedule for cleaning and inspections. The PMP has instructions for each task. These instructions help your
personnel understand what to do and what to look for during each task. Usually, operators can do the daily, weekly, and
bi-monthly tasks, and maintenance personnel can do the monthly, bi-annual, and annual tasks.

A maintenance log is in the back of this manual. You can make photocopies of the maintenance log to record tasks.

Tab l e 1

Maintenance task or activity Daily Weekly Bi-Monthly Monthly Bi-Yearly Yearly

Do a check of the gas flow settings X

Examine the torch and consumables X

Examine the torch leads X

Examine all of the hoses and hose fittings X

Clean inside of the power supply X

Clean the torch threads and the ring inside of the torch
main body

Do a check of the cooling fans X

Do a check of the coolant level X

Examine the air filter inside of the power supply

Clean the coolant pump strainer

Make sure that the system is correctly grounded X

Examine the exterior of the power supply X

Examine and clean the interior of the power supply X

Examine the coolant filter in the power supply

Test the rate of coolant flow to the torch X

Test the rate of coolant return from the torch X

Look for coolant leaks X

Clean the torch threads and the rings inside of the torch
main body

Examine and lubricate all of the O-rings

Examine the optional water tube (if applicable) and the
torch main body

X

X

X

X

X

X

X

Examine the torch insulator for cracks X

Examine the retaining cap and shield X

Examine all of the hoses and hose fittings

Examine all of the torch leads X

Examine all of the cables and cable connections X

Do tests for gas leaks X

X

12 HySpeed HT2000 Instruction Manual 809020

Preventive Maintenance Program

Maintenance task or activity Daily Weekly Bi-Monthly Monthly Bi-Yearly Yearly

Examine the air filter in the power supply

Examine the remote high-frequency console (if
applicable)

Examine the motor valve console

Examine the gas console

Replace the coolant and the coolant filter X

Clean the coolant pump strainer X

Do all maintenance tasks (see page 19)

Replace all service parts (see page 34)

Do all maintenance tasks (see page 19)

Replace all service parts (see page 34)

X

X

X

X

X

X

X

X

Daily

Do a check of the gas flow settings

 When you use oxygen, nitrogen, or argon-hydrogen as the plasmas gas, make sure that the regulator setting for the

gas supply is 8.2 bar +/- 0.7 bar (120 psi +/- 10 psi).

 When you use air as the plasma gas, make sure that the regulator setting for the gas supply is 6.2 bar +/- 0.7 bar

(90 psi +/- 10 psi).

 Make sure that the regulator setting for shield gas is 6.2 bar +/- 0.7 bar (90 psi +/- 10 psi).

If you changed consumable parts or if the power supply is off for more than 1 hour, purge



the gas line before use. To purge the gas lines, leave the system in test preflow mode for
1 minute. See your system’s instruction manual for information on how to do this.

See Gas requirements and Daily start-up in your system’s instruction manual for



information about correct gas flow settings and about how to adjust preflow and cut flow
gases.

Examine the torch and consumables

Always examine the torch main body and consumables before you cut. Worn or damaged parts can cause gas and water
leaks, which can affect the cut quality.

1. Examine the consumables for pitting and burn marks.

2. Replace any consumable that has damage or excess wear.

See Cut charts and consumable parts index and the Parts list in your system’s instruction



manual for information on replacement parts.

3. Examine the torch insulator for cracks.

HySpeed HT2000 Instruction Manual 809020 13

Preventive Maintenance Program

9

10

12

4. If you find cracks in the torch insulator, replace the entire torch main body.

Installation in your system’s instruction manual for information on how to do this.



5. Examine all of the O-rings on the torch main body and the consumables for damage or excess wear. Replace any
O-ring or consumable that has damage or excess wear.

Receptacle O-rings and O-rings on the torch main body are available as part of a kit.



Other O-rings are included with the consumables. See Parts list and Changing
consumable parts in your system’s instruction manual for information about replacement

parts.

6. Examine all of the O-rings for the correct amount of lubricant. The O-rings should look shiny. Too much lubricant can
prevent gas flows.

7. If you find excess lubricant, remove it.

See Examine and lubricate all of the O-rings on page 25 of this manual for information



on how to do this.

8. Examine the retaining cap and shield:

 Make sure that the retaining cap and shield are tight to the torch main body.

Tighten loose connections, if found, but do not over tighten.

 Make sure that the gas holes along the edge of the shield are not blocked with

debris. If you cannot remove the blockage in the gas holes, replace the shield.

 Make sure that the center hole in the shield is not blocked with debris. If you

cannot remove the blockage in the center hole, replace the shield.

 Make sure that the shield does not have any nicks, gouges, or signs of arcing. If

you find damage, excess wear, or signs of arcing, replace the shield.

9. If the torch has an optional water tube to cool the electrode:

 Examine the water tube for bends and pitting. See Examine the optional water tube (if applicable) and the torch

main body on page 25 of this manual for information on how to do this.

 If you find bends and pitting, replace the water tube. See Changing the water tube in your system’s instruction

manual for information on how to do this.

10. Examine the nozzle and electrode mating surfaces on the torch main body. Look for pitting, damage, and excess
wear.

11 . Replace any consumable that has damage, or excess wear.

12. Use a clean cloth to clean the internal and external surfaces of the torch main body. Use a cotton swab for internal

surfaces that are not easy to reach.

Make sure that you do not leave any cotton fibers on the inner surfaces of the torch main



body.

13. Use compressed air to remove any remaining particles from the torch main body.

14 HySpeed HT2000 Instruction Manual 809020

Preventive Maintenance Program

Examine the torch leads

1. Examine the torch leads for kinks, cracks, cuts, or excessive wear. Replace any torch lead that has kinks, damage, or
excess wear.

2. Make sure that all connections between the torch and torch leads are tight. Tighten loose connections if found, but
do not over tighten.

Examine all of the hoses and hose fittings

1. Examine all of the air hoses and coolant hoses for:

 Scrapes, cuts, or holes

 Chemical spills or burns

 Kinks or bends that can cause a restriction

Make sure to examine the following hoses:



 hoses connected to the motor valve

 gas hoses between the gas console and motor valve

 the off-valve hose between the off valve and the torch main body

2. If the cutting table uses a power track system to support hoses between the power supply and gas console, examine
the position of the hoses in the power track. Make sure that these hoses do not kink, bend, or twist during cutting
table operation.

3. Examine all of the hose fittings at the rear of the torch. Damage to the threads on the hose fittings can indicate that
over tightening has occurred.

4. If the hose fittings at the rear of the torch have damage or excess wear, replace the entire torch main body.

See Installation in your system’s instruction manual for information on how to do this.



5. Replace any hose that has damage or excess wear.

HySpeed HT2000 Instruction Manual 809020 15

Preventive Maintenance Program

Weekly

Clean inside of the power supply

ELECTRIC SHOCK CAN KILL

Disconnect electric power before performing any maintenance.

All work requiring removal of the power supply cover must be performed by
a qualified technician.

See the safety information provided with your product for more safety
precautions.

1. Disconnect the electric power to the power supply.

2. Remove the top and side panels of the power supply.

3. Blow out or vacuum any accumulation of dust and particles from:

WARNING!

 The top and side panels

 The inside of the power supply

 The fans

CAUTION!

Static electricity can damage circuit boards. Use proper precautions when handling
printed circuit boards.

Store PC boards in anti-static containers.

Wear a grounded wrist strap when handling PC boards.

4. Remove dust and particles from the circuit boards.

Be careful not to damage the circuit boards.



5. Install the top and side panels of the power supply before you reconnect the power supply to electric power.

Clean the torch threads and the ring inside of the torch main body

Damage to the torch threads or to the ring inside of the torch main body usually results from unsatisfactory cleaning of the
torch and retaining cap threads. Unsatisfactory cleaning can cause dirt and particulates to accumulate in the torch
threads or cause pitting on the ring inside of the torch main body.

1. Clean all threads on the front of the torch head with a cotton swab, pipe cleaner, or clean cloth that is moistened with
clean water. Do not use alcohol.

16 HySpeed HT2000 Instruction Manual 809020

Preventive Maintenance Program

2. Examine the ring inside of the torch main body. Look for pitting.

3. If the pitting on the ring is slight, the torch could be repaired. Contact your OEM or regional Hypertherm Technical

Services to assess the damage.

4. If the ring inside of the torch main body cannot be repaired, replace the entire torch main body.

5. If there is no pitting, damage, or excess wear on the ring inside of the torch main body, clean the ring with a cotton

swab that is moistened with clean water. Do not use alcohol.

Do a check of the cooling fans

Make sure that the cooling fans are:

 Moving freely

 Not making excess noise

 Not clogged

 Not showing signs of damage or excess wear

Do a check of the coolant level

WARNING!

ELECTRIC SHOCK CAN KILL

Disconnect electric power before performing any maintenance.

All work requiring removal of the power supply cover must be performed by
a qualified technician.

See the safety information provided with your product for more safety
precautions.

1. Disconnect the electric power to the power supply.

2. Remove the rear panel of the power supply and find the coolant reservoir.

3. Make sure that the coolant reservoir is full of coolant.

4. If the level of the coolant is below the top of the reservoir, refill the coolant reservoir with coolant (028872).

See Torch coolant requirements in your system’s instruction manual.



5. Record the number of liters (US gallons) that your system requires in Coolant requirements on page 47 of this

manual.

6. Install the rear cover of the power supply before you reconnect the power supply to electric power.

HySpeed HT2000 Instruction Manual 809020 17

Preventive Maintenance Program

Bi-monthly

Examine the air filter inside of the power supply

WARNING!

ELECTRIC SHOCK CAN KILL

Disconnect electric power before performing any maintenance.

All work requiring removal of the power supply cover must be performed by
a qualified technician.

See the safety information provided with your product for more safety
precautions.

1. Disconnect the electric power to the power supply.

2. Remove the front panel of the power supply to expose the air filter.

3. Examine the air filter for contamination.

 If you find moisture, oil, or a large quantity of solid

contamination, replace the air filter (027441).

 If you find a moderate quantity of solid contamination, such

as dust, blow air through the air filter or use suction to clean
it.

4. If the original air filter looks clean, return it to the air filter housing.

5. Install the front panel of the power supply before you reconnect

the power supply to electric power.

18 HySpeed HT2000 Instruction Manual 809020

Preventive Maintenance Program

Monthly

Make sure that the system is correctly grounded

WARNING!

ELECTRIC SHOCK CAN KILL

Make sure the equipment remains properly grounded at all times in compliance with local and national
regulations. Failure to follow proper grounding techniques can result in serious personal injury or
death.

Make sure that all components of the system are individually grounded to a driven earth ground. Do a check that:

 Unless noted, use only 110 mm

 The cutting table is used for the common, or star, EMI ground point and should have threaded studs welded to the

table with a copper bus bar mounted on them. A separate bus bar should be mounted on the gantry as close to
each motor as possible. If there are motors at each end of the gantry, run a separate EMI ground cable from the
far motor to the gantry bus bar. The gantry bus bar should have a separate, heavy EMI ground cable 21.2 mm
(4 AWG; 047031) to the table bus bar. The EMI ground cables for the torch lifter and the RHF console must each
run separately to the table ground bus.

2

(8 AWG) welding cables for the electromagnetic interference (EMI) ground cables.

2

 A ground rod that meets all applicable local and national electrical codes must be installed within 6 m (20 ft) of the

cutting table. This is a potential earth (PE) ground and should be connected to the cutting table ground bus bar using

2

13.3 mm

 For the most effective shielding, use the Hypertherm CNC interface cables for I/O signals, serial communication

(6 AWG) green and yellow grounding cable (047121) or equivalent.

signals, between plasma systems in multi-drop connections, and for interconnections between all parts of the
Hypertherm system.

 All hardware used in the ground system must be brass or copper. While you can use steel studs welded to the

cutting table for mounting the ground bus, no other aluminum or steel hardware can be used in the ground system.

 AC power, PE, and service grounds must be connected to all equipment according to local and national codes.

 For a system with a remote high frequency console (RHF), the positive, negative, and pilot arc leads should be

bundled together for as long a distance as possible. The torch lead, work lead, and the pilot arc (nozzle) leads may be
run parallel to other wires or cables only if they are separated by at least 150 mm (6 inches). If possible, run power
and signal cables in separate cable tracks.

 For a system with an RHF console, the ignition console should be mounted as closely as possible to the torch, and

must have a separate ground cable that connects directly to the cutting table ground bus bar.

 Each Hypertherm component, as well as any other CNC or motor drive cabinet or enclosure, must have a separate

ground cable to the common (star) ground on the table. This includes the ignition console, whether it is bolted to the
plasma system or to the cutting table.

 The metal braided shield on the torch lead must be connected firmly to the ignition console and to the torch. It must

be electrically insulated from any metal and from any contact with the floor or building. The torch lead can be run in a
plastic cable tray or track, or covered with a plastic or leather sheath.

 The torch holder and the torch breakaway mechanism – the part mounted to the lifter, not the part mounted to the

torch – must be connected to the stationary part of the lifter with copper braid at least 12.7 mm (0.5 inches) wide. A
separate cable must run from the lifter to the gantry ground bus bar. The valve assembly should also have a separate
ground connection to the gantry ground bus bar.

HySpeed HT2000 Instruction Manual 809020 19

Preventive Maintenance Program

 If the gantry runs on rails that are not welded to the table, then each rail must be connected with a ground cable from

the end of the rail to the table. The rail ground cables connect directly to the table and do not need to connect to the
table ground bus bar.

 If you are installing a voltage divider board, mount it as closely as possible to where the arc voltage is sampled.

One recommended location is inside the plasma system enclosure. If a Hypertherm voltage divider board is used, the
output signal is isolated from all other circuits. The processed signal should be run in twisted shielded cable
(Belden 1800F or equivalent). Use a cable with a braided shield, not a foil shield. Connect the shield to the chassis
of the plasma system and leave it unconnected at the other end.

 All other signals (analog, digital, serial, and encoder) should run in twisted pairs inside a shielded cable. Connectors

on these cables should have a metal housing. The shield, not the drain, should be connected to the metal housing of
the connector at each end of the cable. Never run the shield or the drain through the connector on any of the pins.

See Module grounding and grounding checks in your system’s instruction manual for



information on how to ground the system.

Examine the exterior of the power supply

Examine the exterior of the power supply for damage. If there is damage, make sure that it does not affect safe operation
of the power supply. If you have concerns, contact your OEM or regional Hypertherm Technical Services to assess the
damage.

Examine and clean the interior of the power supply

WARNING!

ELECTRIC SHOCK CAN KILL

Disconnect electric power before performing any maintenance.

All work requiring removal of the power supply cover must be performed by
a qualified technician.

See the safety information provided with your product for more safety
precautions.

1. Disconnect the electric power to the power supply.

2. Remove the top and side panels of the power supply.

3. Examine the interior of the power supply:

 Examine the wiring harnesses. If any wiring harness has damage or excess wear, replace it.

 Look for loose connections. Tighten loose connections, if found, but do not over tighten.

 Look for areas of discoloration due to overheating. If you see signs of overheating, look for the source. If you

discover the source of overheating or if you find parts with damage or excess wear, replace them.

20 HySpeed HT2000 Instruction Manual 809020

4. Examine the pilot arc relay inside the rear wall of the power

4

supply:.

a. Remove the pilot arc relay.

b. Examine the contacts inside of the pilot arc relay. Look for

black or rough surfaces.

c. If you find black or rough surfaces, replace the pilot arc

relay.

d. Reinstall of the pilot arc relay.

Be careful that you do not pinch the wires between the



cover and the center panel.

5. Blow out or vacuum any accumulation of dust and particles
from:

 The top and side panels

 The inside of the power supply

 The fans

Preventive Maintenance Program

CAUTION!

Static electricity can damage circuit boards. Use proper precautions when handling
printed circuit boards.

Store PC boards in anti-static containers.

Wear a grounded wrist strap when handling PC boards.

6. Remove dust and particles from circuit boards.

Be careful not to damage the circuit boards.



7. Install the top and side panels of the power supply before you reconnect the power supply to electric power.

HySpeed HT2000 Instruction Manual 809020 21

Preventive Maintenance Program

Examine the coolant filter in the power supply

A dirty coolant filter can slow the flow of coolant to the torch, which will cause the LED coolant flow indicator to illuminate.

WARNING!

ELECTRIC SHOCK CAN KILL

Disconnect electric power before performing any maintenance.

All work requiring removal of the power supply cover must be performed by
a qualified technician.

See the safety information provided with your product for more safety
precautions.

1. Disconnect the electric power to the power supply.

2. Examine the rear of the power supply and find the housing for the coolant filter.

3. Remove the coolant filter housing from the rear of the power supply and examine the coolant filter.

The coolant filter changes to a brown color when dirty.



4. If the coolant filter looks dirty, replace it (027005). If the coolant filter looks clean, return it to the coolant filter
housing.

5. Install the coolant filter housing into the rear of the power supply.

6. Reconnect the electric power to the power supply.

Test the rate of coolant flow to the torch

The best rate of coolant flow to the following torches is approximately 4 liters per minute (4 L/min) (1 US gal/min):

 HySpeed HT2000 machine torch with valve and 50.8 mm (2 in.) diameter sleeve (standard body) (128381)

 HySpeed HT2000 machine torch with valve and 50.8 mm (2 in.) diameter sleeve (stainless steel body) (128367)

 HySpeed HT2000 machine torch with 44.5 mm (1-3/4 in.) diameter sleeve (standard body) (128141)

 HyPro2000 quick disconnect torch with valve (standard body) (220921)

 HT2000 high precision torch with valve (standard body) (120356)

 HyPro2000 straight machine torch with valve (standard body) (220961)

To test the rate of coolant flow to the torch:

1. Get an empty container with an approximate capacity of 4 liters (1 US gallon).

2. Turn OFF the electric power to the power supply.

3. Remove the following from the torch:

 Retaining cap

22 HySpeed HT2000 Instruction Manual 809020

Preventive Maintenance Program

 Shield

 Electrode

 Nozzle

 Swirl ring

4. Install the retaining cap on the torch again. Do not install the electrode, nozzle, swirl ring, or shield.

5. Put the container under the torch.

6. Turn ON the electric power to the power supply.

7. Hold down the ON button on the power supply for 1 minute.

8. After 1 minute, release the ON button on the power supply.

9. Examine the coolant in the container.

10. If the torch delivers at least 4 L/min (1 US gal/min), then the rate of coolant flow to the torch is satisfactory.

11 . If the coolant flow is satisfactory, install the following consumables on the torch again:

 Electrode

 Nozzle

 Swirl ring

 Shield

12. If the torch delivers less than 4 L/min (1 US gal/min), then the rate of coolant flow is not satisfactory.

13. If the flow rate is not satisfactory, see Check the pump, motor and solenoid valve in your system’s instruction manual.

Test the rate of coolant return from the torch

The best rate of coolant return from the following torches is approximately 2.6 liters per minute (2.6 L/min)
(3/4 US gal/min):

 HySpeed HT2000 machine torch with valve and 50.8 mm (2 in.) diameter sleeve (standard body) (9128381)

 HySpeed HT2000 machine torch with valve and 50.8 mm (2 in.) diameter sleeve (stainless steel body) (128367)

 HySpeed HT2000 machine torch with 44.5 mm (1-3/4 in.) diameter sleeve (standard body) (128141)

 HyPro2000 quick disconnect torch with valve (standard body) (220921)

 HT2000 high precision torch with valve (standard body) (120356)

 HyPro2000 straight machine torch with valve (standard body) (220961)

To test the rate of coolant return from the torch:

1. Get an empty container with an approximate capacity of 4 liters (1 US gallon).

2. Turn OFF the electric power to the power supply.

HySpeed HT2000 Instruction Manual 809020 23

Preventive Maintenance Program

13

4

3

3. Find the 2 coolant hoses that come out of the rear of the cathode block
at the rear of the power supply.

Both hoses are black. One hose has a green band. One hose has a



red band.

4. Remove the hose with the red band from the cathode block.

5. Place the open end of the hose with the red band into the container.

6. Turn ON the electric power to the power supply.

7. Hold down the ON button on the power supply for 30 seconds, while

the coolant flows from the hose with the red band.

8. After 30 seconds, release the ON button on the power supply.

9. Examine the coolant in the container.

10. If the container is approximately 1/2 full after 30 seconds, then the return flow rate is satisfactory.

11 . If the container is not 1/2 full after 30 seconds:

a. Repeat step 7 – step 10 for 1 minute.

b. After 1 minute, examine the coolant in the container.

 If the container is approximately 3/4 full after 1 minute, then there is a problem with either the flow

switch or the coolant filter. If the container is approximately 3/4 full after 1 minute, go to step 12.

 If the container is less than 3/4 full after 1 minute, see Verify flow rate to torch in your system’s

instruction manual.

12. If the container is approximately 3/4 full after 1 minute, look at the LED that indicates coolant flow.

a. If the LED is illuminated, replace the flow switch.

b. If the LED is not illuminated, replace the coolant filter.

13. Reconnect the hose with the red band to the cathode block.

14. Install the rear panel of the power supply before you reconnect the power supply to electric power.

Look for coolant leaks

Examine the power supply for coolant leaks. Primary locations for coolant leaks include the following:

 the back of the power supply

 at the remote high-frequency console, if the system has a one

 at the torch main body

Make sure that the coolant reservoir is full with coolant. If the level of the coolant is below the top of the reservoir, refill the
coolant reservoir with coolant (028872).

24 HySpeed HT2000 Instruction Manual 809020

Preventive Maintenance Program

1

3

5

Clean the torch threads and the rings inside of the torch main body

See Clean the torch threads and the ring inside of the torch main body on page 16 of this manual for instructions.

Examine and lubricate all of the O-rings

1. Examine all of the O-rings in the torch main body. Look for damage
or excess wear.

2. Replace any O-ring that has damage or excess wear.

Receptacle O-rings and torch O-rings for the torch main body



are available as part of a kit. Other O-rings are included with the
consumables. See Parts list in your system’s instruction manual.

3. Apply a thin film of silicone lubricant (027055) to all O-rings.

The O-rings should look shiny. Too much lubricant can prevent



gas flow. Remove excess lubricant if found.

4. Install all O-rings so they fit snugly.

5. Examine all threaded consumables, and remove any dirt from the

threads.

Examine the optional water tube (if applicable) and the torch main body

1. If the torch has an optional water tube to cool the torch electrode, examine the water tube for bends and pitting.

2. If you find bends or pitting, replace the water tube.

See Changing the water tube in your system’s instruction manual for information



on how to do this.

3. Examine the nozzle and electrode mating surfaces on the torch main body. Look for
damage or pitting.

4. If any consumable has damage or excess wear, replace it.

5. Use a clean cloth to clean the internal and external surfaces of the torch main body.

Use a cotton swab for internal surfaces that are not easy to reach.

Make sure that you do not leave any cotton fibers on the inner surfaces of the



torch main body.

6. Use compressed air to remove any remaining particles from the torch main body.

Examine the torch insulator for cracks

Examine the torch insulator for cracks. If you find cracks in the torch insulator, replace the entire torch main body.

HySpeed HT2000 Instruction Manual 809020 25

Preventive Maintenance Program

Examine the retaining cap and shield

1. Make sure that the retaining cap and shield are tight to the torch main body. Tighten loose connections if found, but
do not over tighten.

2. Examine the retaining cap and shield. If you find any consumable with damage or excess wear, replace it.

Examine all of the hoses and hose fittings

See Examine all of the hoses and hose fittings on page 15 of this manual for instructions.

Examine all of the torch leads

1. Examine all of the torch leads for kinks, cracks, cuts, or excessive wear. Replace any torch lead that has damage or
excess wear.

2. Make sure that all connections between the torch and torch leads are tight, but do not over tighten.

3. If the cutting table uses a power track to support hoses that connect the power supply and the gas console, examine

the position of the hoses in the power track. Make sure that they do not kink, bend, or twist during cutting table
operation.

4. Replace any lead or lead fitting that has damage or excess wear.

Examine all of the cables and cable connections

1. Examine all of the cables for damage or excess wear:

 If the system has the optional remote high-frequency console, examine the control cables that connect the

remote high-frequency console and the gas console to the power supply.

 If the system has the optional Initial Height Sense (IHS), examine the cables that connect the inductive probes to

the IHS console.

2. If the outside insulation on a cable is damaged or cut, examine the wires inside.

3. Replace any cable or cable fitting that has damage or excess wear.

Examine the gas line connections

CAUTION!

Do not clean brass connections with ammonia-based cleaners. Ammonia causes crack and become
brittle.

1. Use the provided plug to obstruct the inlet gas fitting on the gas console.

2. Increase the plasma gas pressure to 8.3 bar (120 psi).

26 HySpeed HT2000 Instruction Manual 809020

Preventive Maintenance Program

PLASMA

N

2

/Air

O

2

SHIELD

N

2

/Air

psi

psi

psi

DC

N2/Air

O

2

O

2

PLASMA

Cut Flow

PreFlowPreFlow

Run

10

9

8

7

6

5

4

3

2

1

0

10

9

8

7

6

5

4

3

2

1

0

Test

Preflow

Test

Cutflow

b

c

d

c

a

3. Close the plasma gas valve at the source. Watch for a pressure drop.

If the supply line from the source is a hose, there can be a 0.3 bar to 0.5 bar (5 to 7 psi)



decrease because of hose length.

4. If the pressure continues to drop, try to find the leak:

a. Spray all of the gas lines and connections with soapy water.

b. If bubbles appear on a gas line or on a connection, replace the gas line or tighten the connection.

If you cannot find the source of the leak, contact Hypertherm Technical Service for



recommended action.

5. Repeat step 1 – step 4 for the nitrogen gas supply source, except increase the pressure to 10.34 bar (150 psi) for

nitrogen gas.

6. Repeat step 1 – step 4 for the air, carbon dioxide (or argon-hydrogen), and methane gas supply source (or sources,

as applicable), except increase the pressure to 6.2 bar (90 psi) for these gases.

7. If the system operates on compressed air:

a. Make sure that a filter system is in place to prevent oil or moisture from entering the plasma system.

b. Examine all filters and oil separators. Replace any filter or oil separator that looks dirty.

Do tests for gas leaks

1. Place the gas console in the Test PreFlow mode.

Detailed descriptions of the front panel of the gas



console can be found in Front panel controls and
indicators in your system’s instruction manual.

2. If you changed consumable parts or if the power supply
has been off for more than 1 hour, purge the gas line
before use. To purge the gas lines, leave the system in
test preflow mode for 1 minute.

See your system’s instruction manual for information



on how to do this.

3. Adjust the settings on the front panel of the gas console
to the appropriate preflow gas settings:

a. Se t the Te st Pr ef low / Ru n/ Test C ut Fl ow Tog gl e

Switch to Test PreFlow.

b. Make sure that both of the plasma gas pressure

gauges on the gas console are set at 8.2 bar
(120 psi).

c. Use the oxygen and/or nitrogen-air PreFlow Meter Adjust knob to adjust the PreFlow Gas Flow Rate percentage

(%) to match the Cut chart specifications.

HySpeed HT2000 Instruction Manual 809020 27

Preventive Maintenance Program

d. Use the Shield Gas Adjust knob adjust the shield gas press to match the Cut chart specifications.

Cut chart specifications can be found in your system’s instruction manual.



4. Disconnect the off-valve solenoid from the gas console.

If the digital pressure indicator does not slowly decrease to zero, then there is a leak. The



pressure gauges on the gas console should maintain their pressure. If either the oxygen
or nitrogen pressure gauge decreases by more than 0.1 bar (2 psi) in 10 minutes, than
there is an unacceptable leak. Contact your OEM or regional Hypertherm technical
service team if you need advice on how to find and resolve an unacceptable leak.

5. If you suspect a gas leak, try to find the source:

a. Close the shut-off valves for the oxygen and nitrogen supplies at the source.

b. Spray all of the gas lines and connections with soapy water.

c. If bubbles appear on a gas line or connection, replace the gas line or tighten the connection.

If you cannot find the source of the leak, contact Hypertherm Technical Service for



recommended action.

Examine the air filter in the power supply

See Examine the air filter inside of the power supply on page 18 of this manual for instructions on how to do this.

Examine the remote high-frequency console (if applicable)

WARNING!

ELECTRIC SHOCK CAN KILL

Disconnect electric power before performing any maintenance.

All work requiring removal of the power supply cover must be performed by
a qualified technician.

See the safety information provided with your product for more safety
precautions.

If the system has an optional remote high-frequency console:

1. Disconnect the electric power to the remote high-frequency console.

2. Examine the exterior of the remote high-frequency console:

a. Make sure that the exterior door opens and closes properly.

b. Make sure that the connections are tight for all hoses, cables, and leads. Tighten loose connections if found, but

do not over tighten.

3. Open the door on the remote high-frequency console.

4. Examine the interior of the remote high-frequency console:

28 HySpeed HT2000 Instruction Manual 809020

Preventive Maintenance Program

a. If you find moisture, use a clean cloth to dry the interior of the remote high-frequency console and then contact

Hypertherm Technical Service for recommended action.

b. Make sure that the connections are tight for all hoses, cables, and leads. Tighten loose connections if found, but

do not over tighten.

c. Blow out or vacuum any accumulation of dust and particles.

d. Examine the spark gap assembly:

 Make sure that the 3 electrodes are 0.508 mm (0.200 in.) apart. Contact your OEM or regional

Hypertherm technical service team if you need advice on how to measure the distances between
the electrodes.

 Make sure that the ends of the 3 electrodes are flat and clean.

If needed, use a diamond file to clean the electrodes.



e. Make sure that the wiring connections to the spark gap assembly are tight.

5. Close the door on the remote high-frequency console before you reconnect the remote high-frequency console to

electric power.

Keep the doors closed at all times, except when you do maintenance or clean the remote



high-frequency console.

Examine the motor valve console

WARNING!

ELECTRIC SHOCK CAN KILL

Disconnect electric power before performing any maintenance.

All work requiring removal of the power supply cover must be performed by
a qualified technician.

See the safety information provided with your product for more safety
precautions.

1. Disconnect the electric power to the motor valve console.

2. Examine the exterior of the motor valve console:

a. Make sure that the side panel opens and closes properly.

b. Make sure that the connections for all hoses, cables, and leads are tight. Tighten loose connections if found, but

do not over tighten.

c. Make sure that there are no leaks.

3. Open the side panel of the motor valve console.

4. Examine the interior of the motor valve console:

a. If you find moisture, use a clean cloth to dry the interior of the motor valve console and then contact Hypertherm

Technical Service for recommended action.

HySpeed HT2000 Instruction Manual 809020 29

Preventive Maintenance Program

b. Make sure that the connections are tight for all hoses, cables, and leads. Tighten loose connections if found, but

do not over tighten.

c. Examine the hoses, cables, and leads for kinks, cracks, cuts, or excessive wear. Replace any hose, cable, or lead

that has damage or excess wear.

d. Blow out or vacuum any accumulation of dust and particles.

5. Close the side panel of the motor valve console before you reconnect the motor valve console to electric power.

Keep the side panel closed at all times, except when you do maintenance or clean the



motor valve console.

Examine the gas console

WARNING!

ELECTRIC SHOCK CAN KILL

Disconnect electric power before performing any maintenance.

All work requiring removal of the power supply cover must be performed by
a qualified technician.

See the safety information provided with your product for more safety
precautions.

1. Disconnect the electric power to the gas console.

2. Examine the exterior of the gas console:

a. Make sure that the connections are tight for all hoses, cables, and leads. Tighten loose connections if found, but

do not over tighten.

b. Make sure that there are no leaks.

c. Examine the flow meters for damage, including broken glass tubes (“float stops”) inside. Replace any flow meter

or float stop that has damage or excess wear.

d. Examine the pressure gauges for damage. Replace any pressure gauge that has damage.

See Part’s list in your system’s instruction manual for information on replacement parts.



3. Remove the rear panel from the gas console.

4. Examine the interior of the gas console:

a. Make sure that the connections are tight for all hoses, cables, and leads. Tighten loose connections if found, but

do not over tighten.

b. Blow out or vacuum any accumulation of dust and particles.

5. Install the rear panel of the gas console before you reconnect the gas console to electric power.

Keep the rear panel on at all times, except when you do maintenance or clean the gas



console.

30 HySpeed HT2000 Instruction Manual 809020

Preventive Maintenance Program

6

8

7

Bi-yearly

Replace the coolant and the coolant filter

1. Get an empty container with an approximate capacity of 11.4 liters (3 US gallons).

2. Disconnect the electric power to the power supply.

3. Remove the rear panel of the power supply and find the coolant reservoir.

4. Remove the cap from fill inlet on the coolant reservoir to allow the coolant

reservoir to vent.

5. Place the 11.5 liter (3 US gallons) container under the drain on the
bottom of the coolant reservoir.

6. Remove the drain cap from the coolant reservoir; allow the coolant to flow
into the container.

For older systems, there may be no drain or the drain may be in a



different location. Siphon coolant out of the coolant reservoir, if
needed.

7. Find the 2 coolant supply hoses that exit the rear of the cathode block at
the rear of the power supply.

Both hoses are black. One hose has a green band. One hose has a red



band.

8. Remove the hose with the green band from the cathode block.

9. Blow clean, dry, oil-free air at 5.5 – 8.3 bar (80 – 120 psi) into the hose

with the green band until coolant ceases to flow into the coolant reservoir.

10. Remove the reservoir drain cap, if applicable.

11 . Remove the coolant filter housing from the rear of the power supply.

12. Drain any coolant from the coolant filter housing into the container, if needed.

13. Dispose of the used coolant and coolant filter according to local regulations.

14. Insert a new coolant filter (027005) into the coolant filter housing.

15. Screw the coolant filter housing back into the rear of the power supply.

16. Make sure that the coolant reservoir is full of coolant.

17. If the level of the coolant is below the top of the reservoir, fill the coolant reservoir with coolant (028872).

18. Screw on the fill inlet cap on the coolant reservoir.

19. Install the rear panel of the power supply before you reconnect the power supply to electric power.

HySpeed HT2000 Instruction Manual 809020 31

Preventive Maintenance Program

4

7

5

8

20. Record the number of liters (US gallons) that your system requires in Coolant requirements on page 47 of this

manual.

Clean the coolant pump strainer

WARNING!

ELECTRIC SHOCK CAN KILL

Disconnect electric power before performing any maintenance.

All work requiring removal of the power supply cover must be performed by
a qualified technician.

See the safety information provided with your product for more safety
precautions.

1. Disconnect the electric power to the power supply.

2. Remove the coolant pump from the power supply to reduces the risk that debris will fall into the strainer housing.

3. Drain the coolant from the coolant reservoir, if not already drained. See Replace the coolant and the coolant filter on

page 31.

4. Remove the nut from the strainer housing to release the coolant pump strainer.

5. Remove the coolant pump strainer from the strainer housing.

6. Clean the coolant pump strainer:

a. Clean it in a solution of mild soap and water.

b. Flush it with clean, running water.

7. Insert the coolant pump strainer into the strainer housing.

8. Install the nut to hold the coolant pump strainer in place.

9. Examine the coolant filter.

10. If the coolant filter looks clean, install the coolant filter housing.

11 . If the coolant filter looks dirty, replace the coolant filter (027005).

12. Make sure that the coolant reservoir is full of coolant.

13. If the level of the coolant is below the top of the reservoir, refill the coolant reservoir with coolant (028872).

14. Screw on the fill inlet cap.

15. Install the rear panel of the power supply before you reconnect the power supply to electric power.

32 HySpeed HT2000 Instruction Manual 809020

Do all maintenance tasks

See Monthly on page 19 of this manual.

Replace all service parts

See Component replacement schedule on page 34 of this manual.

Ye ar ly

Do all maintenance tasks

See Monthly on page 19 of this manual.

Replace all service parts

See Component replacement schedule on page 34 of this manual.

Preventive Maintenance Program

HySpeed HT2000 Instruction Manual 809020 33

34 HySpeed HT2000 Instruction Manual 809020

Component replacement schedule

This is a list of components and their recommended replacement schedule. The schedule uses total arc hours to estimate when to replace components. The
use of cumulative arc hours is the most accurate method to estimate when you need to replace a component. For more information about how to calculate
arc hours, contact your OEM manufacturer.

Your cutting area and operations can have an effect on this schedule. See Cutting area and operation effects on page 36 of this manual.

See HT2000 preventive maintenance kits on page 35 for a list of HT2000 Preventive Maintenance kits and for the part number and quantity of each item in
every kit.

Preventive Maintenance Program

Item

Number

Quantity Component

300 600 900 1,200 1,500 1,800 2,100 2,400 2,700 3,000 3,300 3,600

Cumulative number of arc hours

027005 1 Coolant filter element XXXXXXXXXXXX
028872 4 Coolant solution 30/70* XXXXXXXXXXXX

003249 1 Main contactor XXXXXX

– 1 Torch main body*** X XXXXX
003021 1 Pilot arc relay X X X X X X
128384 1 Coolant pump X X X

–1 Torch leads** XXX
004061 3 Spark gap electrode X X X
129840 1 Off-valve assembly X X

027080 2 Cooling fan X X

027079 1 Cooling fan X X
129150 1 High voltage transformer X
041534 1 Power distribution board X

– 1 Pilot arc lead** X
– 1 Gas leads** X

* The number of liters/US gallons you need depends on the length of the leads. See your system’s instruction manual for more information, then record this number in

Coolant requirements on page 47 of this manual.

** Part numbers are system dependent. See Part numbers for hoses, leads, and cables on page 41 for reorder information.

*** Part numbers are system dependent. See HT2000 preventive maintenance kits on page 35 for configurations.

HT2000 preventive maintenance kits

Preventive Maintenance Program

Kit part
number

128907 Preventive maintenance kit with standard torch main body

228840 Preventive maintenance kit with stainless steel torch main

Kit description Part description

(120584), for systems that use the standard torch main
body

body (120356), for systems that use the stainless steel
torch main body

Part

number

Pilot arc relay 003021 1

Main contactor 003249 1

Lens: white 005089 1

Light bulb 005149 1

Coolant filters 027005 2

Coolant 028882 8 US

Torch main body 120584 1

Pilot arc relay 003021 1

Main contactor 003249 1

Lens: white 005089 1

Light bulb 005149 1

Quantity

in kit

gallons

228774 Preventive maintenance kit with HyPro2000

quick disconnect torch main body (220921), for systems
that have been upgraded to the HyPro2000
quick disconnect torch main body

Coolant filters 027005 2

Coolant 028882 8 US

gallons

Torch main body 120356 1

Pilot arc relay 003021 1

Main contactor 003249 1

Lens: white 005089 1

Light bulb 005149 1

Air filters 015299 3

Coolant filters 027005 2

Coolant 028882 8 US

gallons

Torch main body 220921 1

HySpeed HT2000 Instruction Manual 809020 35

Preventive Maintenance Program

Kit part
number

Kit description Part description

228911 Preventive maintenance kit with HyPro2000 straight torch

main body (220961). for systems that have been
upgraded to the HyPro2000 straight torch main body

Part

number

Quantity

in kit

Pilot arc relay 003021 1

Main contactor 003249 1

Lens: white 005089 1

Light bulb 005149 1

Air filters 015299 3

Coolant filters 027005 2

Coolant 028882 8 US

gallons

Torch main body 220961 1

O-rings 044026 2

Water tube 220521 1

Silicone lubricant 027055 1

Cutting area and operation effects

The Component replacement schedule is for reference only. Your cutting area conditions and operations can have an
effect on your component replacement schedule.

Wear decreases system performance and component life. The most common conditions and operations that can increase
the wear on some components in your plasma system include:

 External cutting area

 Incoming air supply quality

 Metal dust inside of the power supply cabinet

 Consumable use

 Cut cycle time

If any of these conditions or operations apply, adjust your replacement schedule as suggested.

How much you need to adjust your replacement schedule depends on how bad the condition is. If you have questions
about your replacement schedule, contact your OEM or regional Hypertherm Technical Services team.

External cutting area

Consumables and torch assemblies stored in dirty cutting areas with no protection can collect contamination, such as dirt
and metal dust. If this contamination gets into the torch or coolant, it can cause the following problems:

 Prevent O-rings and seals on the torch heads and receptacles from sealing

 Increase wear on torch heads and receptacles

36 HySpeed HT2000 Instruction Manual 809020

Preventive Maintenance Program

 Increase wear on the coolant pump

 Cause unsatisfactory operation of the coolant flow switch

It can help to flush the coolant system or clean the flow switch. But, it can be necessary



to replace the coolant switch to fully repair the operation of the coolant loop system.

The best solution is to store consumables and torch assemblies in a clean, protective space. Another solution is to use
compressed air to clean these parts before you use them.

If you cannot store your consumables and torch heads in a protective space, you can replace the following components
more frequently:

Description Part number

Torch assembly: HySpeed HT2000 machine torch with valve and 50 mm (2 in.) diameter sleeve
(standard body)

Torch assembly: HySpeed HT2000 machine torch with valve and 50 mm (2 in.) diameter sleeve
(stainless steel body)

Torch assembly: HySpeed HT2000 machine torch with 44 mm (1-3/4 in.) diameter sleeve (standard
body)

Torch assembly: HyPro2000 quick disconnect torch with valve (standard body) 220921

Torch assembly: HT2000 high precision torch with valve (standard body) 120356

Torch assembly: HyPro2000 straight machine torch with valve (standard body) 220961

Torch main body only: HySpeed HT2000 machine torch (standard body) 120584

Torch main body only: HySpeed HT2000 machine torch (stainless steel body) 120356

Sleeve, HyPro2000 torch mounting, 279.4-mm X 50.8-m (11-in. X 2-in.) (standard body) 220943

Sleeve, HyPro2000 torch mounting, 279.4-mm X 44.45-m (11-in. X 1-3/4-in.) (standard body) 220942

Sleeve, HySpeed2000 torch mounting, 279.4-mm X 44.45-mm (11-in. X 2-in.) (standard body) 120894

Sleeve, HySpeed2000 torch mounting, 279.4-mm X 44.45-mm (11-in. X 1-3/4-in.) (standard body) 020431

128381

128367

128141

Sleeve, HySpeed2000 torch mounting, 279.4-mm X 44.45-mm (11-in. 1-3/4-in.) (stainless steel
body)

Kit: HySpeed HT2000 Consumable Starter Kit 128824

Kit: HT2000 standard consumable parts 028602

Kit: HySpeed HT2000 consumable parts 128825

Kit: Beveling consumable parts 128406

020041

HySpeed HT2000 Instruction Manual 809020 37

Preventive Maintenance Program

Incoming air supply quality

To maintain system performance, it is important that the incoming air supply is clean. If the air supply has dirt, oil, or water
in it, components can become clogged or defective. An air supply of bad quality can cause the following problems:

 Decrease air flow

 Increase system errors

 Decrease cut quality and performance

Oil in the torch head can cause a fire when the oil reacts with the oxygen cutting process. Also, unwanted material in
pressure sensors can cause false pressure readings.

The best solution, if possible, is to improve the quality of the air supply. Contact your OEM or regional Hypertherm
Technical Service team if you need advice on how to improve the quality of your air supply.

If you cannot change your air supply quality, you can replace the following components more frequently:

Description Part number

Fan assembly, 225 CFM: includes 027080 fan and fan guard 129307

Fan only: 225 CFM, 120 VAC, 50Hz – 60Hz (16.19 cm, 6.375 in.) 027080

Fan assembly, 450 CFM – 550 CFM, 120 VAC, 50Hz – 60Hz: includes 027079 fan and fan

129308

guard

Fan only: 450 CFM – 550 CFM, 120 VAC, 50Hz – 60Hz (22.23 cm; 8-3/4 in.) 027079

Air filter, fiberglass (60.98-cm X 60.98-cm X 5.08-cm) (24-in. X 24-in. X 2-in.) 027441

Heat exchanger assembly MAX200: includes water/air heat exchange fan 027978 029324

Water/air heat exchanger fan 027978

Gas console pressure switch (5.51 bar / 80 psi) 005243

Gas console solenoid valve: 10.34 bar / 150 psi, Manf 120V 2-way NC) 006109

Gas console pressure gauge: 6.89 bar / 100 psi (6.35 cm / 2.5 in. diameter) 022008

Gas console pressure gauge: 11.03 bar / 160 psi (5.08 cm / 2 in. diameter) 022020

Metal dust inside of the power supply cabinet

Plasma cutting makes metal dust. If metal dust collects inside the plasma power supply, it can decrease the life of the
fans and coolant pump motor.

The main power supply, chopper, or heat exchanger fans can operate more slowly, or failure of the fans can occur. This
can cause temperature-related errors. The coolant pump motor can become too hot and operate incorrectly.

The best solution to extend the life of the fans and coolant pump motor is to clean inside the power supply. For
instructions, see Clean inside of the power supply on page 16.

38 HySpeed HT2000 Instruction Manual 809020

Preventive Maintenance Program

If metal dust has collected inside the power supply, you can replace the following components more frequently:

Description Part number

Fan only: 225 CFM, 120 VAC, 50Hz – 60Hz 027080

Fan only: 450 CFM – 550 CFM, 120 VAC, 50Hz – 60 Hz 027079

Air filter, fiberglass (60.98-cm X 60.98-cm X 5.08-cm) (24-in. X 24-in. X 2-in.) 027441

Water/air heat exchanger only 027978

Water pump assembly 129252

Kit: Water pump motor (1/3 HP Carbon 230/50-60) 128385

Kit: Water pump motor (264.98 L/min., 70 US gallons/min. positive displace) 128384

Water/air heat exchanger fan 027978

Consumable use

If you let consumables reach complete failure, they can melt. Copper pieces can then break off and go into the coolant. In
the coolant, these pieces can cause the following problems:

 Decrease coolant flow

 Increase coolant flow errors

 Cause damage to the consumables

 Cause coolant to leak at the check vale when you change the consumables

 Cause inaccurate coolant flow readings

 Decrease the life of the coolant pump

 Decrease the lief of the check valve

When you do maintenance, examine the coolant filter for copper pieces. If you find copper pieces in the coolant filter,
replace both the coolant filter and the coolant. If a coolant flow error occurs after you replace the coolant filter and
coolant, use the troubleshooting procedure in your system’s instruction manual to find the correct action.

The best solution is to follow the usage guidelines for your consumables. However, if overuse occurs, you can replace the
following components more frequently:

Description Part number

Coolant reservoir 002304

Coolant 028872

Coolant filter element 027005

Gauge, coolant level 022036

HySpeed HT2000 Instruction Manual 809020 39

Preventive Maintenance Program

Description Part number

Coolant level switch, assembly, 1/2 NPT 129618

Coolant flow switch, 0.5 GPM 029361

Coolant check valve 006053

Coolant temperature switch, assembly (72.2°C / 162°F) 029323

Cut cycle time

When the cut-cycle is very short, relays operate more frequently. The system also pierces more frequently. Examples of
this type of cycle are when you cut many small holes or make markings for numbers and letters. These types of operations
can cause the following problems:

 Increase wear on pilot arc relay contact pads

 Increase wear on the starting components, such as the high-frequency transformer and the high-frequency ignition

board

 Increase misfires and error codes

If your cut-cycle is short, you can replace the following components more frequently:

Description Part Number

Pilot arc relay 003021

Pilot arc lead System dependent

Main contactor (90 A, 3P, 120 VAC) 003249

Spark gap electrode 004061

Off-valve assembly* 129470

Cable, torch off-valve 123185

Hose (off valve assembly to torch main body) (for both standard and stainless steel torch

024355

bodies)

Hose (motor-valve box to off-valve assembly) (for both standard and stainless steel torch

024354

bodies)

High voltage transformer 129150

Power distribution board 041534

Torch main body (HySpeed HT2000) machine torch (standard body) 120584

Torch main body (HySpeed HT2000) machine torch (stainless steel body) 120356

* Off-valve assembly is required with the optional 44.45 mm (1-3/4 in.) mounting sleeve (020431).

40 HySpeed HT2000 Instruction Manual 809020

Preventive Maintenance Program

Part numbers for hoses, leads, and cables

Hoses

Oxygen supply hoses (oxygen supply to gas console)

Part number Length Part number Length

024204 4.6 m (15 ft) 024450 35.1 m (115 ft)
024205 7.6 m (25 ft) 024516 36.6 m (120 ft)
024155 15.3 m (50 ft) 024490 38.1 m (125 ft)
024398 22.9 m (75 ft) 024159 45.8 m (150 ft)
024487 25.9 m (85 ft) 024470 54.9 m (180 ft)
024206 30.5 m (100 ft) 024333 61 m (200 ft)
024481 33.6 m (110 ft) — —

Nitrogen supply hoses (nitrogen supply to gas console)

Part number Length Part number Length

024505 1.8 m (6 ft) 024116 30.5 m (100 ft)
024210 3 m (10 ft) 024482 33.6 m (110 ft)
024203 4.6 m (15 ft) 024451 35.1 m (115 ft)
024232 6.1 m (20 f) 024517 36.6 m (120 ft)
024134 7.6 m (25 ft) 024491 38.1 m (125 ft)
024211 10.7 m (35 ft) 024120 45.8 m (150 ft)
024112 15.3 m (50 ft) 024185 54.9 m (180 ft)
024148 22.9 m (75 ft) 024124 61 m (200 ft)
024488 25.9 m (85 ft) — —

Plasmas preflow gas hoses (gas console to motor valve console)

Part number Length Part number Length

024317 1.5 m (5 ft) 024031 12.2 m (40 ft)
024026 3 m (10 ft) 024207 13.7 m (45 ft)
024027 4.6 m (15 ft) 024340 15.3 m (50 ft)
024017 6.1 m (20 ft) 024419 17.1 m (56 ft)
024028 7.6 m (25 ft) 024127 18.3 m (60 ft)
024029 9.2 m (30 ft) 024343 22.9 m (75 ft)
024030 10.7 m (35 ft) 024344 30.5 m (100 ft)

Plasma cut flow gas hoses (gas console to motor valve console)

Part number Length Part number Length

024316 1.5 m (5 ft) 024310 12.2 m (40 ft)
024307 3 m (10 ft) 024323 13.7 m (45 ft)
024320 4.6 m (15 ft) 024311 15.3 m (50 ft)
024308 6.1 m (20 ft) 024420 17.1 m (56 ft)
024321 7.6 m (25 ft) 024367 18.3 m (60 ft)
024309 9.2 m (30 ft) 024357 22.9 m (75 ft)
024322 10.7 m (35 ft) 024358 30.5 m (100 ft)

HySpeed HT2000 Instruction Manual 809020 41

Preventive Maintenance Program

Shield gas hoses (shield gas supply to gas console)

Part number Length Part number Length

024043 1.2 m (4 ft) 024486 25.9 (85 ft)
024341 3 m (10 f) 024115 30.5 m (100 ft)
024200 4.6 m (15 ft) 024452 33. 6 (110 ft)
024342 6.1 m (20 ft) 024449 35.1 m (115 ft)
024133 7.6 m (25 ft) 024515 36.6 m (120 ft)
024448 10.7 m (35 ft) 024395 38.1 m (125 ft)
024407 13.7 m (45 ft) 024119 45.8 m (150 ft)
024012 15.3 m (50 ft) 024480 51.9 m (170 ft)
024472 18.3 m (60 ft) 024184 54.9 m (180 ft)
024147 22.9 m (75 ft) 024123 61 m (200 ft)

Shield gas hoses (gas console to remote high-frequency console)

Part number Length Part number Length

024348 1.5 m (5 ft) 024352 12.2 m (40 ft)
024313 3 m (10 ft) 024353 13.7 m (45 ft)
024302 4.6 m (15 ft) 024304 15.3 m (50 ft)
024349 6.1 m (20 ft) 024305 22.9 m (75 ft)
024303 7.6 m (25 ft) 024306 30.5 m (100 ft)
024350 9.2 m (30 ft) 024312 45.8 m (150 ft)
024351 10.7 m (35 ft) — —

Shield gas hoses (gas console to remote high-frequency console)

Part number Length Part number Length

024061 1.5 m (5 ft) 024092 12.2 m (40 ft)
024063 3 m (10 ft) 024403 13.7 m (45 ft)
024065 4.6 m (15 ft) 024096 15.3 m (50 ft)
024067 6.1 m (20 ft) 024174 18.3 m (60 ft)
024069 7.6 m (25 ft) 024468 22.9 m (75 ft)
024071 9.2 m (30 ft) 024523 30.5 m (100 ft)
024356 10.7 m (35 ft) — —

Argon/hydrogen gas hoses (argon/hydrogen console to torch)

Part number Length Part number Length

024354 3 m (10 ft) 024370 12.2 m (40 ft)
024355 3.7 m (12 ft) 024443 15.3 m (50 ft)
024368 6.1 m (20 ft) 024467 22.9 m (75 ft)
024369 9.2 m (30 ft) — —

42 HySpeed HT2000 Instruction Manual 809020

Preventive Maintenance Program

Cooling system hoses (sets of 2: 1 red, 1 green) (power supply to remote high-frequency console)

Part number Length Part number Length

028760 0.9 m (3 ft) 128078 25.9 m (85 ft)
028860 2.1 m (7 ft) 028444 30.5 m (100 ft)
028652 3 m (10 ft) 028902 33.6 m (110 ft)
028440 4.6 m (15 ft) 028896 35.1 m (115 ft)
028653 6.1 m (20 ft) 128129 36.6 m (120 ft)
028441 7.6 m (25 ft) 028747 38.1 m (125 ft)
028442 15.3 m (50 ft) 028445 45.8 m (150 ft)
128052 18.3 m (60 ft) 128064 53 m (175 ft)
028443 22.9 m (75 ft) 028637 61 m (200 ft)

Remote high frequency console hoses (remote high-frequency console to gas console)

Part number Length Part number Length

028683 10 ft (3 m) 028687 30 ft (9.1 m)
028684 15 ft (4.6 m) 028688 35 ft (10.6 m)
028685 20 ft (6.2 m) 028689 50 ft (15 m)
028686 25 ft (7.6 m) — —

Gas console hoses (gas console to motor valve)

Part number Length Part number Length

028622 3 m (10 ft) 028627 10.6 m (35 ft)
028623 4.6 m (15 ft) 028654 15 m (50 ft)
028624 6.2 m (20 ft) 028655 23 m (75 ft)
028625 7.6 m (25 ft) 028656 30 m (100 ft)
028626 9.1m (30 ft) — —

Leads

Shielded torch leads

Part number Part 1 Part 2 Part 3 Part 4 Length

028657 023429 024221 023032 023032 3 m (10 ft)
028658 023430 024222 023034 023034 4.6 m (15 ft)
028659 023431 024223 023012 023012 6.1 m (20 ft)
028546 023326 024192 023013 023013 7.6 m (25 ft)
028660 023432 024224 023014 023014 9.2 m (30 ft)
028661 023433 024225 023015 023015 10.7 m (35 ft)
028662 023434 024226 023016 023016 12.2 m (40 ft)
028663 023435 024227 023387 023387 13.7 m (45 ft)
028547 023327 024193 023199 023199 15.3 m (50 ft)
028767 023773 024404 023772 023772 16.9 m (55 ft)
028768 023515 024259 023052 023052 18.3 m (60 ft)

HySpeed HT2000 Instruction Manual 809020 43

Preventive Maintenance Program

Negative lead and work cable (power supply to remote high-frequency console)

Part number Length Part number Length

023755 1.2 m (4 ft) 023406 22.9 m (75 ft)
023920 2.4 m (8 ft) 123074 25.9 m (85 ft)
023508 3 m (10 ft) 023407 30.5 m (100 ft)
023403 4.6 m (15 f) 023964 33.6 m (110 ft)
023404 7.6 m (25 ft) 023959 35.1 m (115 ft)
023968 9.2 m (30 ft) 123144 36.6 m (120 ft)
023986 10.7 m (35 ft) 023738 38.1 m (125 ft)
023405 15.3 m (50 ft) 023408 45.8 m (150 ft)
123041 18.3 m (60 ft) 023644 61 m (200 ft)

Power supply leads (power supply to remote high-frequency console)

Part number Length Part number Length

028604 7.6 m (25 ft) 028607 30 m (100 ft)
028605 15 m (50 ft) 028608 45 m (150 ft)
028606 23 m (75 ft) 028651 61 m (200 ft)

Cables

Pilot arc cables (power supply to remote high-frequency console)

Part number Length Part number Length

023754 1.2 m (4 ft) 023966 30.5 m (100 ft)
023919 2.4 m (8 ft) 023634 33.6 m (110 ft)
023987 3 m (10 ft) 023961 35.1 m (115 ft)
023631 7.6 m (25 ft) 123146 36.6 m (120 ft)
023632 15.3 m (50 ft) 023740 38.1 m (125 ft)
123043 18.3 m (60 ft) 023635 45.8 m (150 ft)
023633 22.9 m (75 ft) 023652 61 m (200 ft)
123076 25.9 m (85 ft) — —

HT2000 remote high frequency (RHF) console leads (power supply to remote high-frequency console)

Part number Length Part number Length

023756 0.9 m (3 ft) 123075 25.9 m (85 ft)
023921 2.1 m (7 ft) 023613 30.5 m (100 ft)
023988 3 m (10 ft) 023965 33.6 m (100 ft)
023550 4.6 m (15 ft) 023960 35.1 m (115 ft)
023610 7.6 m (25 ft) 123145 36.6 m (120 ft)
023611 15.3 m (50 ft) 023739 38.1 m (125 ft)
123042 18.3 m (60 ft) 023614 45.8 m (150 ft)
023612 22.9 (75 ft) 023645 61 m (200 ft)

44 HySpeed HT2000 Instruction Manual 809020

Preventive Maintenance Program

Gas console cables (power supply to gas console)

Part number Length Part number Length

023989 3 m (10 ft) 123077 25.9 m (85 ft)
023549 4.6 m (15 ft) 023608 30.5 m (100 ft)
023605 7.6 m (25 ft) 023963 35.1 m (115 ft)
023757 11.6 m (38 ft) 123147 36.6 m (120 ft)
023606 15.3 m (50 ft) 023743 38.1 m (125 ft)
123044 18.3 m (60 ft) 023609 45.8 m (150 ft)
023607 22.9 m (75 ft) 023953 61 m (200 ft)

Motor valve console cables (power supply to motor valve console)

Part number Length Part number Length

023551 4.6 m (15 ft) 023593 30.5 m (100 ft)
023590 27.6 m (25 ft) 123078 33.6 m (110 ft)
023776 10.7 m (35 ft) 023967 36.6 m (120 ft)
023591 15.3 m (50 ft) 123143 39.7 m (130 ft)
023592 22.9 m (75 ft) 023594 45.8 m (150 ft)
123045 25.9 m (85 ft) 023658 61 m (200 ft)

Machine interface cables (power supply to machine I/O)

Part number Length Part number Length

023841 1.8 m (6 ft) 123080 25.9 m (85 ft)
023842 4.6 m (15 ft) 023847 30.5 m (100 ft)
023843 7.6 m (25 ft) 023962 35.1 m (115 ft)
023844 10.7 m (35 ft) 123148 36.6 m (120 ft)
023845 15.3 m (50 ft) 023848 38.1 m (125 ft)
123047 18.3 m (60 ft) 023849 45.8 m (150 ft)
023846 22.9 m (75 ft) 023850 61 m (200 ft)

Machine interface V/C cables (power supply to machine computer)

Part number Length Part number Length

023902 1.8 m (6 ft) 023855 22.9 m (75 ft)
023851 4.6 m (15 ft) 023856 30.5 m (100 ft)
023852 7.6 m (25 ft) 023903 38.1 m (125 ft)
023853 10.7 m (35 ft) 023857 45.8 m (150 ft)
023854 15.3 m (50 ft) 023858 61 m (200 ft)

Remote V/C cables (power supply to digital (DR)/Programmable (PR) V/C)

Part number Length Part number Length

023990 2.1 m (7 ft) 123188 36.6 m (120 ft)
023911 4.6 m (15 ft) 023882 38.1 m (125 ft)
023878 7.6 m (25 ft) 023883 45.8 m (150 ft)
023879 15.3 m (50 ft) 023884 61 m (200 ft)
123040 18.3 m (60 ft) 023885 76.3 m (250 ft)
023880 22.9 m (75 ft) 023886 83.9 m (275 ft)
123073 25.9 m (85 ft) 023887 91.5 m (300 ft)
023881 30.5 m (100 ft) — —

HySpeed HT2000 Instruction Manual 809020 45

Preventive Maintenance Program

Power supply/programmable remote (PR) cables (power supply to PR V/C)

Part number Length Part number Length

023834 4.6 m (15 ft) 023839 45.8 m (150 ft)
023835 7.6 m (25 ft) 023840 61 m (200 ft)
023836 15.3 m (50 ft) 023899 76.3 m (250 ft)
023837 22.9 m (75 ft) 023900 83.9 m (275 ft)
023838 30.5 m (100 ft) 023901 91.5 m (300 ft)
023898 38.1 m (125 ft) — —

Argon/hydrogen console cables (power supply to argon/hydrogen console)

Part number Length Part number Length

023660 4.6 m (15 ft) 023663 22.9 m (75 ft)
023661 7.6 m (25 ft) 023664 30.5 m (100 ft)
023662 15.3 m (50 ft) 023665 45.8 m (150 ft)

Time/counter cables (power supply to timer/counter)

Part number Length Part number Length

023687 3 m (10 ft) 123079 25.9 m (85 ft)
023692 7.6 m (25 ft) 023695 30.5 m (100 ft)
023758 11.6 m (38 ft) 023993 35.1 m (115 ft)
023693 15.3 m (50 ft) 123189 36.6 m (120 ft)
123046 18.3 m (60 ft) 023696 45.8 m (150 ft)
023694 22.9 m (75 ft) 023954 61 m (200 ft)

Hold cables (power supply to power supply)

Part number Length Part number Length

023340 4.6 m (15 ft) 023343 30.5 m (100 ft)
023341 7.6 m (25 ft) 023344 45.8 m (150 ft)
023342 15.3 m (50 ft) — —

Water muffler pump cables (power supply to water muffler)

Part number Length Part number Length

023866 15.3 m (50 ft) 023868 30.5 m (100 ft)
023867 22.9 m (75 ft) — —

Initial height sensing cables (power supply to initial height sensor)

Part number Length Part number Length

023859 7.6 m (25 ft) 023862 30.5 m (100 ft)
023860 15.3 m (50 ft) 023863 45.8 m (150 ft)
023861 22.9 m (75 ft) 023864 61 m (200 ft)

Initial height sensing cables (initial height sensor to sensors)

Part number Length m Part number Length

023888 0.6 m (2 ft) 023889 0.6 m (2 ft)
023869 12.2 m (40 ft) 023870 12.2 m (40 ft)

46 HySpeed HT2000 Instruction Manual 809020

Preventive Maintenance Program

System information

Model number Serial number

System voltage

 200 V

 208 V

 220 V

 220 V

 240 V

 380 V

 400 V

 415 V

 440 V

 480 V

 600 V

Coolant requirements

 11.4 L (3 US gallons)

 Other:

HySpeed HT2000 Instruction Manual 809020 47

Preventive Maintenance Program

Notes

48 HySpeed HT2000 Instruction Manual 809020

Maintenance log for the HySpeed HT2000 (page 1 of 3)

Daily tasks 12345678910111213141516171819202122232425262728293031

Do a check of the gas flow
settings

Examine the torch and
consumables

Examine the torch leads

Examine all of the hoses and hose
fittings

Weekly tasks Week 1 Week 2 Week 3 Week 4 Week 5

Clean inside of the power supply

Clean the torch threads and the ring inside of the torch
main body

Do a check of the cooling fans

Do a check of the coolant level

Bi-monthly task

circle one: January February March April May June July August September October November December

Examine the air filter inside of the power supply Week 1 Notes:

Week 2 Notes:

Maintenance log for the HySpeed HT2000 (page 2 of 3)

Monthly tasks

circle one: January February March April May June July August September October November December

Make sure that the system is correctly grounded Notes:

Examine the exterior of the power supply

Examine and clean the interior of the power supply

Examine the coolant filter in the power supply

Test the rate of coolant flow to the torch

Test the rate of coolant return from the torch

Look for coolant leaks

Clean the torch threads and the rings inside of the torch
main body

Examine and lubricate all of the O-rings

Examine the optional water tube (if applicable) and the
torch main body

Examine the torch insulator for cracks

Examine the retaining cap and shield

Examine all of the hoses and hose fittings

Examine all of the torch leads

Examine all of the cables and cable connections

Maintenance log for the HySpeed HT2000 (page 3 of 3)

Monthly tasks (continued)

circle one: January February March April May June July August September October November December

Do tests for gas leaks Notes:

Examine the air filter in the power supply

Examine the remote high-frequency console
(if applicable)

Examine the motor valve console

Examine the gas console

Bi-yearly tasks
circle one: January June

Replace the coolant and the coolant filter Notes:

Clean the coolant pump strainer

Do all maintenance tasks (page 19)

Replace all service parts (page 34)

Yearly tasks

Do all maintenance tasks (page 19) Notes:

Replace all service parts (page 34)