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HySpeed HT2000 LHF

Hypertherm HySpeed HT2000 LHF Instruction Manual (IM)

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HySpeed HT2000LHF
Plasma Arc Cutting System
Instruction Manual 803020 – Revision 11
®
Changed Page Description
p
4.7 Updated noise level data to match regulatory table. LED error codes for the control board were corrected. A new board was introduced about
5.14 and 5.15
2 years ago, but the error codes were not updated. The old board (041590) information is still included in the manual.
5.19-5.25 Added preventive maintenance information.
6.15
6.16-6.17
dated art and part numbers from standard to HySpeed consumables.
U Corrected item numbers. The numbers in the graphic did not match the numbers in the
tables.
Rev 9 to 10
12/10/04
Changed Page Description
Item # 7 changed from 041560 to 041764. Item # 8 081031
6.2
(firmware) was removed. Item numbers following Item # 7 changed to agree.
Section 7
Wiring diagram revision changed from H to K (all pages)
Changed Page Description
Cover & title page
Changed Page Description
TOC Updated table of contents to reflect changes.
Plasma gas flow rate for Oxygen changed from 80 scfh (2265 l/h) to 90 scfh
2.2
3.6
3.8
4.7
4.10
4.11
4.12
4.13
4.30
4.34
5.4
5.14
5.19
6.8
6.15
6.16
6.17
Section 7
App F & G
Index
(2549 l/h) Removed reference to neon light in warning box. changed. Added info on SilverPlus electrode under check torch/first bullet point. Put conversion information on page 4.10 under “conversions.” Removed from bottom of cutchart pages Added HySpeed parts to chart. All processes now listed (like the HT2000 IM) Added HySpeed cut chart. All following page #s bumped up by 1. Added info on SilverPlus electrode. Added info on SilverPlus electrode under # 6. Updated cut quality info. Removed reference to neon light in warning box. #4 - it is 300ms for all processes. Added preventive maintenance schedule. Changed item # 10, Off-valve subassembly, to 027978 (was 027136). Added HySpeed consumables to standard torch assembly. Changed item #5 to 129840 (was 129290) Added page with HySpeed starter kit part #s. Added page with HySpeed consumable parts kit. Following page and figure numbers redone. Wiring Diagram format changed from 8-1/2 X 11" to 11 X 17" Appendix G, Aeration manifold, changed to App F. Appendix F, Standards, dropped. Info in safety section under "additional safety information." justify it.
Revision change only. All content changes made in revision 7
Rev 8 to 9
8/31/03
5/06/03
Rev 6 to 7
4/11/03
Changed Page Description
Rev 5 to 6
8/31/03
6.2
Item # 7 changed from 041560 to 041764. Item # 8 081031 (firmware) was removed.
Section 7
Changed Page Description
0.01 Uprevved because of ECNs 10483, 10484, 10639m, 10145, 10670
0.02 Added plumbing and electrical codes statement to warranty
1.0-1a.06
3.18
3.19
5.17
5.18
6.08
6.15
6.18
7.05-7.13
Wiring diagram revision changed from H to K (all pages)
New safety sections New graphic of valve cluster Modified graphic of torch Changed graphic of coolant reservoir New graphic of coolant reservoir New coolant reservoir #, new level switch SA # New Torch mounting sleeve # Added new level switch SA # to recommended spare parts Uprevved wiring diagrams to G
IM304 Rev 4 to 5 9/27/99
Changed Page Description
0.01 Uprevved because of request to add cut quality info and ECNs 10228, 10308, 10344, 10417
0.03-.08 Updated TOC
2.03
3.03
3.04
3.11
4.10
4.33-4.36
6.04
6.05
6.09
6.13
6.16
6.17
6.18
7.01-7.13 a.01-a.14
i.01-i.06
Added 440V power supplies Changed spec. on coolant Added power specs for 440V Added note referencing DC relay kit part number Added line referencing cutting techniques Adding cutting techniques Added 440V control xfrmr Added 440V power xfrmr Changed p/n of items 6 and 7 for new pressure switch Added 015049 to parts list Changed figure title to HT2000 Consumable Parts Added HT2000 Beveling Consumable Parts Kit Bumped page - also changed p/n for pressure switch in gas console recommended spare parts Wiring diagram change to reflect new 440V power supply rev E to rev F Added argon-hydrogen cutting and installation Updated index
IM304 Rev 3 to 4 5/26/99
Changed Page Description
0.01 Uprevved because of ECNs 10078, 10079, 10070, 9753, 10012, 9864, 10020, 9926
0.06 Changed TOC to reference HT2000LHF Torches
0.08
2.01
2.02
2.03
2.06
3.07
3.11
3.13
4.11
4.12-4.29
5.02
6.05
6.08
6.09
6.15
6.16
6.17
Changed TOC to reference HT2000LHF Torches Added line in spec description to specify recommended production cutting thickness Added note to Water Muffler description stating that it cannot be used with the stainless torch Added dimension on torch diameter and referenced an additional drawing in Section 6 Added note to Water Muffler description stating that it cannot be used with the stainless torch Added note to Water Muffler description stating that it cannot be used with the stainless torch Updated signal labels for I/O cable Added note to Water Muffler cable stating that it cannot be used with the stainless torch Changed index to cut chart and consumables to include new electrode and swirl ring Updated cut charts with new electrode, swirl ring, and clearer cutting capacities Removed old style pump clamp from drawing New part number for valve SV7 Added kits for pump and motor replacement New part number for valves SV1-3 Added new stainless steel torch Added new electrode to parts kit New part numbers for valves, pump
IM304 Rev 2 to 3 1/18/99
Changed Page Description
0.01 Uprevved because of ECNs 9763, 9758, 9803
0.08 Added figure of coolant flow diagram to TOC
3.08
5.17
6.08
7.04
New graphic of rear panel Added figure of coolant flow diagram New graphic of rear panel, new p/ns for valve assembly, water pump assembly Added coolant flow diagram to wiring diagrams
Changed Page Description
0.01 Uprevved because of ECNs 9523, 9483, grounding appendix, serial # jump to 2LHF-000150
0.07 Added System Grounding to TOC
0.08
3.03
4.15
4.16
5.05
5.14
6.02
6.06
6.16
7.01 i.02 i.04 j.01 j.02 j.03 j.04 j.05
Added System Grounding to TOC Referenced new grounding appendix Added a sentence to Mild Steel 100A cutting cut chart Added a sentence to Mild Steel 100A cutting cut chart New power distribution PCB graphic, added fuse Added error code for phase loss New firmware rev New graphic of chopper with phase loss board, new phase loss board # Changed some quantities in consumable parts kit Uprevved wiring diagrams to E Added j1 to grounding requirements in index Added phase loss to index New system grounding appendix New system grounding appendix New system grounding appendix New system grounding appendix New system grounding appendix
IM304 Rev 1 to 2 8/21/98
IM304 Rev 0 to 1 7/24/98
HySpeed HT2000LHF
Instruction Manual
(P/N 803020)
Revision 11 – November, 2013
Hypertherm, Inc.
Hanover, NH USA
www.hypertherm.com
© Copyright 2013 Hypertherm, Inc.
All Rights Reserved
Hypertherm, HT, LongLife, and HySpeed are trademarks of Hypertherm, Inc.
and may be registered in the United States and/or other countries
11/30/04
Hypertherm, Inc.
Etna Road, P.O. Box 5010 Hanover, NH 03755 USA 603-643-3441 Tel (Main Office) 603-643-5352 Fax (All Departments) info@hypertherm.com (Main Office Email)
800-643-9878 Tel (Technical Service)
technical.service@hypertherm.com (Technical Service Email) 800-737-2978 Tel (Customer Service) customer.service@hypertherm.com (Customer Service Email)
Hypertherm Automation, LLC
5 Technology Drive, Suite 300 West Lebanon, NH 03755 USA 603-298-7970 Tel 603-298-7977 Fax
Hypertherm Plasmatechnik, GmbH
Technologiepark Hanau Rodenbacher Chaussee 6 D-63457 Hanau-Wolfgang, Deutschland 49 6181 58 2100 Tel 49 6181 58 2134 Fax
49 6181 58 2123 (Technical Service)
Hypertherm (S) Pte Ltd.
No. 19 Kaki Bukit Road 2 K.B. Warehouse Complex Singapore 417847, Republic of Singapore 65 6 841 2489 Tel 65 6 841 2490 Fax
65 6 841 2489 (Technical Service)
Hypertherm (Shanghai) Consulting Co., Ltd.
Suite 305, CIMIC Towers 1090 Century Boulevard, Pudong Shanghai 200120 P.R. China 86-21-5835-5362 /3 Tel 86-21-5835 5220 Fax
86-21-5835-5362 /3 (Technical Service)
Hypertherm
Branch of Hypertherm, UK, UC PO Box 244 Wigan, Lancashire, England WN8 7WU 00 800 3324 9737 Tel 00 800 4973 7329 Fax
00 800 4973 7843 (Technical Service)
France
15 Impasse des Rosiers 95610 Eragny, France 00 800 3324 9737 Tel 00 800 4973 7329 Fax
Hypertherm S.r.l.
Via Torino 2 20123 Milano, Italia 39 02 725 46 312 Tel 39 02 725 46 400 Fax
39 02 725 46 314 (Technical Service)
Hypertherm Europe B.V.
Vaartveld 9 4704 SE Roosendaal, Nederland 31 165 596907 Tel 31 165 596901 Fax 31 165 596908 Tel (Marketing)
31 165 596900 Tel (Technical Service) 00 800 49 73 7843 Tel (Technical Service)
Japan
1952-14 Yata-Natsumegi Mishima City, Shizuoka Pref. 411-0801 Japan 81 0 559 75 7387 Tel 81 0 559 75 7376 Fax
HYPERTHERM BRASIL LTDA.
Rua Jati, 33 CEP 07180-350 Cumbica Guarulhos, SP - Brasil 55 11 6482 1087 Tel 55 11 6482 0591 Fax

ELECTROMAGNETIC COMPATIBILITY (EMC)

EMC INTRODUCTION
Hypertherm's CE-marked equipment is built in compliance with standard EN50199. The equipment should be installed and used in accordance with the information below to achieve electromagnetic compatibility.
The limits required by EN50199 may not be adequate to completely eliminate interfer­ence when the affected equipment is in close proximity or has a high degree of sensitivity. In such cases it may be neces­sary to use other measures to further reduce interference.
This plasma equipment is designed for use only in an industrial environment.
INSTALLATION AND USE
The user is responsible for installing and using the plasma equipment according to the manufacturer's instructions. If electro­magnetic disturbances are detected then it shall be the responsibility of the user to re­solve the situation with the technical assis­tance of the manufacturer. In some cases this remedial action may be as simple as earthing the cutting circuit, see Earthing of Workpiece. In other cases it could involve constructing an electromagnetic screen enclosing the power source and the work complete with associated input filters. In all cases electromagnetic disturbances must be reduced to the point where they are no longer troublesome.
ASSESSMENT OF AREA
Before installing the equipment the user shall make an assessment of potential elec­tromagnetic problems in the surrounding area. The following shall be taken into account: a. Other supply cables, control cables, signalling and telephone cables; above, below and adjacent to the cutting equip­ment. b. Radio and television transmitters and receivers. c. Computer and other control equipment. d. Safety critical equipment, for example guarding of industrial equipment. e. Health of the people around, for example the use of pacemakers and hear­ing aids. f. Equipment used for calibration or mea­surement. g. Immunity of other equipment in the en­vironment. User shall ensure that other equipment being used in the environment is compatible. This may require additional protection measures. h. Time of day that cutting or other activities are to be carried out.
Earthing of Workpiece
Where the workpiece is not bonded to earth for electrical safety, nor connected to earth because of its size and position, for example, ship's hull or building steelwork, a connection bonding the workpiece to earth may reduce emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users, or damage to other electrical equip­ment. Where necessary, the connection of the workpiece to earth should be made by a direct connection to the workpiece, but in some countries where direct connection is not permitted, the bonding should be achieved by suitable capacitances selected according to national regulations.
Note. The cutting circuit may or may not be earthed for safety reasons. Changing the earthing arrangements should only be au­thorized by a person who is competent to assess whether the changes will increase the risk of injury, for example, by allowing parallel cutting current return paths which may damage the earth circuits of other equipment. Further guidance is given in IEC TC26 (sec)94 and IEC TC26/108A/CD Arc Welding Equipment Installation and Use.
Screening and Shielding
Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference. Screening of the entire plasma cutting installation may be considered for special applications.
The size of the surrounding area to be considered will depend on the structure of the building and other activities that are tak­ing place. The surrounding area may extend beyond the boundaries of the premises.
METHODS OF REDUCING EMISSIONS
Mains Supply
Cutting equipment must be connected to the mains supply according to the manufactur­er's recommendations. If interference occurs, it may be necessary to take additional precautions such as filtering of the mains supply. Consideration should be given to shielding the supply cable of per­manently installed cutting equipment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The shielding should be connect­ed to the cutting mains supply so that good electrical contact is maintained between the conduit and the cutting power source enclosure.
Maintenance of Cutting Equipment
The cutting equipment must be routinely maintained according to the manufacturer's recommendations. All access and service doors and covers should be closed and properly fastened when the cutting equipment is in operation. The cutting equipment should not be modified in any way except for those changes and adjust­ments covered in the manufacturer's instructions. In particular, the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer's recommendations.
Cutting Cables
The cutting cables should be kept as short as possible and should be positioned close together, running at or close to the floor level.
Equipotential Bonding
Bonding of all metallic components in the cutting installation and adjacent to it should be considered. However, metallic compo­nents bonded to the workpiece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode at the same time. The operator should be insulated from all such bonded metallic components.
Hypertherm Plasma Systems i

WARRANTY

ii Hypertherm Plasma Systems
WARNING
Genuine Hypertherm parts are the factory-recommended replacement parts for your Hypertherm system. Any damage caused by the use of other than genuine Hypertherm parts may not be covered by the Hypertherm warranty.
WARNING
You are responsible for the safe use of the Product. Hypertherm does not and cannot make any guarantee or warranty regarding the safe use of the Product in your environment.
GENERAL
Hypertherm, Inc. warrants that its Products shall be free from defects in materials and workmanship, if Hypertherm is notified of a defect (i) with respect to the power supply within a period of two (2) years from the date of its delivery to you, with the exception of Powermax Series power supplies, which shall be within a period of three (3) years from the date of delivery to you, and (ii) with respect to the torch and leads within a period of one (1) year from its date of delivery to you. This warranty shall not apply to any Product which has been incorrectly installed, modified, or otherwise damaged. Hypertherm, at its sole option, shall repair, replace, or adjust, free of charge, any defective Products covered by this warranty which shall be returned with Hypertherm’s prior authorization (which shall not be unreasonably withheld), properly packed, to Hypertherm’s place of business in Hanover, New Hampshire, or to an authorized Hypertherm repair facility, all costs, insurance and freight prepaid. Hypertherm shall not be liable for any repairs, replacement, or adjustments of Products covered by this warranty, except those made pursuant to this paragraph or with Hypertherm’s prior written consent. The warranty above is
exclusive and is in lieu of all other warranties, express, implied, statutory, or otherwise with respect to the Products or as to the results which may be obtained therefrom, and all implied warranties or conditions of quality or of merchantability or fitness for a particular purpose or against infringement. The foregoing shall constitute the sole and exclusive remedy for any breach by Hypertherm of its warranty. Distributors/OEMs may offer
different or additional warranties, but Distributors/OEMs are not authorized to give any additional warranty protection to you or make any representation to you purporting to be binding upon Hypertherm.
PATENT INDEMNITY
Except only in cases of products not manufactured by Hypertherm or manufactured by a person other than Hypertherm not in strict conformity with Hypertherm’s specifications and in cases of designs, processes, formulae, or combinations not developed or purported to be developed by Hypertherm, Hypertherm will defend or settle, at its own expense, any suit or proceeding brought against you alleging that the use of the Hypertherm product, alone and not in combination with any other product not supplied by
Hypertherm, infringes any patent of any third party. You shall notify Hypertherm promptly upon learning of any action or threatened action in connection with any such alleged infringement, and Hypertherm’s obligation to indemnify shall be conditioned upon Hypertherm’s sole control of, and the indemnified party’s cooperation and assistance in, the defense of the claim.
LIMITATION OF LIABILITY
In no event shall Hypertherm be liable to any person or entity for any incidental, consequential, indirect, or punitive damages (including but not limited to lost profits) regardless of whether such liability is based on breach of contract, tort, strict liability, breach of warranties, failure of essential purpose or otherwise and even if advised of the possibility of such damages.
LIABILITY CAP
In no event shall Hypertherm’s liability, whether such liability is based on breach of contract, tort, strict liability, breach of warranties, failure of essential purpose or otherwise, for any claim action suit or proceeding arising out of or relating to the use of the Products exceed in the aggregate the amount paid for the Products that gave rise to such claim.
INSURANCE
At all times you will have and maintain insurance in such quantities and types, and with coverage sufficient and appropriate to defend and to hold Hypertherm harmless in the event of any cause of action arising from the use of the Products.
NATIONAL AND LOCAL CODES
National and Local codes governing plumbing and electrical installation shall take precedent over any instructions contained in this manual. In no event shall Hypertherm be liable for injury to persons or property damage by reason of any code violation or poor work practices.
TRANSFER OF RIGHTS
You may transfer any remaining rights you may have hereunder only in connection with the sale of all or substantially all of your assets or capital stock to a successor in interest who agrees to be bound by all of the terms and conditions of this Warranty.

TABLE OF CONTENTS

HySpeed HT2000LHF Instruction Manual iii
7
Electromagnetic Compatibility (EMC).......................................................................................................................i
Warranty .....................................................................................................................................................................ii
Section 1 SAFETY
Recognize Safety Information...................................................................................................................................1-2
Follow Safety Instructions.........................................................................................................................................1-2
Cutting Can Cause Fire or Explosion .......................................................................................................................1-2
Electric Shock Can Kill..............................................................................................................................................1-3
Cutting Can Produce Toxic Fumes...........................................................................................................................1-3
A Plasma Arc Can Cause Injury and Burns..............................................................................................................1-4
Arc Rays Can Burn Eyes and Skin ...........................................................................................................................1-4
Grounding Safety......................................................................................................................................................1-4
Compressed Gas Equipment Safety ........................................................................................................................1-5
Gas Cylinders Can Explode If Damaged ..................................................................................................................1-5
Noise Can Damage Hearing.....................................................................................................................................1-5
Pacemaker and Hearing Aid Operation ....................................................................................................................1-5
A Plasma Arc Can Damage Frozen Pipes................................................................................................................1-5
Additional Safety Information....................................................................................................................................1-5
Warning Label...........................................................................................................................................................1-6
Section 1a SÉCURITÉ
Identifier les consignes de sécurité.........................................................................................................................1a-2
Suivre les instructions de sécurité ..........................................................................................................................1a-2
Le coupage peut provoquer un incendie ou une explosion ....................................................................................1a-2
Les chocs électriques peuvent être fatals...............................................................................................................1a-3
Le coupage peut produire des vapeurs toxiques....................................................................................................1a-3
L'arc plasma peut provoquer des blessures ou des brûlures .................................................................................1a-4
Mise à la masse et à la terre...................................................................................................................................1a-4
Les rayons de l'arc peuvent brûler les yeux et la peau...........................................................................................1a-4
Sécurité des bouteilles de gaz comprimé ...............................................................................................................1a-5
Les bouteilles de gaz comprimé peuvent exploser en cas de dommages .............................................................1a-5
Le bruit peut provoquer des problèmes auditifs......................................................................................................1a-5
Pacemakers et prothéses auditives........................................................................................................................1a-5
Étiquette de sécurité ...............................................................................................................................................1a-6
Section 2 SPECIFICATIONS
HySpeed HT2000LHF System Components ............................................................................................................2-1
Power Supply ..................................................................................................................................................2-1
HySpeed LHF Machine Torch..........................................................................................................................2-1
Gas Console ....................................................................................................................................................2-1
Argon-Hydrogen Manifold – Optional...............................................................................................................2-1
Digital Remote Voltage & Current Control Console .........................................................................................2-1
Programmable Remote Voltage & Current Control Console............................................................................2-1
Remote Current Control Console.....................................................................................................................2-2
Initial Height Sensing - Optional.......................................................................................................................2-2
Timer/Counter – Optional.................................................................................................................................2-2
TABLE OF CONTENTS
iv HySpeed HT2000LHF Instruction Manual
7
Water Muffler – Optional ..................................................................................................................................2-2
CommandTHC – Optional................................................................................................................................2-2
Specifications............................................................................................................................................................2-2
System Requirements .....................................................................................................................................2-2
Power Supply ...................................................................................................................................................2-3
HySpeed LHF Machine Torch..........................................................................................................................2-3
Gas Console ....................................................................................................................................................2-4
Argon-Hydrogen Manifold – Optional...............................................................................................................2-4
Digital Remote Voltage & Current Control Console .........................................................................................2-5
Programmable Remote Voltage & Current Control Console............................................................................2-5
Remote Current Control Console.....................................................................................................................2-5
Initial Height Sensing (IHS) – Optional.............................................................................................................2-6
Timer/Counter – Optional.................................................................................................................................2-6
Water Muffler – Optional ..................................................................................................................................2-6
CommandTHC – Optional................................................................................................................................2-6
Section 3 INSTALLATION
Upon Receipt ............................................................................................................................................................3-1
Claims.......................................................................................................................................................................3-1
Installation Requirements .........................................................................................................................................3-1
Gas Requirements....................................................................................................................................................3-1
Gas Supply Plumbing.......................................................................................................................................3-2
Torch Coolant Requirements....................................................................................................................................3-3
Grounding Requirements..........................................................................................................................................3-3
Noise Levels .............................................................................................................................................................3-4
Power Requirements ................................................................................................................................................3-4
Line Disconnect Switch ....................................................................................................................................3-4
Power Cable.....................................................................................................................................................3-5
Positioning the Power Supply ..........................................................................................................................3-5
Connecting the Power ..............................................................................................................................................3-5
Torch Lifter Requirement ..........................................................................................................................................3-7
Optional Equipment ..................................................................................................................................................3-7
Water Muffler....................................................................................................................................................3-7
System Units Placement...........................................................................................................................................3-7
Power Supply Connections.....................................................................................................................................3-10
Gas Console Connections ......................................................................................................................................3-14
Valve Cluster and Torch Connections ....................................................................................................................3-17
Routing the Torch Leads................................................................................................................................3-17
Connecting the Torch Leads to the Torch......................................................................................................3-17
Valve Cluster Connections.............................................................................................................................3-18
Mounting the Machine Torch ..................................................................................................................................3-20
Torch Alignment .............................................................................................................................................3-20
Section 4 OPERATION
Front Panel Controls and Indicators .........................................................................................................................4-1
Status Indicators Before Startup ......................................................................................................................4-1
TABLE OF CONTENTS
HySpeed HT2000LHF Instruction Manual v
7
Power Supply ...................................................................................................................................................4-1
Gas Console ....................................................................................................................................................4-2
Digital Remote Voltage & Current Control Console .........................................................................................4-3
Programmable Remote Voltage & Current Control Console............................................................................4-3
Remote Current Control Console.....................................................................................................................4-3
Timer/Counter ..................................................................................................................................................4-4
System Checkout......................................................................................................................................................4-4
Set Switches and Check Torch ........................................................................................................................4-4
Turn Gases On.................................................................................................................................................4-4
Turn Power Supply On and Adjust Voltage/Current.........................................................................................4-5
Adjust Preflow Gases.......................................................................................................................................4-5
Adjust Cut Flow Gases and Check Initial Height Sensing (IHS) ......................................................................4-5
Final Torch Adjustment ....................................................................................................................................4-6
Check Torch Height Control (THC) and Digital Remote Voltage & Current Console ...............................................4-6
Noise Levels .............................................................................................................................................................4-7
Daily Startup .............................................................................................................................................................4-7
Check Torch.....................................................................................................................................................4-7
Turn Gases On.................................................................................................................................................4-8
Turn Power Supply On and Adjust Voltage & Current .....................................................................................4-8
Adjust Preflow Gases.......................................................................................................................................4-8
Adjust Cut Flow Gases and Prepare for Cutting ..............................................................................................4-9
Common Cutting Faults ............................................................................................................................................4-9
Technical Questions ...............................................................................................................................................4-10
Cut Charts...............................................................................................................................................................4-10
Conversions............................................................................................................................................................4-10
Cut Chart and Consumable Parts Index .................................................................................................................4-11
Changing Consumable Parts..................................................................................................................................4-31
Removal and Inspection.................................................................................................................................4-31
Replacement ..................................................................................................................................................4-32
Changing the Water Tube ..............................................................................................................................4-33
How to Optimize Cut Quality...................................................................................................................................4-34
Tips for Table and Torch ................................................................................................................................4-34
Plasma Set-up Tips........................................................................................................................................4-34
Maximize the Life of Consumable Parts.........................................................................................................4-34
Additional Factors of Cut Quality....................................................................................................................4-35
Additional Improvements................................................................................................................................4-36
Section 5 MAINTENANCE
Introduction ...............................................................................................................................................................5-1
Routine Maintenance................................................................................................................................................5-1
Torch and Torch Leads ....................................................................................................................................5-1
Power Supply ...................................................................................................................................................5-2
Gas Console ....................................................................................................................................................5-3
Start Sequence .........................................................................................................................................................5-3
Initial Checks ............................................................................................................................................................5-4
Troubleshooting ........................................................................................................................................................5-6
TABLE OF CONTENTS
vi HySpeed HT2000LHF Instruction Manual
10
Status Led Troubleshooting......................................................................................................................................5-9
Chopper Module Test Procedure............................................................................................................................5-12
Error Codes ............................................................................................................................................................5-14
Coolant Flow Test Procedure .................................................................................................................................5-16
Check Reservoir Coolant ...............................................................................................................................5-16
Verify Flow Rate Return from Torch...............................................................................................................5-16
Verify Flow Rate to Torch...............................................................................................................................5-17
Check Pump, Motor and Solenoid Valve (V1)................................................................................................5-17
Torch Coolant Draining...........................................................................................................................................5-18
Preventive Maintenance .........................................................................................................................................5-20
Section 6 PARTS LIST
Introduction ...............................................................................................................................................................6-1
Power Supply: Front Panel ..............................................................................................................................6-2
Power Supply: THC Assembly (optional) .........................................................................................................6-3
Power Supply: Control Panel ...........................................................................................................................6-3
Power Supply: Center Wall Right Side.............................................................................................................6-4
Power Supply: Center Wall Left Side ...............................................................................................................6-5
Power Supply: Front Wall Inside ......................................................................................................................6-6
Power Supply: Rear Wall Inside.......................................................................................................................6-7
Power Supply: Rear Wall Outside....................................................................................................................6-8
Gas Console ....................................................................................................................................................6-9
Digital Remote Voltage & Current Control Console .......................................................................................6-10
Programmable Remote Voltage & Current Control Console..........................................................................6-11
Initial Height Sensing Control Console...........................................................................................................6-12
Argon-Hydrogen Manifold ..............................................................................................................................6-13
Timer/Counter ................................................................................................................................................6-14
Remote Current Control Console...................................................................................................................6-14
HySpeed HT2000LHF Torches......................................................................................................................6-15
Consumable Parts Kits...................................................................................................................................6-16
Recommended Spare Parts ...................................................................................................................................6-20
Power Supply .................................................................................................................................................6-20
Gas Console ..................................................................................................................................................6-20
Section 7 WIRING DIAGRAMS............................................................................................................................7-1
Introduction ...............................................................................................................................................................7-1
Wiring Diagram Symbols ..........................................................................................................................................7-1
System Wiring Diagrams ..........................................................................................................................................7-5
Appendix A ARGON-HYDROGEN CUTTING and GOUGING............................................................................a-1
Appendix B PROPYLENE GLYCOL SAFETY DATA .........................................................................................b-2
BENZOTRIAZOLE SAFETY DATA.................................................................................................b-7
Appendix C INITIAL HEIGHT SENSING CONNECTIONS..................................................................................c-1
TABLE OF CONTENTS
HySpeed HT2000LHF Instruction Manual vii
7
Appendix D ELECTROMAGNETIC COMPATIBILITY ........................................................................................d-1
Appendix E AIR FILTERS....................................................................................................................................e-1
Appendix F AERATION MANIFOLD FOR CUTTING ALUMINUM .....................................................................f-1
Appendix G IEC SYMBOLS.................................................................................................................................g-1
Appendix H SYSTEM GROUNDING ...................................................................................................................h-1
Hypertherm Plasma Systems 1-1
Section 1
SAFETY
In this section:
Recognize Safety Information...................................................................................................................................1-2
Follow Safety Instructions.........................................................................................................................................1-2
Cutting Can Cause Fire or Explosion .......................................................................................................................1-2
Electric Shock Can Kill..............................................................................................................................................1-3
Cutting Can Produce Toxic Fumes ...........................................................................................................................1-3
A Plasma Arc Can Cause Injury and Burns ..............................................................................................................1-4
Arc Rays Can Burn Eyes and Skin ...........................................................................................................................1-4
Grounding Safety......................................................................................................................................................1-4
Compressed Gas Equipment Safety ........................................................................................................................1-5
Gas Cylinders Can Explode If Damaged ..................................................................................................................1-5
Noise Can Damage Hearing.....................................................................................................................................1-5
Pacemaker and Hearing Aid Operation ....................................................................................................................1-5
A Plasma Arc Can Damage Frozen Pipes................................................................................................................1-5
Additional Safety Information....................................................................................................................................1-5
Warning Label...........................................................................................................................................................1-6
SAFETY
1-2 Hypertherm Plasma Systems
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SAFETY
RECOGNIZE SAFETY INFORMATION
The symbols shown in this section are used to identify potential hazards. When you see a safety symbol in this manual or on your machine, understand the potential for personal injury, and follow the related instructions to avoid the hazard.
FOLLOW SAFETY INSTRUCTIONS
Read carefully all safety messages in this manual and safety labels on your machine.
• Keep the safety labels on your machine in good condition. Replace missing or damaged labels immediately.
• Learn how to operate the machine and how to use the controls properly. Do not let anyone operate it without instruction.
• Keep your machine in proper working condition. Unauthorized modifications to the machine may affect safety and machine service life.
DANGER WARNING CAUTION
A signal word DANGER or WARNING is used with a safety symbol. DANGER identifies the most serious hazards.
• DANGER and WARNING safety labels are located on your machine near specific hazards.
• WARNING safety messages precede related instructions in this manual that may result in injury or death if not followed correctly.
• CAUTION safety messages precede related instructions in this manual that may result in damage to equipment if not followed correctly.
Fire Prevention
• Be sure the area is safe before doing any cutting. Keep a fire extinguisher nearby.
• Remove all flammables within 35 feet (10 m) of the cutting area.
• Quench hot metal or allow it to cool before handling or before letting it touch combustible materials.
• Never cut containers with potentially flammable materials inside – they must be emptied and properly cleaned first.
• Ventilate potentially flammable atmospheres before cutting.
• When cutting with oxygen as the plasma gas, an exhaust ventilation system is required.
Explosion Prevention
• Do not use the plasma system if explosive dust or vapors may be present.
• Do not cut pressurized cylinders, pipes, or any closed container.
• Do not cut containers that have held combustible materials.
CUTTING CAN CAUSE FIRE OR EXPLOSION
WARNING
Explosion Hazard
Argon-Hydrogen and Methane
Hydrogen and methane are flammable gases that present an explosion hazard. Keep flames away from cylinders and hoses that contain methane or hydrogen mixtures. Keep flames and sparks away from the torch when using methane or argon-hydrogen plasma.
WARNING
Hydrogen Detonation with Aluminum Cutting
• When cutting aluminum underwater, or with the water touching the underside of the aluminum, free hydrogen gas may collect under the workpiece and detonate during plasma cutting operations.
• Install an aeration manifold on the floor of the water table to eliminate the possibility of hydrogen detonation. Refer to the Appendix section of this manual for aeration manifold details.
Touching live electrical parts can cause a fatal shock or severe burn.
• Operating the plasma system completes an electrical circuit between the torch and the workpiece. The workpiece and anything touching the workpiece are part of the electrical circuit.
• Never touch the torch body, workpiece or the water in a water table when the plasma system is operating.
Electric Shock Prevention All Hypertherm plasma systems use high voltage
in the cutting process (200 to 400 VDC are common). Take the following precautions when operating this system:
• Wear insulated gloves and boots, and keep your body and clothing dry.
• Do not stand, sit or lie on – or touch – any wet surface when using the plasma system.
• Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground. If you must work in or near a damp area, use extreme caution.
• Provide a disconnect switch close to the power supply with properly sized fuses. This switch allows the operator to turn off the power supply quickly in an emergency situation.
• When using a water table, be sure that it is correctly connected to earth ground.
ELECTRIC SHOCK CAN KILL
• Install and ground this equipment according to the instruction manual and in accordance with national and local codes.
• Inspect the input power cord frequently for damage or cracking of the cover. Replace a damaged power cord immediately. Bare wiring can kill.
• Inspect and replace any worn or damaged torch leads.
• Do not pick up the workpiece, including the waste cutoff, while you cut. Leave the workpiece in place or on the workbench with the work cable attached during the cutting process.
• Before checking, cleaning or changing torch parts, disconnect the main power or unplug the power supply.
• Never bypass or shortcut the safety interlocks.
• Before removing any power supply or system enclosure cover, disconnect electrical input power. Wait 5 minutes after disconnecting the main power to allow capacitors to discharge.
• Never operate the plasma system unless the power supply covers are in place. Exposed power supply connections present a severe electrical hazard.
• When making input connections, attach proper grounding conductor first.
• Each Hypertherm plasma system is designed to be used only with specific Hypertherm torches. Do not substitute other torches which could overheat and present a safety hazard.
Cutting can produce toxic fumes and gases that deplete oxygen and cause injury or death.
• Keep the cutting area well ventilated or use an approved air-supplied respirator.
• Do not cut in locations near degreasing, cleaning or spraying operations. The vapors from certain chlorinated solvents decompose to form phosgene gas when exposed to ultraviolet radiation.
• Do not cut metal coated or containing toxic materi­als, such as zinc (galvanized), lead, cadmium or
CUTTING CAN PRODUCE TOXIC FUMES
beryllium, unless the area is well ventilated and the operator wears an air-supplied respirator. The coatings and any metals containing these elements can produce toxic fumes when cut.
• Never cut containers with potentially toxic materials inside – they must be emptied and properly cleaned first.
• This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer.
Hypertherm Plasma Systems 1-3
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SAFETY
SAFETY
1-4 Hypertherm Plasma Systems
5/6/02
SAFETY
Instant-On Torches
Plasma arc comes on immediately when the torch switch is activated.
A PLASMA ARC CAN CAUSE INJURY AND BURNS
The plasma arc will cut quickly through gloves and skin.
• Keep away from the torch tip.
• Do not hold metal near the cutting path.
• Never point the torch toward yourself or others.
Eye Protection Plasma arc rays produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin.
• Use eye protection in accordance with applicable national or local codes.
• Wear eye protection (safety glasses or goggles with side shields, and a welding helmet) with appropriate lens shading to protect your eyes from the arc’s ultraviolet and infrared rays.
Lens Shade
Arc Current AWS (USA) ISO 4850
Up to 100 A No. 8 No. 11 100-200 A No. 10 No. 11-12 200-400 A No. 12 No. 13 Over 400 A No. 14 No. 14
ARC RAYS CAN BURN EYES AND SKIN
Skin Protection Wear protective clothing to protect
against burns caused by ultraviolet light, sparks and hot metal.
• Gauntlet gloves, safety shoes and hat.
• Flame-retardant clothing to cover all exposed areas.
• Cuffless trousers to prevent entry of sparks and slag.
• Remove any combustibles, such as a butane lighter or matches, from your pockets before cutting.
Cutting Area Prepare the cutting area to reduce reflection and transmission of ultraviolet light:
• Paint walls and other surfaces with dark colors to reduce reflection.
• Use protective screens or barriers to protect others from flash and glare.
• Warn others not to watch the arc. Use placards or signs.
Work Cable Attach the work cable securely to the workpiece or the work table with good metal-to-metal contact. Do not connect it to the piece that will fall away when the cut is complete.
Work Table Connect the work table to an earth ground, in accordance with appropriate national or local electrical codes.
GROUNDING SAFETY
Input Power
• Be sure to connect the power cord ground wire to the ground in the disconnect box.
• If installation of the plasma system involves connecting the power cord to the power supply, be sure to connect the power cord ground wire properly.
• Place the power cord's ground wire on the stud first, then place any other ground wires on top of the power cord ground. Fasten the retaining nut tightly.
• Tighten all electrical connections to avoid excessive heating.
SAFETY
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SAFETY
• Never lubricate cylinder valves or regulators with oil or grease.
• Use only correct gas cylinders, regulators, hoses and fittings designed for the specific application.
• Maintain all compressed gas equipment and associated parts in good condition.
• Label and color-code all gas hoses to identify the type of gas in each hose. Consult applicable national or local codes.
GAS CYLINDERS CAN EXPLODE IF DAMAGED
COMPRESSED GAS EQUIPMENT SAFETY
Gas cylinders contain gas under high pressure. If damaged, a cylinder can explode.
• Handle and use compressed gas cylinders in accordance with applicable national or local codes.
• Never use a cylinder that is not upright and secured in place.
• Keep the protective cap in place over valve except when the cylinder is in use or connected for use.
• Never allow electrical contact between the plasma arc and a cylinder.
• Never expose cylinders to excessive heat, sparks, slag or open flame.
• Never use a hammer, wrench or other tool to open a stuck cylinder valve.
Prolonged exposure to noise from cutting or gouging can damage hearing.
• Use approved ear protection when using plasma system.
• Warn others nearby about the noise hazard.
NOISE CAN DAMAGE HEARING
Pacemaker and hearing aid operation can be affected by magnetic fields from high currents. Pacemaker and hearing aid wearers should consult a doctor before going near any plasma arc cutting and gouging operations.
To reduce magnetic field hazards:
• Keep both the work cable and the torch lead to one side, away from your body.
• Route the torch leads as close as possible to the work cable.
• Do not wrap or drape the torch lead or work cable around your body.
• Keep as far away from the power supply as possible.
PACEMAKER AND HEARING AID OPERATION
ADDITIONAL SAFETY INFORMATION
1. ANSI Standard Z49.1, Safety in Welding and Cutting, American Welding Society, 550 LeJeune Road P.O. Box 351020, Miami, FL 33135
2. ANSI Standard Z49.2, Fire Prevention in the Use of Cutting and Welding Processes, American National Standards Institute 1430 Broadway, New York, NY 10018
3. ANSI Standard Z87.1, Safe Practices for Occupation and Educational Eye and Face Protection, American National Standards Institute, 1430 Broadway, New York, NY 10018
4. AWS F4.1, Recommended Safe Practices for the Preparation for
Welding and Cutting of Containers and Piping That Have Held Hazardous Substances, American Welding Society
550 LeJeune Road, P.O. Box 351040, Miami, FL 33135
5. AWS F5.2, Recommended Safe Practices for Plasma Arc Cutting, American Welding Society 550 LeJeune Road, P.O. Box 351040, Miami, FL 33135
6. CGA Pamphlet P-1, Safe Handling of Compressed Gases in Cylinders, Compressed Gas Association 1235 Jefferson Davis Highway, Arlington, VA 22202
7. CSA Standard W117.2, Code for Safety in Welding and Cutting, Canadian Standards Association Standard Sales 178 Rexdale Boulevard, Rexdale, Ontario M9W 1R3, Canada
8. NFPA Standard 51B, Cutting and Welding Processes, National Fire Protection Association 470 Atlantic Avenue, Boston, MA 02210
9. NFPA Standard 70–1978, National Electrical Code, National Fire Protection Association, 470 Atlantic Avenue, Boston, MA 02210
10. OSHA, Safety and Health Standards, 29FR 1910
U.S. Government Printing Office, Washington, D.C. 20402
A PLASMA ARC CAN DAMAGE FROZEN PIPES
Frozen pipes may be damaged or can burst if you attempt to thaw them with a plasma torch.
SAFETY
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SAFETY
WARNING LABEL
This warning label is affixed to some power supplies. It is important that the operator and maintenance technician understand the intent of these warning symbols as described.
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Section 1a
SÉCURITÉ
Dans cette section :
Identifier les consignes de sécurité.........................................................................................................................1a-2
Suivre les instructions de sécurité ..........................................................................................................................1a-2
Danger Avertissement Précaution ........................................................................................................................1a-2
Le coupage peut provoquer un incendie ou une explosion ....................................................................................1a-2
Prévention des incendies, Prévention des explosions...................................................................................1a-2
Risque d’explosion argon-hydrogène et méthane..........................................................................................1a-2
Détonation de l’hydrogène lors du coupage de l’aluminium...........................................................................1a-2
Les chocs électriques peuvent être fatals...............................................................................................................1a-3
Prévention des chocs électriques ..................................................................................................................1a-3
Le coupage peut produire des vapeurs toxiques....................................................................................................1a-3
L’arc plasma peut provoquer des blessures ou des brûlures .................................................................................1a-4
Torches à allumage instantané ......................................................................................................................1a-4
Les rayons de l’arc peuvent brûler les yeux et la peau...........................................................................................1a-4
Protection des yeux, Protection de la peau, Zone de coupage ....................................................................1a-4
Mise à la masse et à la terre...................................................................................................................................1a-4
Câble de retour, Table de travail, Alimentation...............................................................................................1a-4
Sécurité des bouteilles de gaz comprimé ...............................................................................................................1a-5
Les bouteilles de gaz comprimé peuvent exploser en cas de dommages .............................................................1a-5
Le bruit peut provoquer des problèmes auditifs......................................................................................................1a-5
Pacemakers et prothèses auditives........................................................................................................................1a-5
Un arc plasma peut endommager les tuyaux gelés................................................................................................1a-5
Étiquette de sécurité ...............................................................................................................................................1a-6
SÉCURITÉ
1a-2 Hypertherm Systèmes plasma
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IDENTIFIER LES CONSIGNES DE SÉCURITÉ
Les symboles indiqués dans cette section sont utilisés pour identifier les risques éventuels. Si vous trouvez un symbole de sécurité, que ce soit dans ce manuel ou sur l’équipement, soyez conscient des risques de blessures et suivez les instructions correspondantes afin d’éviter ces risques.
SUIVRE LES INSTRUCTIONS DE SÉCURITÉ
Lire attentivement toutes les consignes de sécurité dans le présent manuel et sur les étiquettes de sécurité se trouvant sur la machine.
• Les étiquettes de sécurité doivent rester lisibles. Remplacer immédiatement les étiquettes manquantes ou abîmées.
• Apprendre à faire fonctionner la machine et à utiliser correctement les commandes. Ne laisser personne utiliser la machine sans connaître son fonctionnement.
• Garder la machine en bon état. Des modifications non autorisées sur la machine peuvent engendrer des problèmes de sécurité et raccourcir la durée d’utilisation de l’équipement.
DANGER AVERTISSEMENT PRÉCAUTION
Les signaux DANGER ou AVERTISSEMENT sont utilisés avec un symbole de sécurité, DANGER correspondant aux risques les plus sérieux.
• Les étiquettes de sécurité DANGER et AVERTISSEMENT sont situées sur la machine pour signaler certains dangers spécifiques.
• Les messages d’AVERTISSEMENT précèdent les instructions d’utilisation expliquées dans ce manuel et signalent les risques de blessures ou de mort au cas où ces instructions ne seraient pas suivies correctement.
• Les messages de PRÉCAUTION précèdent les instructions d’utilisation contenues dans ce manuel et signalent que le matériel risque d’être endommagé si les instructions ne sont pas suivies correctement.
Prévention des incendies
• Avant de commencer, s’assurer que la zone de coupage ne présente aucun danger. Conserver un extincteur à proximité.
• Éloigner toute matière inflammable à une distance d’au moins 10 m du poste de coupage.
• Tremper le métal chaud ou le laisser refroidir avant de le manipuler ou avant de le mettre en contact avec des matériaux combustibles.
• Ne jamais couper des récipients pouvant contenir des matières inflammables avant de les avoir vidés et nettoyés correctement.
• Aérer toute atmosphère potentiellement inflammable avant d’utiliser un système plasma.
• Lors de l’utilisation d’oxygène comme gaz plasma, un système de ventilation par aspiration est nécessaire.
Prévention des explosions
• Ne pas couper en présence de poussière ou de vapeurs.
• Ne pas couper de bouteilles, de tuyaux ou autres récipients fermés et pressurisés.
• Ne pas couper de récipients contenant des matières combustibles.
LE COUPAGE PEUT PROVOQUER UN INCENDIE
OU UNE EXPLOSION
AVERTISSEMENT
Risque d’explosion
argon-hydrogène et méthane
L’hydrogène et le méthane sont des gaz inflammables et potentiellement explosifs. Conserver à l’écart de toute flamme les bouteilles et tuyaux contenant des mélanges à base d’hydrogène ou de méthane. Maintenir toute flamme et étincelle à l’écart de la torche lors de l’utilisation d’un plasma d’argon-hydrogène ou de méthane.
AVERTISSEMENT
Détonation de l’hydrogène lors du
coupage de l’aluminium
• Lors du coupage de l’aluminium sous l’eau, ou si l’eau touche la partie inférieure de la pièce d’aluminium, de l’hydrogène libre peut s’accumuler sous la pièce à couper et détonner lors du coupage plasma.
• Installer un collecteur d’aération au fond de la table à eau afin d’éliminer les risques de détonation de l’hydrogène. Se référer à l’annexe du manuel pour plus de renseignements sur les collecteurs d’aération.
SÉCURITÉ
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Toucher une pièce électrique sous tension peut provoquer un choc électrique fatal ou des brûlures graves.
• La mise en fonctionnement du système plasma ferme un circuit électrique entre la torche et la pièce à couper. La pièce à couper et tout autre élément en contact avec cette pièce font partie du circuit électrique.
• Ne jamais toucher le corps de la torche, la pièce à couper ou l’eau de la table à eau pendant le fonctionnement du système plasma.
Prévention des chocs électriques
Tous les systèmes plasma Hypertherm utilisent des hautes tensions pour le coupage (souvent de 200 à 400 V). On doit prendre les précautions suivantes quand on utilise le système plasma :
• Porter des bottes et des gants isolants et garder le corps et les vêtements au sec.
• Ne pas se tenir, s’asseoir ou se coucher sur une surface mouillée, ni la toucher quand on utilise le système plasma.
• S’isoler de la surface de travail et du sol en utilisant des tapis isolants secs ou des couvertures assez grandes pour éviter tout contact physique avec le travail ou le sol. S’il s’avère nécessaire de travailler dans ou près d’un endroit humide, procéder avec une extrême prudence.
• Installer un sectionneur avec fusibles appropriés, à proximité de la source de courant. Ce dispositif permet à l’opérateur d’arrêter rapidement la source de courant en cas d’urgence.
• En cas d’utilisation d’une table à eau, s’assurer que cette dernière est correctement mise à la terre.
LES CHOCS ÉLECTRIQUES PEUVENT ÊTRE FATALS
• Installer et mettre à la terre l’équipement selon les instructions du présent manuel et conformément aux codes électriques locaux et nationaux.
• Inspecter fréquemment le cordon d’alimentation primaire pour s’assurer qu’il n’est ni endommagé, ni fendu. Remplacer immédiatement un cordon endommagé. Un câble dénudé peut tuer.
• Inspecter et remplacer les câbles de la torche qui sont usés ou endommagés.
• Ne pas saisir la pièce à couper ni les chutes lors du coupage. Laisser la pièce à couper en place ou sur la table de travail, le câble de retour connecté lors du coupage.
• Avant de vérifier, de nettoyer ou de remplacer les pièces de la torche, couper l’alimentation ou débrancher la prise de courant.
• Ne jamais contourner ou court-circuiter les verrouillages de sécurité.
• Avant d’enlever le capot du système ou de la source de courant, couper l’alimentation électrique. Attendre en
suite
5 minutes pour que les condensateurs se déchargent.
• Ne jamais faire fonctionner le système plasma sans que les capots de la source de courant ne soient en place. Les raccords exposés de la source de courant sont extrêmement dangereux.
• Lors de l’installation des connexions, attacher tout d’abord la prise de terre appropriée.
• Chaque système plasma Hypertherm est conçu pour être utilisé uniquement avec des torches Hypertherm spécifiques. Ne pas utiliser des torches inappropriées qui pourraient surchauffer et présenter des risques pour la sécurité.
Le coupage peut produire des vapeurs et des gaz toxiques qui réduisent le niveau d’oxygène dans l’air et peuvent provoquer des blessures, voire la mort.
• Conserver le poste de coupage bien aéré ou utiliser un masque respiratoire homologué.
• Ne pas procéder au coupage près d’endroits où s’effectuent le dégraissage, le nettoyage ou la vapori­sation. Certains solvants chlorés se décomposent sous l’effet des rayons ultraviolets et forment du phosgène.
• Ne pas couper des métaux peints ou contenant des matières toxiques comme le zinc (galvanisé), le plomb, le cadmium ou le béryllium, à moins que la zone de travail
LE COUPAGE PEUT PRODUIRE DES VAPEURS TOXIQUES
soit très bien ventilée et que l’opérateur porte un masque respiratoire. Les revêtements et métaux contenant ces matières peuvent produire des vapeurs toxiques lors du coupage.
• Ne jamais couper de récipients pouvant contenir des matières inflammables avant de les avoir vidés et nettoyés correctement.
• Quand on utilise ce produit pour le soudage ou le coupage, il dégage des fumées et des gaz qui contiennent des produits chimiques qui, selon l’État de Californie, provoquent des anomalies congénitales et, dans certains cas, le cancer.
SÉCURITÉ
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Torches à allumage instantané
L’arc plasma s’allume immédiatement après que la torche soit mise en marche.
L’ARC PLASMA PEUT PROVOQUER DES BLESSURES OU DES BRÛLURES
L’arc plasma coupe facilement les gants et la peau.
• Rester éloigné de l’extrémité de la torche.
• Ne pas tenir de métal près de la trajectoire de coupe.
• Ne jamais pointer la torche vers soi ou d’autres personnes.
Protection des yeux Les rayons de l’arc plasma produisent de puissants rayons visibles ou invisibles (ultraviolets et infrarouges) qui peuvent brûler les yeux et la peau.
• Utiliser des lunettes de sécurité conformément aux codes locaux ou nationaux en vigueur.
• Porter des lunettes de protection (lunettes ou masque muni d’écrans latéraux et encore masque de soudure) avec des verres teintés appropriés pour protéger les yeux des rayons ultraviolets et infrarouges de l’arc.
Puissance des verres teintés
Courant de l’arc AWS (É.-U.) ISO 4850
Jusqu’à 100 A No8N
o
11 100-200 A No10 No11-12 200-400 A No12 No13 Plus de 400 A No14 No14
Protection de la peau Porter des vêtements de sécurité pour se protéger contre les brûlures que peuvent causer les rayons ultraviolets, les étincelles et le métal brûlant :
LES RAYONS DE L’ARC PEUVENT BRÛLER LES YEUX ET LA PEAU
• Gants à crispin, chaussures et casque de sécurité.
• Vêtements ignifuges couvrant toutes les parties exposées du corps.
• Pantalon sans revers pour éviter que des étincelles ou des scories puissent s’y loger.
• Avant le coupage, retirer de ses poches tout objet combustible comme les briquets au butane ou les allumettes.
Zone de coupage Préparer la zone de coupage afin de réduire la réverbération et la transmission de la lumière ultraviolette :
• Peindre les murs et autres surfaces de couleur sombre pour réduire la réflexion de la lumière.
• Utiliser des écrans et autres dispositifs de protection afin de protéger les autres personnes de la lumière et de la réverbération.
• Prévenir les autres personnes de ne pas regarder l’arc. Utiliser des affiches ou des panneaux.
Câble de retour Bien fixer le câble de retour (ou de masse) à la pièce à couper ou à la table de travail de façon à assurer un bon contact métal-métal. Ne pas fixer le câble de retour à la partie de la pièce qui doit se détacher.
Table de travail Raccorder la table de travail à la terre, conformément aux codes de sécurité locaux ou nationaux appropriés.
MISE À LA MASSE ET À LA TERRE
Alimentation
• S’assurer que le fil de terre du cordon d’alimentation est connecté à la terre dans le coffret du sectionneur.
• S’il est nécessaire de brancher le cordon d’alimentation à la source de courant lors de l’installation du système, s’assurer que le fil de terre est correctement branché.
• Placer tout d’abord le fil de terre du cordon d’alimentation sur le plot de mise à la terre puis placer les autres fils de terre par-dessus. Bien serrer l’écrou de retenue.
• S’assurer que toutes les connexions sont bien serrées pour éviter la surchauffe.
SÉCURITÉ
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• Ne jamais lubrifier les robinets des bouteilles ou les régulateurs avec de l’huile ou de la graisse.
• Utiliser uniquement les bouteilles, régulateurs, tuyaux et accessoires appropriés et conçus pour chaque application spécifique.
• Entretenir l’équipement et les pièces d’équipement à gaz comprimé afin de les garder en bon état.
• Étiqueter et coder avec des couleurs tous les tuyaux de gaz afin d’identifier le type de gaz contenu dans chaque tuyau. Se référer aux codes locaux ou nationaux en vigueur.
LES BOUTEILLES DE GAZ COMPRIMÉ PEUVENT EXPLOSER EN CAS DE DOMMAGES
SÉCURITÉ DES BOUTEILLES DE GAZ COMPRIMÉ
Les bouteilles de gaz contiennent du gaz à haute pression. Si une bouteille est endommagée, elle peut exploser.
• Manipuler et utiliser les bouteilles de gaz comprimé conformément aux codes locaux ou nationaux.
• Ne jamais utiliser une bouteille qui n’est pas placée à la verticale et bien assujettie.
• Le capuchon de protection doit être placé sur le robinet sauf si la bouteille est en cours d’utilisation ou connectée pour utilisation.
• Éviter à tout prix le contact électrique entre l’arc plasma et une bouteille.
• Ne jamais exposer des bouteilles à une chaleur excessive, aux étincelles, aux scories ou aux flammes nues.
• Ne jamais utiliser des marteaux, des clés ou d’autres outils pour débloquer le robinet des bouteilles.
Une exposition prolongée au bruit du coupage ou du gougeage peut provoquer des problèmes auditifs.
• Utiliser un casque de protection homologué lors de l’utilisation du système plasma.
• Prévenir les personnes aux alentours des risques encourus en cas d’exposition au bruit.
LE BRUIT PEUT PROVOQUER DES
PROBLÈMES AUDITIFS
Les champs magnétiques produits par les courants à haute tension peuvent affecter le fonctionnement des prothèses auditives et des pacemakers. Les personnes portant ce type d’appareil doivent consulter un médecin avant de s’approcher d’un lieu où s’effectue le coupage ou le gougeage plasma.
Pour réduire les risques associés aux champs magnétiques :
• Garder loin de soi et du même côté du corps le câble de retour et le faisceau de la torche.
• Faire passer le faisceau de la torche le plus près possible du câble de retour.
• Ne pas s’enrouler le faisceau de la torche ou le câble de retour autour du corps.
• Se tenir le plus loin possible de la source de courant.
PACEMAKERS ET PROTHÈSES AUDITIVES
Les tuyaux gelés peuvent être endommagés ou éclater si l'on essaie de les dégeler avec une torche plasma.
UN ARC PLASMA PEUT ENDOMMAGER LES TUYAUX GELÉS
SÉCURITÉ
1a-6 Hypertherm Systèmes plasma
2/12/01
Étiquette de sécurité
Cette étiquette est affichée sur la source de courant. Il est important que l’utilisateur et le technicien de maintenance comprennent la signification des symboles de sécurité.
HySpeed HT2000LHF Instruction Manual 2-1
7
HySpeed HT2000LHF System Components
See Figure 3-2 in Section 3 for details of the system interconnections.
Power Supply
The LHF power supply houses two 100-amp, 15 kHz choppers, the torch's high-frequency starting circuit and an optional internal Torch Height Control (THC).
HySpeed LHF Machine Torch
The LHF machine torch is liquid-cooled and capable of cutting most metals from gauge to 2-inch (50 mm) thickness and from gauge to 1-inch (25 mm) thickness for production cutting. To achieve consumable long life, all cuts
must begin and end on the plate surface.
Gas Console
This unit houses metering and solenoid valves for shield and plasma gases, flow meters, pressure gauges for plasma gases, and a pressure gauge for the shield gas supply.
Argon-Hydrogen Manifold – Optional
This unit houses a flowmeter for argon-hydrogen, a metering valve, a plasma gas outlet switch and a plasma-off valve.
Digital Remote Voltage & Current Control Console
This unit includes LED displays that indicate the setpoints for volts and amperes prior to starting the arc. The displays then automatically display the actual values of the voltage and current while cutting. The digital remote has potentiometers to set and adjust the voltage and current.
Programmable Remote Voltage & Current Control Console
This unit includes LED displays that indicate the setpoints for volts and amperes prior to starting the arc. The displays then automatically display the actual values of the voltage and current while cutting. The programmable remote functions are controlled by the CNC.
Section 2
SPECIFICATIONS
SPECIFICATIONS
2-2 HySpeed HT2000LHF Instruction Manual
7
Remote Current Control Console
This unit contains a manually adjustable thumbwheel to set arc current only.
Initial Height Sensing - Optional
This unit, used with 2 inductive probes, is designed to automatically detect the workpiece surface and move the torch to the pierce position. This system can be used for underwater cutting, cutting at the water line, or cutting above water.
Timer/Counter – Optional
The timer/counter allows the operator to monitor the number of arc starts and the cumulative time that the arc is on in hours. The arc starts can be reset.
Water Muffler – Optional
The water muffler for the LHF system is an option which greatly improves cutting safety and pollution control capabilities. The water muffler can be used to cut above, below and at the water line. Refer to the Water Muffler instruction manual 802050 for more detailed information. The water muffler cannot be used with the stainless steel torch.
CommandTHC – Optional
The CommandTHC is an external torch height control and initial height sensing system designed for plasma cutting applications on an x-y cutting table. Refer to the CommandTHC instruction manual 802780 for more detailed information.
Specifications
System Requirements
Power Requirements:
Refer to LHF power supply specifications below:
Gas Requirements:
Plasma Gas Types........................................................Oxygen, Nitrogen, Air,
Argon-Hydrogen (H35 = 35% Hydrogen/ 65% Argon)
Shield Gas Types..........................................................Air, Nitrogen, Carbon Dioxide
Gas Quality:
Oxygen .........................................................................99.5% pure (liquid gas recommended)
Nitrogen ........................................................................99.995% pure (liquid gas recommended)
Air .................................................................................Clean, dry, oil-free (compressed or liquid gas recommended)
Carbon Dioxide .............................................................99.5% pure (compressed or liquid gas recommended)
Plasma Gas Inlet Pressures and Flow Rates:
Air .................................................................................90 psi +/- 10 psi (6.2 bar +/- 0.7 bar) at 82 scfh (2322 l/h)
Oxygen .........................................................................120 psi +/- 10 psi (8.3 bar +/- 0.7 bar) at 90 scfh (2549 l/h)
Nitrogen ........................................................................120 psi +/- 10 psi (8.3 bar +/- 0.7 bar) at 80 scfh (2265 l/h)
Argon-Hydrogen ...........................................................120 psi +/- 10 psi (8.3 bar +/- 0.7 bar) at 105 scfh (2973 l/h)
Shield Gas Inlet Pressures and Flow Rates:
Air .................................................................................90 psi +/- 10 psi (6.2 bar +/- 0.7 bar) at 280 scfh (7929 l/h)
Carbon Dioxide .............................................................90 psi +/- 10 psi (6.2 bar +/- 0.7 bar) at 220 scfh (6230 l/h)
Nitrogen ........................................................................90 psi +/- 10 psi (6.2 bar +/- 0.7 bar) at 275 scfh (7787 l/h)
Oxygen .........................................................................120 psi +/- 10 psi (8.3 bar +/- 0.7 bar) at 35 scfh (991 l/h)
SPECIFICATIONS
HySpeed HT2000LHF Instruction Manual 2-3
6
Power Supply
Maximum OCV (U0)......................................................280 VDC
Output Current (I
2
) ........................................................40 – 200 amps
Output Voltage (U
2
) ......................................................150 VDC
Duty Cycle Rating (X) ..................................................100% up to 30 kW. Beyond 30 kW, Duty Cycle (X) =
(30 kW/Actual Power)
2
Eg: If Actual Power = 32 kW, then Duty
Cycle (X) = (30 kW/32 kW)
2
= 88%
Ambient Temperatures/Duty Cycle ...............................Power supplies will operate between +14° and 104° F (-10° and
+40° C). Power supplies operated in an ambient temperature above 86° F (30° C) may show some decrease in duty cycle.
Power Factor (cos
ϕ
) .....................................................0.86
Input Power (Input Voltage (U
1
) x Input Current ( I1)):
073227 with THC; 073228 without THC .......................200 VAC, 3PH, 50 Hz, 108 amps
073229 with THC; 073230 without THC .......................208 VAC, 3PH, 60 Hz, 104 amps
073231 with THC; 073232 without THC .......................240 VAC, 3PH, 60 Hz, 90 amps
073235 with THC; 073236 without THC .......................400 VAC, CE, 3PH, 50 Hz, 56 amps
073262 with THC; 073263 without THC .......................440 VAC, 3PH, 50-60 Hz, 49 amps
073233 with THC; 073234 without THC .......................480 VAC, 3PH, 60 Hz, 45 amps
073237 with THC; 073238 without THC .......................600 VAC, 3PH, 60 Hz, 36 amps
Dimensions and Weight:
Width.............................................................................28-1/4" (710 mm)
Height ...........................................................................35-1/2" (900 mm); 40-3/4" (1035 mm) on CE units
Depth ............................................................................41-1/4" (1045 mm)
Weight...........................................................................780 lbs (351 kg); 800 lbs (363 kg) on CE units
Cooling..........................................................................Forced Air (Class F)
Coolant Tank Capacity..................................................2.9 gallons (11 liters)
Maximum cutting thickness...........................................2" (50 mm)
Maximum current at 100% duty cycle...........................200 amps
Plasma and Shield Gas Flow........................................Refer to the Cut Charts in the Operation section for specific gas
requirements.
Water coolant flow rate .................................................0.8 gpm (3.0 l/min)
Weight...........................................................................3 lbs (1.36 kg)
Figure 2-1 LHF Machine Torch (standard torch shown. See Section 6 for figure of stainless steel torch)
6"
(152 mm)
15.4"
(391 mm)
23.25"
(590 mm)
2"
(51 mm)
4.3"
(109 mm)
2" (50 mm) or
1.75" (44 mm) See Sect. 6
HySpeed LHF Machine Torch
4"
4"
5"
5"
SPECIFICATIONS
2-4 HySpeed HT2000LHF Instruction Manual
6
Gas Console
Dimensions and Weight:
Width .......................................................11.5" (290 mm)
Height......................................................14.5" (370 mm)
Depth.......................................................4" (100 mm)
Weight .....................................................23 lbs (10.4 kg)
Argon-Hydrogen Manifold – Optional
Dimensions and Weight:
Width .......................................................5" (127 mm)
Height......................................................10" (254 mm)
Depth.......................................................5" (127 mm)
Weight .....................................................5.75 lbs (2.6 kg)
4"
(102 mm)
3"
(76 mm)
5"
(127 mm)
5"
(127 mm)
4"
(102 mm)
4"
(102 mm)
2"
(51 mm)
2"
(51 mm)
0.5"
(13 mm)
3.75"
(95 mm)
3.75"
(95 mm)
1/4-20 PEM (6) – Use 1/4-20 screws that do not enter more than 1/2" into
enclosure
Figure 2-2 Mounting Dimensions – Gas Console
13/64"
(5 mm) dia.
4 places
Figure 2-3 Mounting Dimensions – Argon-
Hydrogen Manifold
0.5"
(13 mm)
SPECIFICATIONS
HySpeed HT2000LHF Instruction Manual 2-5
6
Digital Remote Voltage & Current Control Console
Controls....................Voltage adjust potentiometer: Adjusts arc
cutting voltage and displays value on LEDs. Current adjust potentiometer: Adjusts arc
current and displays value on LEDs.
Control range ...........Current: 40-200 amps/Voltage: 100-200 volts
Control resolution.....Current: 10 amps/ Voltage: 5 volts
Dimensions and Weight:
Width .......................................................11.4" (290 mm)
Height......................................................3" (76 mm)
Depth.......................................................13.4" (340 mm)
Weight .....................................................5.3 lbs (2.4 kg)
Programmable Remote Voltage & Current Control Console
Controls....................None. Controlled through guidance CNC.
Control range ...........Current: 40-200 amps/Voltage: 100-200 volts
Control resolution.....Current: 10 amps/ Voltage: 5 volts
Dimensions and Weight:
Width .......................................................11.4" (290 mm)
Height......................................................3" (76 mm)
Depth.......................................................12.5" (318 mm)
Weight .....................................................5.3 lbs (2.4 kg)
Remote Current Control Console
Dimensions and Weight:
Width .......................................................6-1/2" (165 mm)
Height......................................................2-1/2" (64 mm)
Depth.......................................................8-5/8" (219 mm)
Weight .....................................................3 lbs (1 kg)
10.5" (267 mm)
11.4" (290 mm)
7/32"
(5.5 mm)
dia.
4 places
11.65" (296 mm)
5"
(127 mm)
0.5"
(13 mm)
Figure 2-4 Mounting Dimensions – Digital Remote Voltage & Current Control Console
10.5" (267 mm)
11.4" (290 mm)
7/32" dia. (5.5 mm)
4 places
11.65" (296 mm)
5"
(127 mm)
0.5"
(13 mm)
Figure 2-5 Mounting Dimensions – Programmable
Remote Voltage & Current Control Console
Figure 2-6 Mounting Dimensions –
Remote Current Control Console
5/32" ø (4 mm) – 4 places
3.38" (86 mm)
6.25" (159 mm)
8.5" (216 mm)
0.50" (13 mm)
1.17" (30 mm)
6.50" (165 mm)
SPECIFICATIONS
2-6 HySpeed HT2000LHF Instruction Manual
6
Initial Height Sensing (IHS) – Optional
Input power .............................................120VAC from power supply
Air pressure.............................................20 psi (1.4 bar) regulated
shop air input to solenoid
Dimensions and Weight:
Width .......................................................9" (229 mm)
Height......................................................4.5" (114 mm)
Depth.......................................................11.5" (292 mm)
Weight .....................................................13 lbs (6 kg)
Timer/Counter – Optional
Dimensions and Weight:
Width .......................................................6-1/2" (165 mm)
Height......................................................2-1/2" (64 mm)
Depth.......................................................8-5/8" (219 mm)
Weight .....................................................3 lbs (1 kg)
Water Muffler – Optional
Refer to the Water Muffler Instruction Manual 802050. The water muffler cannot be used with the stainless steel torch.
CommandTHC – Optional
Refer to the CommandTHC Instruction Manual 802780.
6" (152 mm)
8" (290 mm)
5/16" dia.
(8 mm)
4 places
11.5"
(292 mm)
10.75"
(273 mm)
Figure 2-7 Mounting Dimensions – IHS
Figure 2-8 Mounting Dimensions – Timer/Counter
5/32" ø (4 mm) – 4 places
3.38" (86 mm)
6.25" (159 mm)
8.5" (216 mm)
0.50" (13 mm)
1.17" (30 mm)
6.50" (165 mm)
HySpeed HT2000LHF Instruction Manual 3-1
6
Section 3
INSTALLATION
Installation Requirements
All installation and service of the electrical and plumbing systems must conform to national or local electrical and plumbing codes. This work should be performed only by qualified, licensed personnel.
Direct any technical questions to the nearest Hypertherm Technical Service Department listed in the front of this manual, or your authorized Hypertherm distributor.
Gas Requirements
All gases are provided by the customer. Refer to Section 2 for specifications.
Upon Receipt
• Verify that all system components on your order have been received. Contact your supplier if any items are missing.
• Inspect the system components for any physical damage that may have occurred during shipping. If there is evidence of damage, refer to Claims. All communications regarding claims must include the model number and serial number located on the back of the power supply.
Claims
Claims for damage during shipment – If your unit was damaged during shipment, you must file a claim with the
carrier. Hypertherm will furnish you with a copy of the bill of lading upon request. If you need additional assistance, call Customer Service listed in the front of this manual, or your authorized Hypertherm distributor.
Claims for defective or missing merchandise – If any of the merchandise is defective or missing, contact your supplier. If you need additional assistance, call Customer Service listed in the front of this manual, or your authorized Hypertherm distributor.
INSTALLATION
3-2 HySpeed HT2000LHF Instruction Manual
6
Caution: Gas supply pressures not within the parameters outlined in Section 2 can cause
poor cut quality, poor consumable life, and operational problems.
If the purity level of the gas is too low or if there are leaks in the supply hoses or connections,
• Cut speeds can decrease
• Cut quality can deteriorate
• Cutting thickness capability can decrease
• Parts life can shorten
Caution: Only hose designed to carry oxygen may be used for oxygen lines.
The LHF system can cut with air, oxygen, nitrogen or argon-hydrogen as the plasma gas, and use air, nitrogen or carbon dioxide as the shield gas.
Air may be supplied from cylinders, a liquid supply, or from an on-site compressor. Hypertherm recommends a three-stage coalescing filtration system when using air as a supply gas. See the appendix section for suggested filtration.
Other gases may be supplied from cylinders or liquid storage tanks.
Gas Supply Plumbing
If making hard plumbing connections, avoid using iron pipe. Never use PTFE tape on any joint preparation. After installation, pressurize the entire system and check for leaks.
For flexible-hose systems, use a hose designed for inert gas to carry air, nitrogen, argon-hydrogen or carbon­dioxide.
WARNING
Cutting with oxygen as the plasma gas can cause a potential fire hazard due to the oxygen­enriched atmosphere that it creates. As a precaution, Hypertherm recommends that an exhaust ventilation system be installed when cutting with oxygen.
Note: When cutting with oxygen as the plasma gas, nitrogen must also be connected to the gas console to
achieve the proper oxygen/nitrogen mixtures in the preflow and cut flow conditions.
INSTALLATION
HySpeed HT2000LHF Instruction Manual 3-3
9
Torch Coolant Requirements
The power supply is shipped to the customer without any coolant in the tank. Hypertherm recommends a mixture of 30% propylene glycol, 69.9% purified water, and 0.1% benzotriazole. This mixture resists freezing to +10° F (-12° C) and protects copper surfaces in the coolant loop.
See the chart in the appendix section to determine if a stronger propylene glycol/purified water solution is needed for your particular application. The standard coolant mixture is available in 1-gallon containers by ordering 028872. 100% propylene glycol is available by ordering 028873.
Refer to the Material Safety Data Sheets in the appendix section for data on safety, handling, and storage of propylene glycol and benzotriazole.
Grounding Requirements
Proper grounding is essential for personal safety and to prevent emission of high-frequency interference.
See Appendix for system grounding requirements.
Connect the worktable to a high-quality earth ground, not more than 20 feet (6 m) from the table. A suitable ground consists of a solid copper rod of at least 1/2" (12 mm) diameter driven to a depth of at least 8 feet (2.5 m) into the earth, below the permanent moisture level. Ensure that all grounding connections are tight to avoid excessive heating. The power supply enclosure is grounded through the incoming AC conductor and does not require an additional ground. See also Grounding in the Safety section. For additional information consult national or local electric codes.
Caution: For operating temperatures colder than +10° F (-12° C), the percentage of
propylene glycol must be increased to avoid the risk of a cracked torch head, hoses, or other damage to the torch coolant system due to the freezing of the torch coolant.
Caution: Always use propylene glycol in the coolant. Do not substitute automotive
antifreeze which will damage the torch cooling system.
Caution: Always use purified water in the coolant mixture in order to prevent corrosion
in the cooling system. The hardness of the purified water should be between
0.2 and 8.5 ppm. If using a conductivity meter to measure water purity, the recommended level is between 0.5 and 18 µSiemens/cm at 77° F (25° C).
WARNING
Propylene glycol and benzotriazole are irritating to skin and eyes, and harmful or fatal if swallowed. Upon contact, flush skin or eyes with water. If swallowed, drink water and call a physician immediately. Do not induce vomiting.
INSTALLATION
3-4 HySpeed HT2000LHF Instruction Manual
6
Noise levels
This plasma system may produce noise that is harmful to the operator or to those close to the cutting table. See
Noise Protection in the Safety section.
Power Requirements
All switches, slow-blow fuses and power cables are customer supplied and must be chosen as outlined by applicable national and/or local electrical codes. Installation must be performed by qualified personnel. Use a separate primary line disconnect switch for the power supply.
Rated Input Input Current @ Recommended Recommended V
oltage Phase 30 kW Output
Slow-Blow Fuse Size Cable Size (AWG)
200 VAC 3 108 amps 150 amps 1 208 VAC 3 104 amps 150 amps 1 240 VAC 3 90 amps 150 amps 1 400 VAC 3 56 amps 80 amps 4 440 VAC 3 49 amps 70 amps 6 480 VAC 3 45 amps 60 amps 6 600 VAC 3 36 amps 50 amps 8
Line Disconnect Switch
The line disconnect switch serves as the supply voltage disconnecting (isolating) device. Install this switch on a wall near the power supply for easy accessibility by the operator. The line disconnect switch must be installed
by qualified personnel following all applicable local and national codes. The switch should:
• isolate the electrical equipment and disconnect all live conductors from the supply voltage when in the “OFF” position
• have one “OFF” and one “ON” position clearly marked with “0” (OFF) and “1” (ON)
• have an external operating handle capable of being locked in the “OFF” position
• contain a power operated mechanism that serves as an emergency stop
• have slow-blow fuses installed for the proper breaking capacity (see table above)
Caution: All accessory modules in the system must be grounded to earth. Use a minimum
of 8 AWG wire connected from the stud on the side of each module enclosure to the worktable ground.
INSTALLATION
HySpeed HT2000LHF Instruction Manual 3-5
6
Power Cable
Wire sizes vary based on the distance of the receptacle from the main box. The wire sizes listed in the table above were taken from the National Electric Code 1990 handbook, table 310.16. Use a 4-conductor Type SO input power cable with a conductor temperature rating of 140°F (60°C). The cable should be installed only by a licensed electrician.
Note: A lifting eye is provided for moving the power supply into place with a crane or hoist. It may also be moved
by forklift if the forks are long enough to extend the entire length of the base. Take care when lifting with the forks so that the underside of the power supply is not damaged.
• Place the power supply in an area that is free of excessive moisture, has proper ventilation, and is relatively
clean. Allow room for accessing the sides of the power supply for servicing.
• Cooling air is drawn in through the front panel grating, and is exhausted through the rear of the unit by a
cooling fan. Do not place any filter device over the air intake locations. This reduces cooling efficiency and VOIDS THE WARRANTY.
Positioning the Power Supply
WARNING
Remove all electrical connections to power supply before moving or positioning. Transporting unit can cause personal injury and equipment damage.
WARNING
The line disconnect switch must be in the OFF position before making the power cable connections! In the U.S., use a "lock-out/tag-out" procedure until installation is complete. In other countries, follow appropriate local or national safety procedures.
Connecting the Power
INSTALLATION
3-6 HySpeed HT2000LHF Instruction Manual
10
1. Insert the power cable through the strain relief at the lower left rear of the power supply. Connect the power cable leads to TB1 located at the center wall, right side.
2. Connect the power leads to the L1, L2, and L3 terminals of TB1. See Fig. 3-1.
3. Connect the ground lead as shown.
Figure 3-1 Power Cable Connections
Ground lead
To connect the power cable to the 400V CE power supplies refer to the appendix section.
WARNING
There is line voltage at the contactor if the line disconnect switch is in the ON position, even if the ON (l) pushbutton on the power supply has not been pressed. As a common safety practice, ALWAYS verify that the line disconnect switch is in the OFF position before installing, disconnecting or servicing in this area.
Connecting the Power (continued)
INSTALLATION
HySpeed HT2000LHF Instruction Manual 3-7
6
Power Cable from LHF Power Supply to Power Source.
1. Be certain that the line disconnect switch is in the OFF position and remains in the OFF position for the
remainder of the installation of the LHF system.
2. Connect the power cord leads to the line disconnect switch following local and applicable electrical codes.
Torch Lifter Requirements
The LHF system requires a high-quality, motorized torch lifter with sufficient travel to cover all cutting thickness requirements. The lifter must provide 10 inches (254 mm) of vertical travel. The unit should have a constant speed of at least 20 ipm (508 mm/min) with positive braking. A unit which drifts through the stop point is not acceptable.
Optional Equipment
Water Muffler
Refer to Water Muffler instruction manual 802050. A power cable for the Water Muffler pump must be provided by the customer. The pumps provided by Hypertherm take a three-phase input. Part numbers and corresponding voltages are listed in the Water Muffler manual. Input current information is provided on the motor data plate. Present pump systems all draw less than 20 amps and cable sizes should be selected accordingly.
The water muffler cannot be used with the stainless steel torch.
System Units Placement
• Position all required units prior to making electrical, gas and interface connections.
• Ground all external modules in the LHF system to earth.
• To prevent leaks in the system, tighten all gas and water connections to the following specifications:
Use 2 wrenches when tightening to prevent damage to the mating component.
Use the diagram on the following 2 pages to make system interconnections. Follow the number guide on the diagram to find out specific information on each cable, hose or connection. The numbered items are detailed on the pages following the interconnection diagram.
Gas or water
Torque Specification
hose size lbf-in lbf-ft kgf-cm
up to 3/8" 75-85 6.25-7 86-98 1/2" 360-480 30-40 415-550
3-8 HySpeed HT2000LHF Instruction Manual
7
See Valve Cluster and Torch Connections – pages 3-17 to 3-18.
To Second LHF Power Supply
11X1
Timer/Counter
11
12
Blue Green Red Gray
1
2
3
4
5
Customer Supplied Interface
6
Initial Height Sensing
To IHS probes and air supply – see the appendix section
To water muffler pump
To argon-hydrogen manifold – see the appendix section
Worktable
Power Supply
7
8
9
10
13
14
16
15
22
1X3
1X9
1X1
1X2
1X6 1X7
1X5
1X4
1X10
HySpeed HT2000LHF Instruction Manual 3-9
6
Digital Remote
Programmable Remote
Remote Current
To shield gas supply
To oxygen gas supply
To nitrogen or air gas supply
Gas Console
7
8
9
5X1
5X1
5X2
15X1
16
15
17
18
19
20
21
Figure 3-2 System Interconnections
2
See Valve Cluster Connections – page 3-18.
1X2 3X1
INSTALLATION
3-10 HySpeed HT2000LHF Instruction Manual
6
Off-Valve Cable – Power Supply to Valve Cluster Cable
See valve cluster connections on page 3-18.
Gas Console Cable – Power Supply to Gas Console
Part No. Length
023755 4 ft (1.2 m) 023920 8 ft (2.4 m) 023508 10 ft (3 m) 023403 15 ft (4.6 m) 023404 25 ft (7.6 m) 023968 30 ft (9.2 m) 023986 35 ft (10.7 m) 023405 50 ft (15 m)
Power Supply Connections
Positive Lead – Power Supply to Worktable
1
2
3
3
1
1X3 4X1
1x2 3x1 Color Signal
19 19 Black S1 / N2 / O2 20 20 Orange S1 / N2 / O2 13 13 Shield 14 14 Red S2 / Test / Preflow 15 15 White S2 / Test / Common 21 21 Shield 35 35 Red S2 / Test / Operate 36 36 Green S2 / Test / Common 31 31 Shield 32 32 Red PS1&PS2 33 33 Blue PS1&PS2 37 37 Shield
1x2 3x1 Color Signal
2 2 Black LT1 / DC ON 3 3 Green LT1 / DC ON 7 7 Shield 8 8 Black SV1B / O2 / N2 9 9 Blue SV1B / O2 / N2
4 4 Shield 16 16 Black SV2 / O2 / N2 17 17 Yellow SV2 / O2 / N2 10 10 Shield 27 27 Red SV1A / O2 / N2 28 28 Brown SV1A / O2 / N2 22 22 Shield 11 11 Black SV3 / Preflow Trap 12 12 Brown SV3 / Preflow Trap 18 18 Shield
Part No. Length
023989 10 ft (3 m) 023549 15 ft (4.6 m) 023605 25 ft (7.6 m) 023757 38 ft (11.6 m) 023606 50 ft (15 m) 123044 60 ft (18.3 m) 023607 75 ft (23 m) 123077 85 ft (25.9 m) 023608 100 ft (30.5) 023963 115 ft (35.1 m) 123147 120 ft (36.6 m) 023743 125 ft (38.1 m) 023609 150 ft (46 m) 023953 200 ft (62 m)
Part No. Length
123283 15 ft (4.6 m) 123284 20 ft (6 m) 123285 25 ft (7.6 m) 123286 30 ft ( 9.2 m) 123287 35 ft (10.7 m) 123288 40 ft (12.2 m) 123289 50 ft (15 m)
1x3 4x1 Color Signal
1 1 Red SV4A Cutflow 2 2 White SV4A Cutflow 3 3 Green Shield 5 5 Orange SV4B Preflow 6 6 White SV4B Preflow 4 4 White Shield 7 7 Black SV5 Plasma OFF 8 8 White SV5 Plasma OFF 9 9 Yellow Shield
2
1X7
1X6
INSTALLATION
HySpeed HT2000LHF Instruction Manual 3-11
6
Machine V/C Interface Cable – Power Supply to Machine Interface
1x6 Color Signal
2 Yellow Initial Height Sig. (OFF=Closed) 6 Black Initial Height Com.
11 Shield
4 Orange Auto Height Sig. (OFF=Closed)
8 Black Auto Height Com. 13 Shield 34 Red *†Lifter DOWN Load (DOWN=Closed) 29 Black Lifter DOWN Line 23 Shield 35 Green *†Lifter UP Load (UP=Closed) 30 Black Lifter UP Line 24 Shield 36 Red Upper Limit Switch ( OFF=Closed) 31 Blue Upper Limit Switch 25 Shield
1x6 Color Signal
9 Blue Plasma START (START=Closed) 15 Black Plasma START 14 Shield 37 Red †Arc Transfer (TRANSFER=Closed) 32 Green †Arc Transfer 26 Shield
1 White Hold Ignition Sig. (HOLD=Closed)
5 Black Hold Ignition Com. 10 Shield
3 Brown Ramp Down Error
7 Black Ramp Down Error 12 Shield
1x7 Color Signal
2 White Current 10 3 Red Current 20 4 Green Current 40 5 Orange Current 80 6 Blue Current 100 7 White/Black Current 200
10 Shld Shield
11 Blue/Black Current Common
1x7 Color Signal
16 Black/Red Voltage V5 17 White/Red Voltage V10 18 Orange/Red Voltage V20 19 Blue/Red Voltage V40 20 Red/Green Voltage V80 21 Orange/Green Voltage V100 22 Black/White/Red Voltage V200 23 White/Black/Red Voltage VCommon
Part No. Length
023841 6 ft (1.8 m) 023842 15 ft (4.6 m) 023843 25 ft (7.6 m) 023844 35 ft (10.7 m) 023845 50 ft (15 m) 123047 60 ft (18.3 m) 023846 75 ft (23 m)
Part No. Length
123080 85 ft (25.9 m) 023847 100 ft (30.5) 023962 115 ft (35.1 m) 123148 120 ft (36.6 m) 023848 125 ft (38.1 m) 023849 150 ft (46 m) 023850 200 ft (62 m)
4 4
5 5
* Signals are AC relays. DC relays are available as an option from Hypertherm by ordering kit: 128404
Machine I/O Interface Cable – Power Supply to Machine Interface
Part No. Length
023902 6 ft (1.8 m) 023851 15 ft (4.6 m) 023852 25 ft (7.6 m) 023853 35 ft (10.7 m) 023854 50 ft (15 m)
Part No. Length
023855 75 ft (23 m) 023856 100 ft (30.5) 023903 125 ft (38.1 m) 023857 150 ft (46 m) 023858 200 ft (62 m)
WARNING
When installing or servicing the power supply, AC or DC line voltages may be present on the UP, DOWN and TRANSFER signals even if the power supply line disconnect switch is OFF. Make certain that all
line disconnect switches relating to the system are OFF during installation and when servicing.
Note: If you are using a remote V/C to set voltage and current, skip this step.
Before connecting the machine V/C interface cable, see the wiring diagrams in this manual and verify that the correct plug is attached to the µP control PCB REC6 receptacle.
1X1
INSTALLATION
3-12 HySpeed HT2000LHF Instruction Manual
6
Note: If you are using a machine computer interface to set voltage and current and do not want the programmable
voltage current readout, skip references 7-9.
Remote Voltage and Current Cable – Power Supply to Digital Remote or Programmable Remote
1x4 5x1 Color Signal
4 1 Green SID Data 8 2 Black SID Common
13 Grn/Blk Shield
9 3 Red SOD Data 15 6 Black SOD Common 14 Red/Blk Shield 35 7 White AC Power 36 8 Black AC Power 31 Wht/Blk Shield
5 Key
22 Key
6
6
Notes: • If using this Remote I/O Cable, remove jumpers from power supply
TB5 terminals 1&2 and 4&5 and terminate Remote I/O Cable wires for PB2A and PB2B to a normally closed switch.
• Terminate wires for PB1A and PB1B to a normally open switch.
• Input requirements for interlocks: DC current between 15 and 20 mA; DC voltage between 12 and 15 V.
• Refer also to pages 3 and 6 of the wiring diagrams in Section 7.
Remove jumper Remove jumper
7
7
1X4 5X1
Part No. Length
123294 6 ft (1.8 m) 123295 15 ft (4.6 m) 123296 25 ft (7.6 m) 123297 35 ft (10.7 m) 123298 50 ft (15.3 m) 123299 60 ft (18.3 m) 123300 75 ft (23 m)
Part No. Length
123301 85 ft (25.9 m) 123302 100 ft (30.5) 123303 115 ft (35.1 m) 123304 120 ft (36.6 m) 123305 125 ft (38.1 m) 123306 150 ft (46 m) 123307 200 ft (62 m)
Remote I/O Cable – Power Supply to Remote Interface
1x1 Color Signal
19 White FS1 Interlock 20 Red FS1 Interlock 13 Shield Ground
23 Blue LT1 120 VAC 24 Black LT1 120 VAC
25 Shield Ground 26 Red PB2A 24 VAC 27 Green PB2A 24 VAC 28 Shield Ground
29 White PB2B 120 VAC 30 Black PB2B 120 VAC
34 Shield Ground 32 Brown PB1A 24 VAC 33 Black PB1A 24 VAC 37 Shield Ground
35 Red PB1B 120 VAC 36 Brown PB1B 120 VAC
31 Shield Ground
1x1 Color Signal
2 Yellow PB1 LT1 24VAC 3 Black PB1 LT1 24VAC 7 Shield Ground 5 Orange TS1 Interlock 6 Black TS1 Interlock 1 Shield Ground 8 Red LS1 Interlock 9 Black LS1 Interlock
4 Shield Ground 11 Green PS3 Interlock 12 Black PS3 Interlock 18 Shield Ground 14 Red PS1,PS2 Interlock 15 Blue PS1,PS2 Interlock 21 Shield Ground
16 Red TS2 Interlock 17 Yellow TS2 Interlock 10 Shield Ground
Part No. Length
023990 7 ft (2.1 m) 023911 15 ft (4.6 m) 023878 25 ft (7.6 m) 023879 50 ft (15.3 m) 123040 60 ft (18.3 m) 023880 75 ft (22.9 m) 123073 85 ft (25.9 m) 023881 100 ft (30.5 m)
Part No. Length
123188 120 ft (36.6 m) 023882 125 ft (38.1 m) 023883 150 ft (45.8 m) 023884 200 ft (61 m) 023885 250 ft (76.3 m) 023886 275 ft (83.9 m) 023887 300 ft (91.5 m)
WARNING
• Be certain to properly terminate 120 VAC wire connections!
• Provide proper strain relief for remote I/O cable at customer interface.
1X10
INSTALLATION
HySpeed HT2000LHF Instruction Manual 3-13
6
Programmable Remote Voltage and Current Cable – Power Supply to Programmable Remote
Note: If you are using the digital remote to set voltage and current, skip this reference.
8
8
1X5
5X2
1X7
15X1
Current Control Cable – Power Supply to Remote Current Control
Note: If you are using the digital remote, programmable remote or machine computer to set current, skip
this reference.
9
9
Water Muffler Pump Cable – Power Supply to Water Muffler Pump
See water muffler instruction manual 802050 to connect cable to pump motor, and to make remaining water muffler connections. The water muffler cannot be used with the stainless steel torch.
10
10
1x5 5x2 Color Signal
10 10 Black/Green Voltage 20 11 11 Black/Orange Voltage 40 12 12 Black/Red Voltage 80 13 13 White/Green Voltage 100 14 14 White/Red Voltage 200 15 15 Black/White Spare 16 16 Shld Shield
1x5 5x2 Color Signal
1 1 Black Current 20 2 2 Blue Current 40 3 3 Green Current 80 4 4 White Current 100 5 5 Orange Current 200 7 7 White/Black Common 8 8 White/Blue Voltage 5 9 9 Black/Blue Voltage 10
Part No. Length
023834 15 ft (4.6 m) 023835 25 ft (7.6 m) 023836 50 ft (15.3 m) 023837 75 ft (22.9 m) 023838 100 ft (30.5 m)
Part No. Length
023898 125 ft (38.1 m) 023839 150 ft (45.8 m) 023840 200 ft (61 m) 023899 250 ft (76.3 m) 023900 275 ft (83.9 m) 023901 300 ft (91.5 m)
Part No. Length
123150 10 ft (3 m) 023871 25 ft (7.6 m) 023872 38 ft (11.6 m) 023873 50 ft (15 m) 023874 75 ft (23 m) 023875 100 ft (30.5 m) 123068 110 ft (33.6 m) 123277 120 ft (36.6 m) 123088 125 ft (38.1 m) 023876 150 ft (46 m) 123032 170 ft (51.9 m) 023877 200 ft (61 m)
Part No. Length
023866 50 ft (15 m) 023867 75 ft (23 m) 023868 100 ft (30.5)
1X7 15X1 Color Current Signal (I)
2 8 Black I-10 3 7 White I-20 4 10 Black I-40 5 9 Green I-80 6 15 Black I-100 7 16 Red I-200
11 3 I-Com
From 1X10 Color To WM Pump Contactor
2 Black Coil 4 White AC Neut. 3 Green Ground
Gas Console Connections
See page 3-9 for gas console connection to power supply.
Argon-Hydrogen Cable – Power Supply to Argon-Hydrogen Manifold
See the appendix section for Argon-Hydrogen installation and operation.
INSTALLATION
3-14 HySpeed HT2000LHF Instruction Manual
6
11X1
Hold Cable – Power Supply 1 to Power Supply 2
Color TB3 Signal Black 13 Hold Signal
Red 14 Hold Common Shield 15 Hold Shield
Part No. Length
023340 15 ft (4.6 m) 023341 25 ft (7.6 m) 023342 50 ft (15 m) 023343 100 ft (30.5) 023344 150 ft (46 m)
12
13
Initial Height Sensing Cable – Power Supply to Initial Height Sensing Console
See the appendix section for Initial Height Sensing connections.
14
Shield Gas Hose – Gas Console to Power Supply
Note: Turn counterclockwise to tighten
15
15
12
Part No. Length
024348 5 ft (1.5 m) 024313 10 ft (3 m) 024302 15 ft (4.6 m) 024349 20 ft (6.1 m) 024303 25 ft (7.6 m) 024350 30 ft (9.1 m) 024351 35 ft (10.7 m) 024352 40 ft (12.2 m) 024353 45 ft (13.7 m) 024304 50 ft (15 m) 024305 75 ft (23 m) 024306 100 ft (30.5 m) 024312 150 ft (46 m)
Timer/Counter Cable – Power Supply to Timer/Counter
11
11
Part No. Length
023687 10 ft (3 m) 023692 25 ft (7.6 m) 023758 38 ft (11.6 m) 023693 50 ft (15 m) 123046 60 ft (18.3 m) 023694 75 ft (23 m) 123079 85 ft (25.9 m) 023695 100 ft (30.5) 023993 115 ft (35.1 m) 123189 120 ft (36.6 m) 023696 150 ft (46 m) 023954 200 ft (62 m)
11x1 TB3 Color Signal
1 2 White Starts and Arc time (CON1 Closed) 2 1 Black Starts and Arc time (CON1 Closed)
3 3 Drain Drain 15 5 Red Error Counter (Ramp Down Error) 16 4 Black Error Counter (Ramp Down Error) 12 6 Drain Drain
INSTALLATION
HySpeed HT2000LHF Instruction Manual 3-15
6
Shield Gas Sense Hose – Gas Console to Power Supply
16
16
Part No. Length
024061 5 ft (1.5 m) 024063 10 ft (3 m) 024065 15 ft (4.6 m) 024067 20 ft (6.1 m) 024069 25 ft (7.6 m) 024071 30 ft (9.1 m) 024356 35 ft (10.7 m) 024092 40 ft (12.2 m) 024403 45 ft (13.7 m) 024096 50 ft (15 m) 024174 60 ft (18.3 m) 024468 75 ft (23 m) 024523 100 ft (30.5 m)
Shield Gas Supply Hose – Shield Supply to Gas Console
Any supply gases that will be used for the shield gas, attach to the same point on the gas console.
17
17
Part No. Length
024043 4 ft (1.2 m) 024341 10 ft (3 m) 024200 15 ft (4.6 m) 024342 20 ft (6 m) 024133 25 ft (7.6 m) 024448 35 ft (10.7 m) 024407 45 ft (13.7 m) 024012 50 ft (15 m) 024472 60 ft (18.3 m) 024147 75 ft (23 m) 024486 85 ft (25.9 m) 024115 100 ft (30 m) 024452 110 ft (33.6 m) 024449 115 ft (35.1 m) 024515 120 ft (36.6 m) 024395 125 ft (38.1 m) 024119 150 ft (46 m) 024480 170 ft (51.9 m) 024184 180 ft (55 m) 024123 200 ft (61 m)
Oxygen Plasma Supply Hose – Oxygen Supply to Gas Console
Note: If cutting with oxygen as the plasma gas, nitrogen
must also be connected to the gas console to achieve the proper oxygen/nitrogen mixtures in the preflow and cut flow conditions.
18
18
Part No. Length
024204 15 ft (4.6 m) 024205 25 ft (7.6 m) 024155 50 ft (15 m) 024398 75 ft (22.9 m) 024487 85 ft (25.9 m) 024206 100 ft (30 m) 024481 110 ft (33.6 m) 024450 115 ft (35.1 m) 024516 120 ft (36.6 m) 024490 125 ft (38.1 m) 024159 150 ft (46 m) 024470 180 ft (54.9 m) 024333 200 ft (61 m)
INSTALLATION
3-16 HySpeed HT2000LHF Instruction Manual
6
Nitrogen Plasma Supply Hose – Nitrogen Supply to Gas Console
19
Air Plasma Supply Hose (Customer Supplied) – Air Supply to Gas Console
19
19
Part No. Length
024505 6 ft (1.8 m) 024210 10 ft (3 m) 024203 15 ft (4.6 m) 024232 20 ft (6 m) 024134 25 ft (7.6 m) 024211 35 ft (10.6 m) 024112 50 ft (15 m) 024148 75 ft (23 m) 024488 85 ft (25.9 m) 024116 100 ft (30 m) 024482 110 ft (33.6 m) 024451 115 ft (35.1 m) 024517 120 ft (36.6 m) 024491 125 ft (38.1 m) 024120 150 ft (46 m) 024185 180 ft (55 m) 024124 200 ft (61 m)
Plasma Preflow Gas Hose – Gas Console to Valve Cluster
See valve cluster connections on page 3-18.
20 20
Part No. Length
024317 5 ft (1.5 m) 024026 10 ft (3 m) 024027 15 ft (4.6 m) 024017 20 ft (6.1 m) 024028 25 ft (7.6 m) 024029 30 ft (9.1 m) 024030 35 ft (10.7 m) 024031 40 ft (12.2 m) 024207 45 ft (13.7 m) 024340 50 ft (15 m) 024419 56 ft (17.1 m) 024127 60 ft (18.3 m) 024343 75 ft (23 m) 024344 100 ft (30.5 m)
Plasma Cut Flow Gas Hose – Gas Console to Valve Cluster
See valve cluster connections on page 3-18.
21
21
Part No. Length
024316 5 ft (1.5 m) 024307 10 ft (3 m) 024320 15 ft (4.6 m) 024308 20 ft (6.1 m) 024321 25 ft (7.6 m) 024309 30 ft (9.1 m) 024322 35 ft (10.7 m) 024310 40 ft (12.2 m) 024323 45 ft (13.7 m) 024311 50 ft (15 m) 024420 56 ft (17.1 m) 024367 60 ft (18.3 m) 024357 75 ft (23 m) 024358 100 ft (30.5 m)
Gas Console Connections (continued)
Note: Turn counterclockwise to tighten
INSTALLATION
HySpeed HT2000LHF Instruction Manual 3-17
6
Valve Cluster and Torch Connections
Routing the Torch Leads
Caution: Before routing the leads, make sure that the torch is removed from the torch leads.
1. If the 12" off-valve hose is connected from the torch to the valve cluster, disconnect it at the valve cluster. Note that the fitting is left-hand threaded and turns in a clockwise direction to remove.
2. Slide the torch sleeve over the torch leads and out of the way.
3. Attach the red and green torch leads to the red and green tubes of the torch main body using a 3/8" wrench to hold the torch fittings, and a 1/2" wrench to tighten the torch lead fittings.
4. Attach the pilot/shield lead to the shortest tube on the torch main body. Use a 5/16" wrench to hold the torch body fitting and a 7/16" wrench to tighten the torch lead fitting.
5. Attach the gray torch lead to the remaining torch fitting. Use a 5/16" wrench to hold the torch body fitting and a 7/16" wrench to tighten the torch lead fitting.
Note: If the 12" off-valve hose is not connected to the torch, make the left-
hand threaded connection at this time. Use the same wrenches as in steps 4 and 5.
6. Slide the torch sleeve over the torch main body and screw together.
Power Supply Side
Torch Side
Pilot/Shield Lead
Gray
Red
Green
Figure 3-3 Torch Lead
Connections to Torch
Red and Green Tubes
12" Off-Valve Hose
Pilot/Shield Lead
Gray
Route the torch leads from the power supply to the torch through a festoon or a power track.
Connecting the Torch Leads to the Torch
See page 3-8 for torch lead connections to the power supply. See page 3-7 for torque specifications.
Torch Leads – Power Supply to Torch
22 22
Part No. Length
028657 10 ft (3 m) 028658 15 ft (4.6 m) 028659 20 ft (6.1 m) 028546 25 ft (7.6 m) 028660 30 ft (9.1 m) 028661 35 ft (10.7 m) 028662 40 ft (12.2 m) 028663 45 ft (13.7 m) 028547 50 ft (15 m)
INSTALLATION
3-18 HySpeed HT2000LHF Instruction Manual
6
Valve Cluster Connections
See page 3-9 for plasma preflow and cutflow hose connections to the gas console. See page 3-16 for plasma preflow and cutflow hose part numbers. See page 3-7 for torque specifications.
1. Loosen the valve cluster screw and slide the valve cluster up the torch sleeve. Secure in place approximately as shown in Figure 3-5.
2. Attach the plasma preflow hose from the gas console to SV4B.
3. Attach the plasma cut flow hose from the gas console to SV4A. Note that this connection is left-hand threaded.
4. Attach the 12" plasma hose from the torch to off-valve SV5. Note that this connection is left-hand threaded.
Figure 3-4 Valve Cluster Connections – Top View
20
21
Preflow SV4B
Cut Flow SV4A
Valve Cluster Screw
12" Plasma Hose from torch to Off-Valve SV5
INSTALLATION
HySpeed HT2000LHF Instruction Manual 3-19
6
Figure 3-5 Torch with Valve Cluster and Cable Attached
23
Valve Cluster Cable to Power Supply Off-Valve Cable
12" plasma hose from torch
Torch Sleeve
SV5
Valve Cluster Cable – Valve Cluster to Power Supply Off-Valve Cable
SV
4x1 Socket Color Signal
1 SV4A-1 Red SV4A 2 SV4A-2 Black SV4A 3 SV4A-Gnd Clear Ground 4 SV4B-Gnd Clear Ground 5 SV4B-1 Red SV4B 6 SV4B-2 Black SV4B 7 SV5-1 Red SV5 8 SV5-2 Black SV5 9 SV5-Gnd Clear Ground
23
4X1
2
1
Gnd
2
1
Gnd
2
1
Gnd
3
23
Part No. Length
123282 10" (254 mm) 123321 24" (610 mm)
INSTALLATION
3-20 HySpeed HT2000LHF Instruction Manual
6
Mounting the Machine Torch
1. Loosen the securing screws and install the machine torch (with torch leads attached) in the torch mounting bracket. See Figure 3-6.
2. Position the torch until the torch body extends all the way through the bracket, so that the bracket is now around the plastic torch sleeve and not touching the stainless steel torch body. Position the torch approximately 0.25" (6 mm) from the work surface.
3. Tighten the securing screws.
Torch Alignment
Prior to cutting with the machine torch, ensure that the torch is at right angles to the workpiece to get a clean, vertical cut. Use a square to align the torch. The torch should be aligned at 0° and 90°. See Figure 3-6.
Securing screws
Torch sleeve
Torch mounting bracket
Figure 3-6 Torch Alignment
Torch (typical)
HySpeed HT2000LHF Instruction Manual 4-1
6
Front Panel Controls and Indicators
Status Indicators Before Startup
When power is applied from the line disconnect switch and before the POWER ON (I) button is pushed, the coolant flow LED will always be illuminated. Once the POWER ON button is pushed and held for a few seconds, this LED will extinguish if the system is in proper working condition.
Other fault conditions may also be indicated when the line power is switched on. Be sure to press and hold the power supply POWER ON (I) button (in some cases up to 1 minute) to extinguish all status indicators. If any LEDs remain illuminated, shut down the system and correct the problem. See Status LED Troubleshooting in Section 5, if necessary.
Figure 4-1 Power Supply Front Panel Controls and Indicators
Section 4
OPERATION
ON (I)
Activates the power supply and its control circuits. Indicator illuminates when power up is complete and status indicators are satisfied.
OFF (O)
Shuts the power supply down.
DC ON
Illuminates when main contactor closes, indicating DC power is being supplied to the torch.
INTERLOCK LED Spare. This LED is always extinguished.
TRANSFORMER LED
When illuminated, indicates that either the power supply main transformer or one of the choppers is operating above the proper temperature range.
COOLANT LEVEL LED
When illuminated, indicates that the coolant level is inadequate.
SHIELD GAS/CAP LED
When illuminated, indicates that either the shield gas pressure is inadequate, or that the retaining cap is installed improperly on the torch.
PLASMA GAS LED
When illuminated, indicates that the plasma gas pressure is inadequate.
COOLANT TEMP LED
When illuminated, indicates that the torch coolant temperature is too hot.
COOLANT FLOW LED
When illuminated, indicates that the coolant flow from the torch is inadequate.
Power Supply
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
HySpeed ® HT2000LHF
®
OPERATION
4-2 HySpeed HT2000LHF Instruction Manual
6
Gas Console
Figure 4-2 LHF Gas Console Front Panel Controls and Indicators
S2
Test Preflow – Used when setting the
plasma preflow flow rate on the flowmeter. In this position the contactor is disabled. Test Cut Flow – Allows the selected plasma gas flow rate to be adjusted on the flowmeter for cutting conditions. In this position the contactor is disabled. Run – Enables the contactor and the subsequent firing of the arc after the gas rates have been set in the Test Preflow and
Test Cut Flow positions.
LT1
Illuminates when the main contactor closes, indicating that DC power is being supplied to the torch.
FM1
Indicates the flow rate % of nitrogen or air plasma gas. Percentages are specified in the Cut Charts.
PG1
Indicates the nitrogen or air plasma inlet pressure. Gas inlet pressures are specified in the Cut Charts.
FM2
Indicates the flow rate % of oxygen plasma gas. Oxygen flow rate percent­age is specified in the Cut Charts.
PG2
Indicates the oxygen plasma inlet pressure. Gas inlet pressures are specified in the Cut Charts.
MV1
Adjusts flow rate % of nitrogen, air or oxygen plasma gas while in Test Cut Flow mode. Cut Flow plasma gas flow rate percentages are specified in the Cut Charts.
S1
Selects the use of either nitrogen, air or oxygen as the plasma cutting gas.
MV2
Adjusts flow rate % of nitrogen, or air plasma gas while in the Test Preflow mode. Preflow plasma gas flow rate percent­ages are specified in the Cut Charts.
MV3
Adjusts flow rate % of oxygen plasma gas while in Test Preflow mode. Preflow plasma gas flow rate percentages are specified in the Cut Charts.
PG3
Indicates the shield gas pressure at the torch.
MV4
Adjusts shield gas pressure to the torch.
Designations
FM1-FM2 –– Flowmeters LT1 –– Indicator Lamp MV1-MV3 –– Motor Valve PG1-PG3 –– Pressure Gauges S1-S2 –– Toggle Switch
OPERATION
HySpeed HT2000LHF Instruction Manual 4-3
6
VOLTAGE Adjust Potentiometer
Adjusts the cutting arc voltage from 100 to 200 volts. Values are chosen from the Cut Charts and depend on the thickness and type of metal to cut.
CURRENT Adjust Potentiometer
Adjusts the cutting arc current from 40 amps to 200 amps. Values are chosen from the Cut Charts and depend on the thickness and type of metal to cut.
VOLTAGE LEDs
Display cutting voltage.
UP / DOWN LEDs
Indicate that torch height is being adjusted up or down.
CURRENT LEDs
Display cutting current.
Figure 4-3 Digital Remote Voltage & Current Control Console Front Panel Controls and Indicators
VOLTAGE LEDs
Display cutting voltage during cut sequence
CURRENT LEDs
Display cutting current during cut sequence
UP / DOWN LEDs
Indicate that torch height is being adjusted up or down.
Figure 4-4 Programmable Remote Voltage & Current Control Console Front Panel Indicators
Digital Remote Voltage & Current Control Console
Programmable Remote Voltage & Current Control Console
Remote Current Control Console
AMPS Thumbwheel
Adjusts the cutting arc current from 40 amps to 200 amps. Values are chosen from the Cut Charts and depend on the thickness and type of metal to cut.
Figure 4-5 Remote Current Control Console Front Panel Controls
OPERATION
4-4 HySpeed HT2000LHF Instruction Manual
6
Timer/Counter
STARTS LCD Counter (w/Reset)
Indicates the number of arc starts
ERRORS LCD Counter (w/Reset)
Indicates the number of times that the arc cut cycle ended before the programmed current ramp-down time had elapsed. This reading provides a direct correlation to the long-life operation of the electrode; the higher the reading, the shorter the electrode life.
Reset
ARC TIME LCD Counter
Indicates the cumulative time that the arc is on in hours.
Reset
Figure 4-6 Timer/Counter Front Panel Controls
System Checkout
The following procedure assumes the plasma system includes an IHS system, a Digital Remote (DR) Voltage & Current Control Console, and the optional internal THC.
Set Switches and Check Torch
1. Ensure that the switches listed below are positioned as follows:
The main disconnect switch for the power supply is set to Off.
S2 toggle switch on the gas console is set to Run.
2. Ensure that the proper consumables are installed in the torch. Refer to the Cut Charts to choose the correct consumables for your cutting needs. See also Changing Consumable Parts at the end of this section.
3. Ensure that the torch is squared to the material. Refer to Section 3 for the torch alignment procedure.
Turn Gases On
4. Set S1 toggle switch on the gas console to N2/Air or O2.
5. Turn the required supply gases On.
• When using oxygen, or nitrogen as the plasma gas, adjust supply regulator to read 120 psi +/- 10 psi (8.3 bar +/- 0.7 bar).
When using air as the plasma gas, adjust supply regulator to read 90 psi +/- 10 psi (6.2 bar +/- 0.7 bar).
• Adjust the supply regulator for shield gas to read 90 psi +/- 10 psi (6.2 bar +/- 0.7 bar).
OPERATION
HySpeed HT2000LHF Instruction Manual 4-5
6
Turn Power Supply On and Adjust Voltage/Current
6. Set the main disconnect switch for the power supply to the On position. See Status Indicators Before Startup.
Depress the POWER ON (I) button on the power supply. Ensure that the green POWER ON indicator on the power supply illuminates.
7. Set the VOLTAGE and CURRENT on the Digital Remote. Select the arc current and arc voltage from the
Cut Charts for the type and thickness of metal to test cut.
Adjust Preflow Gases
8. Set S2 toggle switch to Test Preflow . Verify that the plasma gas pressure gauges on the gas console both
read 120 psi (8.3 bar).
9. Look at FM1 and/or FM2 and set the Preflow plasma gas flow rate. Refer to the Cut Charts for flow rate
percentage.
10. Look at PG3 on the gas console, and set the Shield gas flow rate. Refer to the Cut Charts for flow rate percentage.
Adjust Cut Flow Gases and Check Initial Height Sensing (IHS)
11. Set S2 toggle switch to Test Cut Flow.
12. Look at FM1 and/or FM2 and set the Cut Flow plasma gas flow rate. Refer to the Cut Charts for flow rate percentage.
13. Set S2 to Run after setting the preflow and plasma flow rates.
14. Check the pilot arc operation by positioning the torch a minimum of 3 inches (75 mm) above the work.
15. Depress the START button. After 2 seconds of gas preflow, the primary contactor will close and the pilot arc will start. The pilot arc should emit a steady, hissing sound and a cone of light should appear at the face of the torch nozzle. The pilot arc will continue for approximately 300ms (O2) and 600 ms (Air/N2) and then extinguish automatically.
16. Place the workpiece on the work table to make a test pierce. With manual starting, no machine motion will occur.
Note: The cutting machine must retract the torch at least 1 inch (25.4 mm) from the work before the start
cycle, or probes may hit the workpiece when the START button is depressed.
17. Depress the START button. The IHS probes will immediately descend and approximately 0.5 seconds later, the torch will move toward the workpiece. The DOWN indicator lamp on the Digital Remote should be illuminated. When the torch nears the workpiece, the probes will inductively detect the work surface and the down motion should stop. The DOWN indicator lamp on the Digital Remote will extinguish and the probes will retract.
At this point, depress the STOP button and disable the IHS system. You are now ready for the Final Torch Adjustment.
OPERATION
4-6 HySpeed HT2000LHF Instruction Manual
6
Final Torch Adjustment
18. Make a reference mark on the top and bottom of the torch sleeve where it meets the torch mounting bracket.
19. Loosen the securing screw on the torch mounting bracket and position the torch higher in the mounting bracket until the arc will not transfer when the START button is depressed.
20. Slowly lower the torch in 1/16" (1.6 mm) increments until the arc transfers after the START button is depressed. Tighten the securing screw at this position.
21. Enable the IHS system and press the START button. Once the arc transfers and the machine delay time has elapsed, the metal should be pierced. Press the STOP button to terminate the plasma arc. Observe that the UP indicator illuminates and the torch retracts to the upper limit switch.
22. Disable the IHS system.
Check Torch Height Control (THC) and Digital Remote Voltage & Current Console
23. Position the workpiece on the work table with one end higher than the other end to check the auto height (torch height control) mode. Position the torch at the highest point on the workpiece. Program a square cut pattern into the controller. (See controller instruction manual.)
24. Enable the Auto Height Control for the THC.
25. Manually lower the torch to approximately .25 inches (6 mm) above the workpiece.
26. Start the arc transfer from the controller.
27. When the arc transfers and the machine delay time has elapsed, the workpiece should be pierced and machine motion will start. As the torch travels from a high point to a low point on the workpiece, note that the torch stand-off distance from the workpiece should remain constant, and that the DOWN indicator illuminates on the Digital Remote.
As the torch travels from a low point to a high point on the workpiece, note that the torch stand-off distance from the workpiece should remain constant and that the UP indicator illuminates on the Digital Remote.
As the torch makes a corner cut, the machine motion speed should remain constant and the UP and DOWN indicators do not illuminate. Machine motion and plasma arc will automatically stop when the cut is complete.
The system is now operational.
If the system does not function as outlined in this procedure, recheck the installation requirements and directions in this manual. If all installation directives have been followed and you are still experiencing difficulty with the system, call the Hypertherm Technical Service number listed in the front of this manual.
OPERATION
HySpeed HT2000LHF Instruction Manual 4-7
10
WARNING
Before operating this system, you must read the Safety section thoroughly! Turn main disconnect switch to the power supply OFF before proceeding with the following steps.
Daily Startup
Prior to startup, ensure that your cutting environment and that your clothing meet the safety requirements outlined in the Safety section of this manual.
Note: For operation with argon-hydrogen manifold, see the appendix section of this manual.
Check Torch
1. Remove the consumables from the torch and check for worn or damaged parts. Always place the
consumables on a clean, dry, oil-free surface after removing. Dirty consumables can cause the torch to malfunction.
• Check the pit depth of the electrode using the electrode gauge assembly. A standard electrode should be replaced when the depth exceeds .044 inch (1.1 mm). The SilverPlus electrode may be replaced when the pit
depth exceeds approximately double the recommended depth of a standard electrode.
• Wipe the current ring in the torch with a clean paper towel or cotton swab (see Figure 4-7).
• Refer to the Cut Charts to choose the correct consumables for your cutting needs.
2. Replace consumable parts. Refer to Changing Consumable Parts later in this section for detailed information on replacing consumables.
3. Ensure that the torch is perpendicular to the material. Refer to Section 3 for the torch alignment procedure.
Noise Levels (Decibels)
Decibels experienced by an operator standing 1 meter from the torch while cutting at 50 Amps, with the torch 1/2” above water = 94.7 dbs.
OPERATION
4-8 HySpeed HT2000LHF Instruction Manual
6
Turn Gases On
4. Set S2 toggle switch on the gas console to Run.
5. Set S1 on the gas console to N2/Air (for nitrogen or air as plasma gas), or O2(for oxygen as plasma gas).
6. Turn the required supply gases On.
Note: See the Cut Charts to set the plasma and shield gas inlet pressures.
Turn Power Supply On and Adjust Voltage & Current
7. Turn the main disconnect switch ON. See Status Indicators Before Startup earlier in this section.
8. Turn on the power supply by depressing and holding down the POWER ON (I) button (PB1) on the power supply. Ensure that the green POWER ON indicator illuminates. Hold PB1 down until all of the status indicators extinguish.
9. Set the voltage and current from the Digital Remote Voltage and Current Console or from the machine computer interface. Select the arc current and arc voltage from the Cut Charts for the type and thickness of metal to cut.
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
HySpeed ® HT2000LHF
®
Adjust Preflow Gases
10. Set S2 on the gas console to Test Preflow. Verify the plasma gas inlet pressure reading on the plasma pressure gauges (PG1, PG2) on the gas console. Refer to the Cut Charts for the proper pressure setting.
11. Look at the oxygen (FM2) and/or nitrogen-air (FM1)
flowmeters on the gas console and set the Preflow plasma gas flow rate % by referring to the Cut Charts and turning the oxygen (MV3) and/or nitrogen / air (MV2) preflow metering valves.
12. Look at the shield gas pressure gauge (PG3) on the gas console, and set to the Cut Chart specifications by turning the shield gas metering valve (MV4).
Note: If you have changed consumable parts or if the
power supply has been off for more than 1 hour, purge gas lines by leaving system in Test Preflow for 1 minute.
FM1
PG1
PG2
PG3
MV4
S1 FM2
MV2 MV1 MV3 S2
OPERATION
HySpeed HT2000LHF Instruction Manual 4-9
6
Adjust Cut Flow Gases and Prepare for Cutting
13. Set S2 on the gas console to Test Cut Flow.
14. Look at the oxygen (FM2) and/or nitrogen / air (FM1) flowmeters on the gas console and set the Cut Flow plasma gas flow rate % by referring to the Cut Charts and adjusting the Plasma Cut Flow metering valve (MV1).
Note: If you have changed consumable parts or if the power supply has been off for more than 1 hour, purge gas
lines by leaving the system in Test Cut Flow for one minute.
15. Set S2 to Run after the test preflow and test operate flow rates have been set.
The system is now ready for operation.
Common Cutting Faults
• Torch pilot arc will initiate, but will not transfer. Causes can be:
1. Work cable connection on the cutting table is not making good contact.
2. Malfunction in the system. See Section 5.
• The workpiece is not totally penetrated, and there is excessive sparking on top of the workpiece. Causes can be:
1. Current is set too low (check Cut Chart information).
2. Cut speed is too high (check Cut Chart information).
3. Torch parts are worn (see Changing Consumable Parts).
4. Metal being cut is too thick.
• Dross forms on the bottom of the cut. Causes can be:
1. Cutting speed is too slow or too fast (check Cut Chart information).
2. Arc current is set too low (check Cut Chart information).
3. Torch parts are worn (see Changing Consumable Parts).
• Cut angle is not square. Causes can be:
1. Wrong direction of machine travel.
High quality side is on the right
with respect to the forward motion of the torch.
2. Torch-to-work distance is not correct (check Cut Chart information).
3. Cutting speed is not correct (check Cut Chart information).
4. Arc current is not correct (check Cut Chart information).
OPERATION
4-10 HySpeed HT2000LHF Instruction Manual
7
5. Damaged consumable parts (see Changing Consumable Parts ).
• Short consumable life. Causes can be:
1. Arc current, arc voltage, travel speed, motion delay, gas flow rates, or initial torch height not set as specified in the Cut Charts.
2. Attempting to cut highly magnetic metal plate (some metals such as armor plate with a high nickel content) will shorten consumable life. Long consumable life is difficult to achieve when cutting plate that is magnetized or becomes magnetized easily.
3. Not beginning or ending the cut on the plate surface. To achieve consumable long life, all cuts must begin
and end on the plate surface.
Also see Cutting Techniques later in this section for methods to improve cutting performance.
Technical Questions
If your system does not function correctly:
1. Recheck all pre-installation and installation requirements and connections.
2. If you are unable to solve the problem, call your distributor. He will be able to help you, or refer you to an authorized Hypertherm repair facility.
3. If you need assistance, call the Hypertherm Technical Service number listed in the front of this manual.
Cut Charts
The Cut Charts on the following pages provide the necessary information for the operator using the system to be successful in plasma arc cutting. The system provides a wide travel speed operating window: usually ± 10 ipm (± 254 mm/min) on most materials. The data listed in the charts are for making drop cuts with minimal dross.
Caution: Before cutting, check all settings and adjustments and check for
damaged torch parts and worn consumable parts.
Conversions
1 inch = 25.4 mm; 1 scfh = 28.316 liter/hour; 1 psi = .0689 bar = 6.895 KPa
OPERATION
HySpeed HT2000LHF Instruction Manual 4-11
9
CUT CHART AND CONSUMABLE PARTS INDEX
Plasma Gas/ Retaining Swirl
Metal Amps Shield Gas Shield Cap Nozzle Ring Electrode Page
Mild Steel
Mild Steel
Mild Steel
Stainless Steel
Stainless Steel
Aluminum
Aluminum
200 HySpeed O
2
/ Air 220239 220242 220237 220236 220235 4-12
200 O
2
/ Air 020424 120837 020605 120833 120667 4-13
200 Air / Air 020424 120837 020608 020679 120667 4-14 200 N
2
/ CO
2
020424 120837 020608 020607 020415 4-15
100 Air / Air 020448 120837 020611 020607 120547 4-16 100 O
2
/ Air 020424 120837 020690 020613 120547 4-17
50 O
2
/ O
2
120186 120185 120182 120179 120178 4-18
200 Air / Air 020424 120837 020608 020679 120667 4-19 200 N
2
/ Air 020424 120837 020608 020607 020415 4-20
200 N
2
/ CO
2
020424 120837 020608 020607 020415 4-21
200 H35 / N
2
* 020602 120837 020608 020607 020415 Ap-A 100 Air / Air 020448 120837 020611 020607 120547 4-22 100 H35 / N
2
* 020448 120837 020611 020607 020415 Ap-A
40 Air / Air 020688 020423 020689 020613 120667 4-23
200 Air / Air 020424 120837 020608 020679 120667 4-24 200 N2/ Air 020424 120837 020608 020607 020415 4-25 200 N
2
/ CO
2
020424 120837 020608 020607 020415 4-26
200 H35 / N
2
* 020602 120837 020608 020607 020415 Ap-A 100 Air / Air 020448 120837 020611 020607 120547 4-27 100 H35 / N
2
* 020448 120837 020611 020607 020415 Ap-A
40 Air / Air 020688 020423 020689 020613 120667 4-28
200 O
2
/Air 120260 120837 120259 120833 120258 4-29
200 Air / Air 020485 120837 020615 020607 120667 4-30
200 H35 / N2* 020485 120837 020615 020607 020415 Ap-A
200 H35 / N
2
* 020485 120837 020615 020607 020415 Ap-A
BEVEL CUTTING
* Argon-Hydrogen Manifold required. See appendix for installation and operation with argon-hydrogen manifold.
** Do not use the water muffler when cutting with argon-hydrogen (H35)!
Water Muffler cannot be used with the stainless steel torch
Note: If the Command THC or other ohmic contact sensing device is NOT in use, retaining caps with no IHS tab: 020423 clockwise; 020955 counterclockwise can be used for all cutting currents except 50A; 120185 for 50A cutting only.
For HySpeed
200A O
2
cutting only; use retaining cap part # 220238 (clockwise cutting) & 220241 (counter-clockwise cutting).
200 HySpeed O2/ Air 220239 220238 220237 220236 220235 200 O
2
/ Air 020566 020423 020605 120833 120667
100 O
2
/ Air 020566 020423 020690 020613 120547
200 Air / Air 020566 020423 020608 020679 120667 100 Air / Air 020618 020423 020611 020607 120547
200 N
2
/ CO
2
020566 020423 020608 020607 020415
200 N
2
/ Air 020566 020423 020608 020607 020415
Consumables
used with
HySpeed
HT2000LHF
Water Muffler**
9
OPERATION
4-12 HySpeed HT2000LHF Instruction Manual
Shield Arc Approx.
Material
Plasma Gas Flow Rate %
Gas (Air) Torch-to-work Initial Torch Voltage Motion
Thickness Preflow Cutflow Pressure Distance Piercing Height Setting Travel Speed Delay Time
(inches) (mm) (O2%N2%) (O2%N2%) (psi) (inches) (mm) (inches) (mm) (volts) (ipm) (mm/min.) (sec)
Shield Arc Approx.
Material
Plasma Gas Flow Rate %
Gas (Air) Torch-to-work Initial Torch Voltage Motion
Thickness Preflow Cutflow Pressure Distance Piercing Height Setting Travel Speed Delay Time
(inches) (mm) (O2%N2%) (O2%N2%) (psi) (inches) (mm) (inches) (mm) (volts) (ipm) (mm/min.) (sec)
1/4 6 12 38 76 0 60 1/16 1.5 1/8 3 145 230 5800 0.3
5/16 8 (12 / 50 (90 / 0 (275 1/8 3 1/4 6 151 165 4200 0.3
3/8 10 SCFH) SCFH) SCFH) 5/32 4 5/16 8 155 140 3500 0.3 1/2 12 1/8 3 1/4 6 155 120 3000 0.3 5/8 15 1/8 3 1/4 6 155 100 2500 0.5 3/4 20 1/8 3 1/4 6 155 75 1900 0.6 7/8 22 1/8 3 1/4 6 159 60 1500 0.7
1 25 1/8 3 1/4 6 160 50 1300 0.7 1 1/4 32 1/8 3 5/16 8 168 30 760 2.6 1-1/2 38 1/8 3 5/16 8 175 20 500 4.0 1-3/4 44 1/8 3 N/A N/A 180 15 380 N/A
2 50 1/8 3 N/A N/A 188 10 250 N/A
Mild Steel
HySpeed 200 amps • O2Plasma / Air Shield
This gas combination gives superior cut speed, minimum dross, minimum surface nitriding and excellent weldability.
Notes: Set oxygen plasma gas inlet pressure to 120 psi (8.3 bar).
Set nitrogen plasma gas inlet pressure to 120 psi (8.3 bar) Set shield gas inlet pressure to 90 psi (6.2 bar)
Production cutting above 1" (25 mm) not recommended. Drop cutting above 1-1/2" (38 mm) not recommended
Above Water
1/4 6 12 38 76 0 60 1/16 1.5 1/8 3 149 230 5800 0.3
5/16 8 (12 / 50 (90 / 0 (275 1/8 3 1/4 6 151 165 4200 0.3
3/8 10 SCFH) SCFH) SCFH) 5/32 4 5/16 8 159 140 3500 0.3 1/2 12 1/8 3 1/4 6 155 105 2700 0.3 5/8 15 1/8 3 1/4 6 161 90 2300 0.5 3/4 20 1/8 3 1/4 6 161 65 1600 0.6 7/8 22 1/8 3 1/4 6 161 55 1400 0.7
1 25 1/8 3 1/4 6 164 45 1100 0.7
3" Under Water
220235 Electrode
220237 Nozzle
220242 (cw) 220243 (ccw) Retaining cap
220239 Shield
220236 (cw) 220244 (ccw) Swirl ring
OPERATION
HySpeed HT2000LHF Instruction Manual 4-13
7
Shield Arc Approx.
Material
Plasma Gas Flow Rate %
Gas (Air) Torch-to-work Initial Torch Voltage Motion
Thickness Preflow Cutflow Pressure Distance Piercing Height Setting Travel Speed Delay Time
(inches) (mm) (O2%N2%) (O2%N2%) (psi) (inches) (mm) (inches) (mm) (volts) (ipm) (mm/min.) (sec)
Shield Arc Approx.
Material
Plasma Gas Flow Rate %
Gas (Air) Torch-to-work Initial Torch Voltage Motion
Thickness Preflow Cutflow Pressure Distance Piercing Height Setting Travel Speed Delay Time
(inches) (mm) (O2%N2%) (O2%N2%) (psi) (inches) (mm) (inches) (mm) (volts) (ipm) (mm/min.) (sec)
1/4 6 12 38 64 0 60 1/8 3 1/4 6 120 160 4060 0.5
.315 8 (14.9 / 50.4 (79.6 / 0 (270 1/8 3 1/4 6 125 120 3000 0.5
3/8 10 SCFH) SCFH) SCFH) 1/8 3 1/4 6 125 100 2540 1.0 1/2 12 .157 4 .314 8 125 80 2030 2.0 5/8 15 .157 4 .314 8 130 70 1780 2.0 3/4 20 3/16 5 3/8 10 135 55 1400 2.5 7/8 22 1/4 6 1/2 12 135 45 1140 2.5
1 25 1/4 6 1/2 12 140 35 890 2.5
1 1/4 32 1/4 6 150 22 560 1-1/2 38 1/4 6 155 15 380 1-3/4 44 5/16 8 165 10 250
2 50 5/16 8 170 7 180
Mild Steel
200 amps • O2Plasma / Air Shield
This gas combination gives superior cut speed, minimum dross, minimum surface nitriding and excellent weldability.
Above Water
1/4 6 12 38 64 0 70 1/8 3 1/4 6 125 145 3700 0.5
.315 8 (14.9 / 50.4 (79.6 / 0 (270 1/8 3 1/4 6 125 110 2800 0.5
3/8 10 SCFH) SCFH) SCFH) 1/8 3 1/4 6 130 80 2000 1.0 1/2 12 1/8 3 1/4 6 130 70 1800 2.0 5/8 15 .157 4 .314 8 135 60 1500 2.0 3/4 20 3/16 5 3/8 10 140 48 1200 2.5 7/8 22 1/4 6 1/2 12 140 38 950 3.0
1 25 1/4 6 1/2 12 145 25 680 3.0
3" Under Water
120833* (cw) 120834 (ccw) Swirl ring
020605 Nozzle
120837 (cw) 120838 (ccw) Retaining cap
020424 Shield
120667 (standard) Electrode 220084 (optional) SilverPlus electrode
+
Notes: Set oxygen plasma gas inlet pressure to 120 psi (8.3 bar).
Set nitrogen plasma gas inlet pressure to 120 psi (8.3 bar) Set shield gas inlet pressure to 90 psi (6.2 bar)
Production cutting above 1" (25 mm) not recommended. Drop cutting above 1-1/2" (38 mm) not recommended
* Use 020679 swirl ring in place of 120833 swirl ring to obtain smoother cut edges on material
1/4" to 3/8" thick, but expect a 30-40% decrease in electrode life
+ SilverPlus provides increased life to high duty cycle users in most applications. The hafnium wears to
approximately twice the depth of a standard electrode (120667). Arc voltage may need to be increased by 5-10 volts throughout the electrode life to maintain proper cut height parameters.
OPERATION
4-14 HySpeed HT2000LHF Instruction Manual
7
Shield Arc Approx.
Material
Plasma Gas Flow Rate %
Gas (Air) Torch-to-work Initial Torch Voltage Motion
Thickness Preflow Cutflow Pressure Distance Piercing Height Setting Travel Speed Delay Time
(inches) (mm) (Air %) (Air %) (psi) (inches) (mm) (inches) (mm) (volts) (ipm) (mm/min.) (sec)
Shield Arc Approx.
Material
Plasma Gas Flow Rate %
Gas (Air) Torch-to-work Initial Torch Voltage Motion
Thickness Preflow Cutflow Pressure Distance Piercing Height Setting Travel Speed Delay Time
(inches) (mm) (Air %) (Air %) (psi) (inches) (mm) (inches) (mm) (volts) (ipm) (mm/min.) (sec)
3/16 5 54 65 60 1/8 3 1/4 6 130 200 5080
1/4 6 (62.3 (75.0 (270 1/8 3 1/4 6 130 135 3400 0.5
.315 8 SCFH) SCFH) SCFH) 1/8 3 1/4 6 135 115 2900 0.5
3/8 10 1/8 3 1/4 6 135 100 2540 1.0 1/2 12 .157 4 .314 8 140 80 2030 2.0 5/8 15 .157 4 .314 8 145 60 1520 2.0 3/4 20 3/16 5 3/8 10 150 45 1140 2.5 7/8 22 1/4 6 1/2 12 155 30 760 2.5
1 25 1/4 6 1/2 12 160 25 635 2.5 1-1/4 32 1/4 6 165 15 380 1-1/2 38 1/4 6 170 10 250 1-3/4 44 5/16 8 180 7 180
2 50 5/16 8 185 5 130
Mild Steel
200 amps • Air Plasma / Air Shield
This gas combination gives good cut speed, low dross levels and is very economical. Some surface nitriding can occur.
Notes: Set plasma gas inlet pressure to 90 psi (6.2 bar)
Set shield gas inlet pressure to 90 psi (6.2 bar)
Production cutting above 1" (25 mm) not recommended Drop cutting above 1-1/2" (38 mm) not recommended
Above Water
1/4 6 54 65 70 1/8 3 1/4 6 130 130 3300 0.5
.315 8 (62.3 (75.0 (280 1/8 3 1/4 6 135 110 2700 0.5
3/8 10 SCFH) SCFH) SCFH) 1/8 3 1/4 6 135 95 2400 1.0 1/2 12 1/8 3 1/4 6 140 75 1900 2.0 5/8 15 .157 4 .314 8 145 50 1200 2.0 3/4 20 3/16 5 3/8 10 150 35 850 2.5 7/8 22 1/4 6 1/2 12 155 20 530 3.0
1 25 1/4 6 1/2 12 165 15 400 3.0
3" Under Water
020424 Shield
120837 Retaining cap
020608 Nozzle
020679 Swirl ring
120667 Electrode
OPERATION
HySpeed HT2000LHF Instruction Manual 4-15
Shield Arc Approx.
Material
Plasma Gas Flow Rate %
Gas (CO2) Torch-to-work Initial Torch Voltage Motion
Thickness Preflow Cutflow Pressure Distance Piercing Height Setting Travel Speed Delay Time
(inches) (mm) (N2%) (N2%) (psi) (inches) (mm) (inches) (mm) (volts) (ipm) (mm/min.) (sec)
3/16 5 50 60 60/4 1/8 3 1/4 6 120 130 3300 0.5
1/4 6 (62.3 (75.0 (270 1/8 3 1/4 6 125 110 2800 1.0 3/8 10 (SCFH) SCFH) SCFH) 1/8 3 1/4 6 130 85 2160 1.5 1/2 12 1/8 3 1/4 6 130 55 1400 2.0 5/8 15 .157 4 .314 8 135 45 1140 2.0 3/4 20 3/16 5 3/8 10 145 25 635 2.5 7/8 22 1/4 6 1/2 12 150 20 510 3.0
1 25 1/4 6 1/2 12 160 15 380 3.0 1-1/4 32 1/4 6 165 10 250 1-1/2 38 1/4 6 175 5 130
Mild Steel
200 amps • N2Plasma / CO2Shield
This gas combination may be used when cut edge quality and surface nitriding are less important. Electrode life is extended when using this combination.
Notes: Set plasma gas inlet pressure to 120 psi (8.3 bar)
Set shield gas inlet pressure to 90 psi (6.2 bar)
Production cutting above 1" (25 mm) not recommended
Above Water Only
020424 Shield
120837 Retaining cap
020608 Nozzle
020607 Swirl ring
020415 Electrode
7
OPERATION
4-16 HySpeed HT2000LHF Instruction Manual
7
Shield Arc Approx.
Material
Plasma Gas Flow Rate %
Gas (Air) Torch-to-work Initial Torch Voltage Motion
Thickness Preflow Cutflow Pressure Distance Piercing Height Setting Travel Speed Delay Time
(inches) (mm) (Air %) (Air %) (psi) (inches) (mm) (inches) (mm) (volts) (ipm) (mm/min.) (sec)
Shield Arc Approx.
Material
Plasma Gas Flow Rate %
Gas (Air) Torch-to-work Initial Torch Voltage Motion
Thickness Preflow Cutflow Pressure Distance Piercing Height Setting Travel Speed Delay Time
(inches) (mm) (Air %) (Air %) (psi) (inches) (mm) (inches) (mm) (volts) (ipm) (mm/min.) (sec)
.075* 2 48 39 60 3/32 2.5 3/16 5 120 235 6050
1/8 3 (55.3 (44.9 (270 3/32 2.5 3/16 5 125 185 4700 0.5
3/16 5 SCFH) SCFH) SCFH) 1/8 3 1/4 6 125 175 4450 0.5
1/4 6 1/8 3 1/4 6 130 125 3175 0.5 3/8 10 1/8 3 1/4 6 135 50 1270 1.0 1/2 12 1/8 3 140 35 890 5/8 15 .157 4 145 25 635 3/4 20 3/16 5 150 20 510
Mild Steel
100* amps • Air Plasma / Air Shield
This gas combination gives good cut speed, low dross levels and is very economical. Some surface nitriding can occur. While this process may be used on thicker materials, optimal recommended range is to 3/8" (10mm).
* Set arc current to 80 amps when cutting .075" (2 mm) thick mild steel
Notes: Set plasma gas inlet pressure to 90 psi (6.2 bar)
Set shield gas inlet pressure to 90 psi (6.2 bar)
Production cutting above 3/8" (10 mm) not recommended
Above Water
1/8 3 48 39 70 5/64 2 5/32 4 130 120 3050
3/16 5 (55.3 (44.9 (270 1/8 3 1/4 6 135 90 2300 0.5
1/4 6 SCFH) SCFH) SCFH) 1/8 3 1/4 6 140 70 1730 0.5 3/8 10 1/8 3 1/4 6 145 42 1050 0.5 1/2 12 1/8 145 28 700
3" Under Water
020448 Shield
120837 Retaining cap
020611 Nozzle
020607 Swirl ring
120547 Electrode
OPERATION
HySpeed HT2000LHF Instruction Manual 4-17
Shield Arc Approx.
Material
Plasma Gas Flow Rate %
Gas (Air) Torch-to-work Initial Torch Voltage Motion
Thickness Preflow Cutflow Pressure Distance Piercing Height Setting Travel Speed Delay Time
(inches) (mm) (O2%N2%) (O2%N2%) (psi) (inches) (mm) (inches) (mm) (volts) (ipm) (mm/min.) (sec)
Shield Arc Approx.
Material
Plasma Gas Flow Rate %
Gas (Air) Torch-to-work Initial Torch Voltage Motion
Thickness Preflow Cutflow Pressure Distance Piercing Height Setting Travel Speed Delay Time
(inches) (mm) (O2%N2%) (O2%N2%) (psi) (inches) (mm) (inches) (mm) (volts) (ipm) (mm/min.) (sec)
1/8 3 728 360 60 3/32 2.5 3/16 5 125 240 6100
3/16 5 (9 / 37 (45 / 0 (270 1/8 3 1/4 6 125 180 4570
1/4 6 SCFH) SCFH) SCFH) 1/8 3 1/4 6 125 120 3050 0.5 3/8 10 1/8 3 1/4 6 130 90 2280 0.5 1/2 12 1/8 3 130 60 1520 5/8 15 .157 4 140 45 1140 3/4 20 3/16 5 145 30 760
Mild Steel
100 amps • O2Plasma / Air Shield
This gas combination gives good cut speed, low dross and is very economical. Some surface nitriding can occur. While this process may be used on thicker materials, optimal recommended range is to 3/8" (10mm).
Notes: Set oxygen plasma gas inlet pressure to 120 psi (8.3 bar)
Set nitrogen plasma gas inlet pressure to 120 psi (8.3 bar) Set shield gas inlet pressure to 90 psi (6.2 bar)
Production cutting above 3/8" (10 mm) not recommended * To maximize consumable life, modify the part lead-in and lead-out to reduce ramp-down errors.
For strip cutting or other applications where proper ramp-down is difficult to achieve, use electrode P/N 120667 in place of electrode P/N120547.
Above Water
1/8 3 728 360 60 5/64 2 5/32 4 125 220 5580
3/16 5 (9 / 37 (45 / 0 (270 1/8 3 1/4 6 125 160 4060 0.5
1/4 6 SCFH) SCFH) SCFH) 1/8 3 1/4 6 125 110 2790 0.5 3/8 10 1/8 3 1/4 6 130 85 2160 0.5 1/2 12 1/8 3 135 60 1520
3" Under Water
020613 (cw) 120252 (ccw) Swirl ring
120547* Electrode
020690 Nozzle
120837 (cw) 120838 (ccw) Retaining cap
020424 Shield
7
OPERATION
4-18 HySpeed HT2000LHF Instruction Manual
7
Shield Arc Approx.
Material
Plasma Gas Flow Rate %
Gas (O2) Torch-to-work Initial Torch Voltage Motion
Thickness Preflow Cutflow Pressure Distance Piercing Height Setting Travel Speed Delay Time
(inches) (mm) (O2%N2%) (O2%N2%) (psi) (inches) (mm) (inches) (mm) (volts) (ipm) (mm/min.) (sec)
.048 (18 GA.) 327 300 18 .060 1.50 .120 3.0 108 160 4060 0 .074 (14 GA.) 2 / 17 18 / 0 17 .060 1.50 .120 3.0 108 120 3050 0.3 .100 (12 GA.) l/min l/min l/min .070 1.75 .140 3.5 113 100 2540 0.3 .125 (10 GA.) .080 2.00 .160 4.0 118 60 1520 0.5
Mild Steel
50 amps • O2Plasma / O2Shield
Notes: Set oxygen plasma gas inlet pressure to 120 psi (8.3 bar)
Set nitrogen plasma gas inlet pressure to 120 psi (8.3 bar) Set shield gas inlet pressure to 120 psi (8.3 bar)
The oxygen shield gas must be supplied from a regulator separate from the oxygen plasma gas regulator. If using the Digital Remote (DR) or Programmable Remote (PR), set current to 60 amps. If using a torch height control system capable of achieving the arc voltage setting on this chart, set accordingly. If using a less sensitive torch height control system, round off the arc voltage numbers to the nearest achievable setting. Torch-to-work Distance tolerances are ± .010 inch (± .25 mm). When using a THC the tolerances are ± 1 volt. Stay within travel speed ranges to produce dross-free cuts. Due to the low gas flow rates associated with the 50 amp process, initial cut quality may be degraded while nitrogen is being purged from the gas line when changing from preflow to cut flow (up to 2 seconds). To compensate, either increase machine motion delay or increase the lead-in distance at the start of the cut. Note that some height control systems may need to be locked out to prevent the torch from diving into the plate if the machine motion delay option is used.
Above Water Only
120185 Retaining cap
120186 Shield
120182 Nozzle
120179 Swirl ring
120178 Electrode
OPERATION
HySpeed HT2000LHF Instruction Manual 4-19
Shield Arc Approx.
Material
Plasma Gas Flow Rate %
Gas (Air) Torch-to-work Initial Torch Voltage Motion
Thickness Preflow Cutflow Pressure Distance Piercing Height Setting Travel Speed Delay Time
(inches) (mm) (Air %) (Air %) (psi) (inches) (mm) (inches) (mm) (volts) (ipm) (mm/min.) (sec)
Shield Arc Approx.
Material
Plasma Gas Flow Rate %
Gas (Air) Torch-to-work Initial Torch Voltage Motion
Thickness Preflow Cutflow Pressure Distance Piercing Height Setting Travel Speed Delay Time
(inches) (mm) (Air %) (Air %) (psi) (inches) (mm) (inches) (mm) (volts) (ipm) (mm/min.) (sec)
3/16 5 54 65 60 1/8 3 1/4 5 125 220 5600
1/4 6 (62.3 (75.0 (270 1/8 3 1/4 6 130 195 5000 0.5 3/8 10 SCFH) SCFH) SCFH) 1/8 3 1/4 6 130 145 3700 1.0 1/2 12 1/8 3 1/4 6 135 105 2700 2.0 5/8 15 .157 4 .314 8 140 75 1900 2.0 3/4 20 3/16 5 3/8 10 140 55 1400 2.5 7/8 22 1/4 6 1/2 12 145 40 1000 3.0
1 25 1/4 6 150 30 760 1-1/4 32 ` 1/4 6 160 15 380 1-1/2 38 1/4 6 170 10 250
Stainless Steel
200 amps • Air Plasma / Air Shield
This gas combination gives good cut speed, low dross and is very economical. Some surface nitriding and surface oxidation of alloying elements can occur.
Notes: Set air plasma gas inlet pressure to 90 psi (6.2 bar)
Set air shield gas inlet pressure to 90 psi (6.2 bar)
Production cutting above 7/8" (22 mm) not recommended
Above Water
3/16 5 54 65 70 1/8 3 1/4 6 125 210 5320
1/4 6 (62.3 (75.0 (280 1/8 3 1/4 6 130 180 4500 0.5 3/8 10 SCFH) SCFH) SCFH) 1/8 3 1/4 6 135 125 3150 1.0 1/2 12 1/8 3 1/4 6 140 90 2300 2.0 5/8 15 .157 4 .314 8 145 60 1520 2.0 3/4 20 3/16 5 3/8 10 145 45 1150 2.5 7/8 22 1/4 6 1/2 12 150 30 750 3.0
1 25 1/4 6 155 22 570
3" Under Water
020424 Shield
120837 Retaining cap
020608 Nozzle
020679 Swirl ring
120667 Electrode
7
OPERATION
4-20 HySpeed HT2000LHF Instruction Manual
7
Shield Arc Approx.
Material
Plasma Gas Flow Rate %
Gas (Air) Torch-to-work Initial Torch Voltage Motion
Thickness Preflow Cutflow Pressure Distance Piercing Height Setting Travel Speed Delay Time
(inches) (mm) (N2%) (N2%) (psi) (inches) (mm) (inches) (mm) (volts) (ipm) (mm/min.) (sec)
Shield Arc Approx.
Material
Plasma Gas Flow Rate %
Gas (Air) Torch-to-work Initial Torch Voltage Motion
Thickness Preflow Cutflow Pressure Distance Piercing Height Setting Travel Speed Delay Time
(inches) (mm) (N2%) (N2%) (psi) (inches) (mm) (inches) (mm) (volts) (ipm) (mm/min.) (sec)
3/16 5 50 60 60 1/8 3 1/4 5 125 135 3430
1/4 6 (66.4 (79.6 (270 1/8 3 1/4 6 130 120 3050 0.5 3/8 10 SCFH) SCFH) SCFH) 1/8 3 1/4 6 130 100 2540 1.0 1/2 12 1/8 3 1/4 6 135 75 1900 2.0 5/8 15 .157 4 .314 8 140 60 1520 2.0 3/4 20 3/16 5 3/8 10 140 45 1140 2.5 7/8 22 1/4 6 1/2 12 145 35 890 2.5
1 25 1/4 6 150 20 510 1-1/4 32 ` 1/4 6 160 15 380 1-1/2 38 1/4 6 160 10 250
Stainless Steel
200 amps • N2Plasma / Air Shield
This gas combination is used when cut edge quality, surface nitriding and surface oxidation of alloying elements are less important. Electrode life is extended when this combination is used.
Notes: Set nitrogen plasma gas inlet pressure to 120 psi (8.3 bar)
Set air shield gas inlet pressure to 90 psi (6.2 bar)
Production cutting above 7/8" (22 mm) not recommended
Above Water
3/16 5 50 60 70 1/8 3 1/4 6 125 130 3250
1/4 6 (66.4 (79.6 (280 1/8 3 1/4 6 130 110 2750 0.5 3/8 10 SCFH) SCFH) SCFH) 1/8 3 1/4 6 135 85 2160 1.0 1/2 12 1/8 3 1/4 6 140 60 1520 2.0 5/8 15 .157 4 .314 8 145 45 1140 2.0 3/4 20 3/16 5 3/8 10 145 30 800 2.5
3" Under Water
020424 Shield
120837 Retaining cap
020608 Nozzle
020607 Swirl ring
020415 Electrode
OPERATION
HySpeed HT2000LHF Instruction Manual 4-21
Shield Arc Approx.
Material
Plasma Gas Flow Rate %
Gas (CO
2
) Torch-to-work Initial Torch Voltage Motion
Thickness Preflow Cutflow Pressure Distance Piercing Height Setting Travel Speed Delay Time
(inches) (mm) (N
2
%) (N2%) (psi) (inches) (mm) (inches) (mm) (volts) (ipm) (mm/min.) (sec)
Shield Arc Approx.
Material
Plasma Gas Flow Rate %
Gas (CO2) Torch-to-work Initial Torch Voltage Motion
Thickness Preflow Cutflow Pressure Distance Piercing Height Setting Travel Speed Delay Time
(inches) (mm) (N2%) (N2%) (psi) (inches) (mm) (inches) (mm) (volts) (ipm) (mm/min.) (sec)
3/16 5 50 60 60 1/8 3 1/4 6 125 190 4800 0.5
1/4 6 (66.4 (79.6 (210 1/8 3 1/4 6 130 170 4300 1.0 3/8 10 SCFH) SCFH) SCFH) 1/8 3 1/4 6 130 125 3200 1.5 1/2 12 1/8 3 1/4 6 135 95 2400 2.0 5/8 15 .157 4 .314 8 140 70 1800 2.0 3/4 20 3/16 5 3/8 10 140 50 1250 2.5 7/8 22 1/4 6 1/2 12 145 40 1000 3.0
1 25 1/4 6 150 30 760 1-1/4 32 ` 1/4 6 160 15 380 1-1/2 38 1/4 6 170 10 250
Stainless Steel
200 amps • N2Plasma / CO2Shield
This gas combination is used when surface nitriding and surface oxidation of alloying elements is less important. Electrode life is extended when using this gas combination.
Notes: Set nitrogen plasma gas inlet pressure to 120 psi (8.3 bar)
Set carbon dioxide shield gas inlet pressure to 90 psi (6.2 bar)
Production cutting above 7/8" (22 mm) not recommended
Above Water
3/16 5 50 60 60 1/8 3 1/4 6 125 180 4550 0.5
1/4 6 (66.4 (79.6 (210 1/8 3 1/4 6 130 150 3850 1.0 3/8 10 SCFH) SCFH) SCFH) 1/8 3 1/4 6 135 110 2700 1.5 1/2 12 1/8 3 1/4 6 140 75 1920 2.0 5/8 15 .157 4 .314 8 145 50 1350 2.0 3/4 20 3/16 5 3/8 10 145 38 950 2.5 7/8 22 1/4 6 1/2 12 150 28 700 3.0
3" Under Water
020424 Shield
120837 Retaining cap
020608 Nozzle
020607 Swirl ring
020415 Electrode
7
OPERATION
4-22 HySpeed HT2000LHF Instruction Manual
7
Shield Arc Approx.
Material
Plasma Gas Flow Rate %
Gas (Air) Torch-to-work Initial Torch Voltage Motion
Thickness Preflow Cutflow Pressure Distance Piercing Height Setting Travel Speed Delay Time
(inches) (mm) (Air %) (Air %) (psi) (inches) (mm) (inches) (mm) (volts) (ipm) (mm/min.) (sec)
Shield Arc Approx.
Material
Plasma Gas Flow Rate %
Gas (Air) Torch-to-work Initial Torch Voltage Motion
Thickness Preflow Cutflow Pressure Distance Piercing Height Setting Travel Speed Delay Time
(inches) (mm) (Air %) (Air %) (psi) (inches) (mm) (inches) (mm) (volts) (ipm) (mm/min.) (sec)
1/8 3 48 39 60 3/32 2.5 3/16 5 125 140 3560
3/16 5 (53.3 (44.9 (270 1/8 3 1/4 6 130 110 2800 0.5
1/4 6 SCFH) SCFH) SCFH) 1/8 3 1/4 6 130 80 2030 0.5 3/8 10 1/8 3 1/4 6 135 55 1400 0.5 1/2 12 1/8 3 140 35 890 5/8 15 .157 4 145 25 635 3/4 20 3/16 5 150 20 510
Stainless Steel
100 amps • Air Plasma / Air Shield
This gas combination gives good cut speed, low dross and is very economical. Some surface nitriding and surface oxidation of alloying elements can occur.
Notes: Set air plasma gas inlet pressure to 90 psi (6.2 bar)
Set air shield gas inlet pressure to 90 psi (6.2 bar)
Production cutting above 3/8" (10 mm) not recommended
Above Water
1/8 3 48 39 60 5/64 2 5/32 4 125 135 3400
3/16 5 (53.3 (44.9 (270 1/8 3 1/4 6 130 100 2520 0.5
1/4 6 SCFH) SCFH) SCFH) 1/8 3 1/4 6 135 65 1720 0.5 3/8 10 1/8 3 1/4 6 140 45 1120 0.5 1/2 12 1/8 3 145 25 670
3" Under Water
020448 Shield
120837 Retaining cap
020611 Nozzle
020607 Swirl ring
120547 Electrode
OPERATION
HySpeed HT2000LHF Instruction Manual 4-23
Shield Arc Approx.
Material
Plasma Gas Flow Rate %
Gas (Air) Torch-to-work Initial Torch Voltage Motion
Thickness Preflow Cutflow Pressure Distance Piercing Height Setting Travel Speed Delay Time
(inches) (mm) (Air %) (Air %) (psi) (inches) (mm) (inches) (mm) (volts) (ipm) (mm/min.) (sec)
.050 (18 GA.) 40 20 60 3/32 2.5 3/16 5 120 145 3700 1/16 1.5 (46.0 (23.1 (275 3/32 2.5 3/16 5 120 120 3050
1/8 3 SCFH) SCFH) SCFH) 3/32 2.5 3/16 5 125 75 1900 0.5 1/4 6 1/8 3 135 24 610 3/8 10 1/8 3 140 12 300
Stainless Steel
40 amps • Air Plasma / Air Shield
This gas combination gives good cut speed, low dross level and is very economical. Some surface nitriding and surface oxidation of alloying elements can occur.
Notes: Set air plasma gas inlet pressure to 90 psi (6.2 bar)
Set air shield gas inlet pressure to 90 psi (6.2 bar) Production cutting above 1/8" (3 mm) not recommended
Above Water Only
020688 Shield
120837 Retaining cap
020689 Nozzle
020613 Swirl ring
120667 Electrode
7
OPERATION
4-24 HySpeed HT2000LHF Instruction Manual
7
Shield Arc Approx.
Material
Plasma Gas Flow Rate %
Gas (Air) Torch-to-work Initial Torch Voltage Motion
Thickness Preflow Cutflow Pressure Distance Piercing Height Setting Travel Speed Delay Time
(inches) (mm) (Air %) (Air %) (psi) (inches) (mm) (inches) (mm) (volts) (ipm) (mm/min.) (sec)
Shield Arc Approx.
Material
Plasma Gas Flow Rate %
Gas (Air) Torch-to-work Initial Torch Voltage Motion
Thickness Preflow Cutflow Pressure Distance Piercing Height Setting Travel Speed Delay Time
(inches) (mm) (Air %) (Air %) (psi) (inches) (mm) (inches) (mm) (volts) (ipm) (mm/min.) (sec)
3/16 5 54 65 60 1/8 3 1/4 6 130 220 5600 0.5
1/4 6 (62.3 (75.0 (270 1/8 3 1/4 6 140 190 4800 1.0 3/8 10 SCFH) SCFH) SCFH) 1/8 3 1/4 6 140 145 3700 2.0 1/2 12 1/8 3 1/4 6 145 110 2800 2.5 5/8 15 .157 4 .314 8 150 85 2200 2.5 3/4 20 3/16 5 3/8 10 155 65 1650 2.5 7/8 22 1/4 6 1/2 12 160 50 1300 2.5
1 25 1/4 6 165 35 900 1-1/4 32 ` 1/4 6 170 20 500 1-1/2 38 1/4 6 175 12 300
Aluminum
200 amps • Air Plasma / Air Shield
This gas combination gives good cut speed, low dross levels and is very economical.
Notes: Set plasma gas inlet pressure to 90 psi (6.2 bar)
Set shield gas inlet pressure to 90 psi (6.2 bar)
Production cutting above 7/8" (22 mm) not recommended
Above Water
3/16 5 54 65 70 1/8 3 1/4 6 135 210 5300 0.5
1/4 6 (62.3 (75.0 (280 1/8 3 1/4 6 140 170 4300 1.0 3/8 10 SCFH) SCFH) SCFH) 1/8 3 1/4 6 145 125 3150 2.0 1/2 12 1/8 3 1/4 6 150 90 2240 2.5 5/8 15 .157 4 .314 8 155 65 1650 3.0 3/4 20 3/16 5 3/8 10 160 45 1150 3.0
3" Under Water
020424 Shield
120837 Retaining cap
020608 Nozzle
020679 Swirl ring
120667 Electrode
OPERATION
HySpeed HT2000LHF Instruction Manual 4-25
Shield Arc Approx.
Material
Plasma Gas Flow Rate %
Gas (Air) Torch-to-work Initial Torch Voltage Motion
Thickness Preflow Cutflow Pressure Distance Piercing Height Setting Travel Speed Delay Time
(inches) (mm) (N2%) (N2%) (psi) (inches) (mm) (inches) (mm) (volts) (ipm) (mm/min.) (sec)
Shield Arc Approx.
Material
Plasma Gas Flow Rate %
Gas (Air) Torch-to-work Initial Torch Voltage Motion
Thickness Preflow Cutflow Pressure Distance Piercing Height Setting Travel Speed Delay Time
(inches) (mm) (N2%) (N2%) (psi) (inches) (mm) (inches) (mm) (volts) (ipm) (mm/min.) (sec)
3/16 5 50 60 60 1/8 3 1/4 6 130 180 4570 0.5
1/4 6 (66.4 (79.6 (270 1/8 3 1/4 6 135 160 4060 1.0 3/8 10 SCFH) SCFH) SCFH) 1/8 3 1/4 6 135 120 3050 1.5 1/2 12 1/8 3 1/4 6 140 80 2030 2.0 5/8 15 .157 4 .314 8 140 70 1780 2.0 3/4 20 3/16 5 3/8 10 150 50 1270 2.5 7/8 22 1/4 6 1/2 12 160 35 890 2.5
1 25 1/4 6 165 25 635 1-1/4 32 ` 1/4 6 175 20 510 1-1/2 38 1/4 6 185 10 250
Aluminum
200 amps • N2Plasma / Air Shield
This gas combination is used when cut edge quality is less important. Electrode life is extended when this combination is used.
Notes: Set plasma gas inlet pressure to 120 psi (8.3 bar)
Set shield gas inlet pressure to 90 psi (6.2 bar)
Production cutting above 7/8" (22 mm) not recommended
Above Water
3/16 5 50 60 70 1/8 3 1/4 6 135 170 4350 0.5
1/4 6 (66.4 (79.6 (280 1/8 3 1/4 6 140 140 3650 1.0 3/8 10 SCFH) SCFH) SCFH) 1/8 3 1/4 6 140 100 2600 1.5 1/2 12 1/8 3 1/4 6 145 65 1620 2.0 5/8 15 .157 4 .314 8 145 55 1350 2.5 3/4 20 3/16 5 3/8 10 155 35 890 3.0 7/8 22 1/4 6 1/2 12 165 25 620 3.0
3" Under Water
020424 Shield
120837 Retaining cap
020608 Nozzle
020607 Swirl ring
020415 Electrode
7
OPERATION
4-26 HySpeed HT2000LHF Instruction Manual
7
Shield Arc Approx.
Material
Plasma Gas Flow Rate %
Gas (CO2) Torch-to-work Initial Torch Voltage Motion
Thickness Preflow Cutflow Pressure Distance Piercing Height Setting Travel Speed Delay Time
(inches) (mm) (N2%) (N2%) (psi) (inches) (mm) (inches) (mm) (volts) (ipm) (mm/min.) (sec)
Shield Arc Approx.
Material
Plasma Gas Flow Rate %
Gas (CO2) Torch-to-work Initial Torch Voltage Motion
Thickness Preflow Cutflow Pressure Distance Piercing Height Setting Travel Speed Delay Time
(inches) (mm) (N2%) (N2%) (psi) (inches) (mm) (inches) (mm) (volts) (ipm) (mm/min.) (sec)
3/16 5 50 60 60 1/8 3 1/4 6 130 185 4700 0.5
1/4 6 (66.4 (79.6 (210 1/8 3 1/4 6 135 160 4050 1.0 3/8 10 SCFH) SCFH) SCFH) 1/8 3 1/4 6 135 120 3050 2.0 1/2 12 1/8 3 1/4 6 140 95 2400 2.5 5/8 15 .157 4 .314 8 140 70 1800 2.5 3/4 20 3/16 5 3/8 10 150 55 1400 3.0 7/8 22 1/4 6 1/2 12 160 42 1050 3.0
1 25 1/4 6 165 33 840 1-1/4 32 ` 1/4 6 175 20 510 1-1/2 38 5/16 8 185 11 280
Aluminum
200 amps • N2Plasma / CO2Shield
This gas combination is used when cut edge quality is less important. Electrode life is extended when this combination is used.
Notes: Set plasma gas inlet pressure to 120 psi (8.3 bar)
Set shield gas inlet pressure to 90 psi (6.2 bar)
Production cutting above 7/8" (22 mm) not recommended
Above Water
3/16 5 50 60 60 1/8 3 1/4 6 130 175 4450 0.5
1/4 6 (66.4 (79.6 (220 1/8 3 1/4 6 135 145 3650 1.0 3/8 10 SCFH) SCFH) SCFH) 1/8 3 1/4 6 140 100 2600 2.0 1/2 12 1/8 3 1/4 6 145 75 1820 2.5 5/8 15 .157 4 .314 8 145 55 1350 2.5 3/4 20 3/16 5 3/8 10 155 40 980 3.0 7/8 22 1/4 6 1/2 12 165 30 750 3.0
3" Under Water
020424 Shield
120837 Retaining cap
020608 Nozzle
020607 Swirl ring
020415 Electrode
OPERATION
HySpeed HT2000LHF Instruction Manual 4-27
Shield Arc Approx.
Material
Plasma Gas Flow Rate %
Gas (Air) Torch-to-work Initial Torch Voltage Motion
Thickness Preflow Cutflow Pressure Distance Piercing Height Setting Travel Speed Delay Time
(inches) (mm) (Air %) (Air %) (psi) (inches) (mm) (inches) (mm) (volts) (ipm) (mm/min.) (sec)
Shield Arc Approx.
Material
Plasma Gas Flow Rate %
Gas (Air) Torch-to-work Initial Torch Voltage Motion
Thickness Preflow Cutflow Pressure Distance Piercing Height Setting Travel Speed Delay Time
(inches) (mm) (Air %) (Air %) (psi) (inches) (mm) (inches) (mm) (volts) (ipm) (mm/min.) (sec)
1/8 3 48 39 60 3/32 2.5 3/16 5 135 110 2800
3/16 5 (55.3 (44.9 (270 1/8 3 1/4 6 140 90 2290 0.5
1/4 6 SCFH) SCFH) SCFH) 1/8 3 1/4 6 145 70 1780 0.5 3/8 10 1/8 3 1/4 6 145 50 1270 0.5 1/2 12 1/8 3 150 40 1010 5/8 15 .157 4 155 30 760 3/4 20 3/16 5 160 25 635
Aluminum
100 amps • Air Plasma / Air Shield
This gas combination gives good cut speed, low dross levels and is very economical.
Notes: Set plasma gas inlet pressure to 90 psi (6.2 bar)
Set shield gas inlet pressure to 90 psi (6.2 bar)
Production cutting above 3/8" (10 mm) not recommended
Above Water
1/8 3 48 39 70 5/64 2 5/32 4 135 100 2650
3/16 5 (55.3 (44.9 (280 1/8 3 1/4 6 140 80 2050 0.5
1/4 6 SCFH) SCFH) SCFH) 1/8 3 1/4 6 145 60 1510 0.5 3/8 10 1/8 3 1/4 6 150 40 1000 0.5 1/2 12 1/8 3 155 30 750
3" Under Water
020448 Shield
120837 Retaining cap
020611 Nozzle
020607 Swirl ring
120547 Electrode
7
OPERATION
4-28 HySpeed HT2000LHF Instruction Manual
7
Shield Arc Approx.
Material
Plasma Gas Flow Rate %
Gas (Air) Torch-to-work Initial Torch Voltage Motion
Thickness Preflow Cutflow Pressure Distance Piercing Height Setting Travel Speed Delay Time
(inches) (mm) (Air %) (Air %) (psi) (inches) (mm) (inches) (mm) (volts) (ipm) (mm/min.) (sec)
3/32 2.5 40 20 60 3/32 2.5 3/16 5 120 140 3550
1/8 3 (46.0 (23.1 (275 3/32 2.5 3/16 5 130 100 2550 0.5 1/4 6 SCFH) SCFH) SCFH) 1/8 3 140 35 900 3/8 10 1/8 3 150 15 350
Aluminum
40 amps • Air Plasma / Air Shield
This gas combination gives good cut speed, low dross levels and is very economical.
Notes: Set plasma gas inlet pressure to 90 psi (6.2 bar)
Set shield gas inlet pressure to 90 psi (6.2 bar)
Production cutting above 1/8" (3 mm) not recommended
Above Water Only
020613
Swirl ring
120667
Electrode
020689 Nozzle
020423
Retaining cap
020688
Shield
OPERATION
HySpeed HT2000LHF Instruction Manual 4-29
Shield Arc Approx.
Material
Plasma Gas Flow Rate %
Gas (Air) Torch-to-work Initial Torch Voltage Motion
Thickness Preflow Cutflow Pressure Distance Piercing Height Setting Travel Speed Delay Time
(inches) (mm) (O2%N2%) (O2%N2%) (psi) (inches) (mm) (inches) (mm) (volts) (ipm) (mm/min.) (sec)
1/4 6 12 38 64 0 60 1/8 3 1/4 6 115 160 4060 0.5
.315 8 (14.9 / 50.4 (79.6 / 0 (270 1/8 3 1/4 6 120 120 3000 0.5
3/8 10 SCFH) SCFH) SCFH) 1/8 3 1/4 6 120 100 2540 1.0 1/2 12 .157 4 .314 8 120 80 2030 2.0 5/8 15 .157 4 .314 8 125 70 1780 2.0 3/4 20 3/16 5 3/8 10 130 55 1400 2.5 7/8 22 1/4 6 1/2 12 135 45 1140 2.5
1 25 1/4 6 1/2 12 135 35 890 2.5
1 1/4 32 1/4 6 140 22 560 1-1/2 38 1/4 6 150 15 380 1-3/4 44 5/16 8 160 10 250
2 50 5/16 8 170 7 180
Mild Steel - Beveling Consumables
200 amps • O2Plasma / Air Shield
Notes: Set oxygen plasma gas inlet pressure to 120 psi (8.3 bar).
Set nitrogen plasma gas inlet pressure to 120 psi (8.3 bar). Set shield gas inlet pressure to 90 psi (6.2 bar).
Production cutting above 1" (25 mm) not recommended
Beveling cuts should be made between 45° and 90° to the work surface.
Above Water Only
120833 (cw)
120834 (ccw)
Swirl ring
120258
Electrode
120257
Water Tube
120259 Nozzle
120837
(cw)
120838 (ccw)
Retaining cap
120260
Shield
7
OPERATION
4-30 HySpeed HT2000LHF Instruction Manual
7
Shield Arc Plasma Gas Shield Gas
Plasma Gas Flow Rate %
Gas (Air) Current (Air) Inlet (Air) Inlet
Preflow Cut Flow Pressure Setting Pressure Pressure
(Air %) (Air %) (psi) (amps) (psi) (psi)
71 71 50 200 90 90
(81.8 SCFH)
Mild Steel Gouging
200 amps • Air Plasma / Air Shield
020607
Swirl ring
120667
Electrode
020615 Nozzle
120837
Retaining cap
020485
Shield
OPERATION
HySpeed HT2000LHF Instruction Manual 4-31
Check the consumable parts daily for wear before cutting. Before removing parts, bring the torch to the edge of the machine, with the lifter raised to its highest point. This prevents the danger of dropping the consumables into the water of the water table.
Removal and Inspection – Refer to Figure 4-7
1. Remove the retaining cap and shield by unscrewing the retaining cap by hand.
2. Check the shield for external signs of wear. It should be clean and clear of metal debris. The gas holes along the edge of the shield should not be blocked with debris. The center hole should not have any nicks or gouges, and should show no signs of arcing activity.
3. Unscrew and remove the shield from the retaining cap. Inspect the gas holes from the inside. The holes should be clear of metal or other debris. (Debris can cause arcing.)
4. Inspect the two O-rings on the torch body. They should be lubricated and undamaged. If they are dry, lubricate them lightly with a very thin film of the lubricant provided in the consumable parts kit. If they are damaged, replace them.
5. Using the 3/4" side of the wrench supplied with the consumable parts kit, remove the nozzle. Inspect it for damage or signs of wear. You can clean the inside of the nozzle with steel wool, but be sure to remove any remnants of the steel wool afterward. The hole in the nozzle should not be worn or oval-shaped.
6. Using the 3/8" center hole in the wrench, remove the Electrode and inspect it. If the center of an all copper electrode has a pit more than .044" (1.1 mm) deep, replace it. A SilverPlus electrode should be replaced when the pit depth exceeds approximately double the recommended depth of a standard copper electrode. Use the electrode gauge assembly supplied in the spare parts kit to measure pit depth. If the electrode is still good, inspect its O-ring: it should be lubricated and undamaged. If it is dry, lubricate it lightly with a very thin film of lubricant provided in the spare parts kit. If it is damaged, replace it.
7. Remove the swirl ring from the electrode and inspect it. It should be clean, and the holes on the top and sides should not be plugged. Inspect its O-ring. It should be lubricated and undamaged. If it is dry, lubricate it lightly with a very thin film of the lubricant provided in the consumable parts kit. If it is damaged, replace it.
8. Inspect the inside of the torch body by using a mirror, or by looking carefully inside. The current ring inside of the torch body should be clean and undamaged. Use a clean paper towel or cotton swab to remove dirt, grease, etc. A preferred method to clean the current ring is with a clean paper towel or cotton swab dipped in water or 3% hydrogen peroxide. If the water tube is damaged at all, it may need to be replaced. See
Changing the Water Tube.
CHANGING CONSUMABLE PARTS
WARNING
Always disconnect power to the power supply before inspecting or changing torch consumable parts.
7
OPERATION
4-32 HySpeed HT2000LHF Instruction Manual
7
Replacement
1. Before installing the electrode, be sure to lubricate the O-ring lightly with a very thin film of the lubricant
provided in the consumable parts kit. Replace the electrode and tighten it with the wrench. Do not overtighten.
2. Before installing the swirl ring, be certain to lubricate the O-rings lightly with a very thin film of the lubricant
provided in the consumable parts kit. Install the swirl ring with the bottom O-ring facing the inside of the torch. Push it into place. Be sure to hold the swirl ring in place until the nozzle is installed to avoid dropping it into the water of the water table.
3. Install the nozzle and tighten by hand. Finish tightening it with the wrench. Do not overtighten
4. Screw on the shield to the retaining cap and tighten by hand. Screw on the retaining cap to the torch and
tighten by hand. Make sure that it is tightened snugly; if it is loose, it can affect the shield gas flow.
Figure 4-7 Changing Consumable Parts
Shield Retaining cap Nozzle Swirl ring Electrode
Current ring
O-rings
Water tube
Torch body (shown without off valve SA and sleeve)
OPERATION
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Changing the Water Tube
Problems and causes you may find with a defective or improperly installed water tube:
• Short electrode life: The water tube is not screwed in tightly.
• Flow switch interlock shutting down the system: Water flow is restricted due to a loose water tube.
• Humming or rattling sound coming from the torch: The water tube is bent or loose.
If you suspect a problem with the water tube, you may need to replace it.
1. Disconnect the power supply from the power source.
2. Remove all consumables from the torch (see Changing Consumable Parts ).
3. Look for any damage or bends in the water tube.
4. Remove and replace the water tube by using the water tube wrench supplied by Hypertherm – Fig. 4-8. When installing the water tube, do not overtighten it! Tighten by hand only.
Figure 4-8 Changing the Water Tube
WARNING
Always disconnect the power supply
from the main power source before
inspecting or changing the torch parts.
OPERATION
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How to Optimize Cut Quality
The following tips and procedures will help produce square, straight, smooth and dross-free cuts.
Tips for Table and Torch
• Use a square to align the torch at right angles to the workpiece.
• The torch may travel more smoothly if you clean, check and “tune” the rails and drive system on the cutting table. Unsteady machine motion can cause a regular, wavy pattern on the cut surface.
• The torch must not touch the workpiece during cutting. Contact can damage the shield and nozzle, and affect the cut surface.
Plasma Set-Up Tips
Follow carefully each step in the Daily Start-Up procedure described earlier in this section.
Purge the gas lines before cutting.
Maximize the Life of Consumable Parts
Hypertherm’s LongLife®process automatically “ramps up” the gas and current flows at the start and ramps them down at the end of each cut, to minimize erosion of the electrode’s center surface. The LongLife process also requires that cuts start and stop on the workpiece.
• The torch should never fire into the air.
– Starting the cut at the edge of the workpiece is acceptable, as long as the arc is not fired in the air. –
To start with a pierce, use a pierce height that is 1.5 to 2 times the torch-to-work distance. See Cut Charts.
• Each cut should end with the arc still attached to the workpiece, to avoid arc blow-outs (ramp-down errors).
– When cutting drop parts (small parts that drop down after being cut from the workpiece), check that the
arc stays attached to the edge of the workpiece, for proper ramp-down.
• If arc blow-outs occur, try one or more of the following:
– Reduce the cutting speed during the final part of the cut. – Stop the arc before the part is completely cut, to allow completion of the cut during the ramp-down. – Program the path of the torch into the scrap area for ramp-down.
Note: Use a “chain cut” if possible, so the path of the torch can lead directly from one cut part into
the next, without stopping and starting the arc. However, do not allow the path to lead off the workpiece and back on, and remember that a chain cut of long duration will cause electrode wear.
Note: It may be difficult to achieve the full benefits of the LongLife process in some conditions.
OPERATION
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Additional Factors of Cut Quality
Cut Angle
A cut part whose 4 sides average less than 4° of cut angle is considered acceptable.
Note: The squarest cut angle will be on the right side with respect to the forward motion of the torch. Note: To determine whether a cut-angle problem is being caused by the plasma system or the
drive system, make a test cut and measure the angle of each side. Next, rotate the torch 90° in its holder and repeat the process. If the angles are the same in both tests, the problem is in the drive system.
If a cut-angle problem persists after “mechanical causes” have been eliminated (See Tips for Table and Torch, previous page), check the torch-to-work distance, especially if cut angles are all positive or all negative.
• A positive cut angle results when more material is removed from the top of the cut than from the bottom.
• A negative cut angle results when more material is removed from the bottom of the cut.
Dross
Low-speed dross forms when the torch’s cutting speed is too slow and the arc shoots ahead. It forms as a heavy, bubbly deposit at the bottom of the cut and can be removed easily. Increase the speed to reduce the dross.
High-speed dross forms when the cutting speed is too fast and the arc lags behind. It forms as a thin, linear bead of solid metal attached very close to the cut. It is welded to the bottom of the cut and is difficult to remove. To reduce high-speed dross:
• Decrease the cutting speed.
• Decrease arc voltage, to decrease the torch-to-work distance.
• Increase O
2
in the shield gas to increase the range of dross-free cutting speeds. (Only HyDefinition and
HT4400 systems can accommodate mixed-gas shield gases.)
Notes: Dross is more likely to form on warm or hot metal than on cool metal. For example, the
first cut in a series of cuts will likely produce the least dross. As the workpiece heats up, more dross may form on subsequent cuts.
Dross is more likely to form on mild steel than on stainless steel or aluminum. Worn or damaged consumables may produce intermittent dross.
Cause
The torch is too low.
The torch is too high.
Square cut
\
Solution
Increase arc voltage to raise the torch.
Decrease arc voltage to lower the torch.
Positive cut angle
Negative cut angle
Problem
OPERATION
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Straightness of the Cut Surface
A typical plasma cut surface is slightly concave.
The cut surface may become more concave, or convex. Correct torch height is required to keep the cut surface acceptably close to straight.
A strongly concave cut surface occurs when the torch-to-work distance is too low. Increase the arc voltage to increase the torch-to-work distance and straighten the cut surface.
A convex cut surface occurs when the torch-to-work distance is too great or the cutting current is too high. First, reduce the arc voltage, then reduce the cutting current. If there is overlap between different cutting currents for that thickness, try the consumables designed for the lower current.
Additional Improvements
Some of these improvements involve trade-offs, as described.
Smoothness of Cut Surface (Surface Finish)
• (HyDefinition and HT4400 only) On mild steel, a higher concentration of N2in the O2-N2shield mixture may produce a smoother cut surface. Trade-off: This may produce more dross.
• (HyDefinition and HT4400 only) On mild steel, a higher concentration of O2in the O2-N2shield mixture may increase the cutting speed and produce less dross. Trade-off: This may produce a rougher cut surface.
Piercing
• The pierce delay must be sufficiently long that the arc can pierce the material before the torch moves, but not so long that the arc “wanders” while trying to find the edge of a large hole.
• A higher shield gas preflow may help blow the molten metal away during piercing. Trade-off: This may reduce starting reliability.
Note: When piercing at maximum thicknesses, the ring of dross that forms during the pierce may
be high enough to contact the torch when the torch begins to move after the pierce is complete. A “flying pierce,” which makes the pierce while the torch is moving, may eliminate the torch vibration that follows contact between the torch and the ring of dross.
How to Increase Cutting Speed
• Decrease the torch-to-work distance. Trade-off: This will increase the negative cut angle
Note: The torch must not touch the workpiece while piercing or cutting.
HySpeed HT2000LHF Instruction Manual 5-1
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Section 5
MAINTENANCE
Introduction
Hypertherm assumes that the service personnel performing the troubleshooting testing are high-level electronic service technicians that have worked with high voltage electro-mechanical systems. Knowledge
of final isolation troubleshooting techniques is also assumed.
In addition to being technically qualified, maintenance personnel must perform all testing with safety in mind. Refer to the Safety section for operating precautions and warning formats.
If you need additional assistance or need to order parts, call our Customer Service or Technical Service groups listed at the front of this manual.
WARNING
SHOCK HAZARD: The large chopper capacitors store large amounts of energy in the form of electric voltage. Even if the power is off, dangerous voltages exist at the capacitor terminals, on the chopper, and the diode heatsinks. Never discharge capacitors with a screwdriver or other implement…explosion, property damage and/or personal injury will result. Wait at least five minutes after turning the power supply off before touching the chopper or the capacitors.
Routine Maintenance
Torch and Torch Leads (See also Torch Coolant Draining at the end of this section)
Inspection
Inspect the torch and torch leads on a routine basis.
• The torch consumable parts and torch main body should always be inspected prior to cutting. Worn or damaged parts can cause gas and water leaks which can affect the cut quality. Check for pitting and burn marks on the consumable parts and replace them, if necessary. See Changing Consumable Parts in Section 4.
• Ensure that all connections are tight, but do not overtighten.
• The torch leads should be checked occasionally for cracking and damage.
MAINTENANCE
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Power Supply (See also Torch Coolant Draining at the end of this section)
Inspection and Cleaning
Inspect the power supply on a routine basis.
• Check the exterior for any damage. If there is damage, ensure that it does not affect the safe operation of the power supply.
• Remove covers and inspect the interior. Check wiring harnesses and connections for wear and damage. Check for loose connections, and look for areas of discoloration due to overheating.
• At the rear of the power supply, inspect the filter element of the water coolant assembly. If the filter becomes excessively dirty, torch coolant flow can slow down causing the flow switch to open (turn off) and make the coolant flow interlock status LED illuminate. The filter changes to a brown color when it is dirty. Replace the filter element (027005) when it starts to turn color.
• Every 2 weeks, inspect the air filter in the front panel of the power supply by removing the access cover and lifting the filter out. Replace the filter (027441) when dirty.
• Every 6 months, flush the power supply of its torch coolant and replace with new coolant (028872). Also, replace the water filter (027005) every 6 months.
• Every 6 months, clean the pump strainer with a mild soap and water solution. Note: Remove the pump from the system before removing the strainer to avoid any debris from falling into the pump housing. See Fig. 5-1.
Cleaning
Check the inside of the power supply periodically for dust and foreign matter.
• Open the cover and blow out the power supply with compressed air. It is important to keep the cover closed except when cleaning or when maintenance is being performed.
Figure 5-1 Cleaning the Pump Strainer
Brass Coupler 031122
Strainer
Pump
MAINTENANCE
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Gas Console
Inspection
Inspect the gas console on a routine basis.
• Check the exterior for any damage. Look for damaged glass tubes in the flowmeters and check the pressure gauges for damage.
• Inspect all interconnecting cables, hoses and leads for wear and damage. Ensure that all connections are tight and that there are no leaks. Do not overtighten fittings.
Cleaning
Keep the flowmeters and pressure gauges free of dirt, dust and foreign matter.
Start Sequence
Shaded boxes represent action taken by the operator.
1. TSW1, TSW2 (Chopper temperature switches)
2. TS1 (Power Supply transformer temperature switch)
3. LS1 (Power Supply coolant level switch)
4. PS3 (Power Supply shield pressure switches)
5. PS1,,PS2 (Gas Console plasma pressure switches)
6. TS2 (Power Supply coolant temperature switch)
7. FS1 (Power Supply coolant flow switch – note this interlock will not be satisfied until M1
Correct
Interlock
Problem
No
All interlocks
listed above
satisfied
?
Yes
CR1 (24V/120V relay) on Power Distribution Board (PCB1) closes.
LT1 (Power Supply ON light) PCB2 (Power Supply-µP Control Board
24VAC interlock)
CH1, CH2 (Power Supply Choppers) PCB3 (Power Supply Analog Board) PCB4 (Power Supply Relay Board) PCB9
(Power Supply THC Board)
24VAC to
120VAC to
Turn line disconnect
switch on
12VDC to the following interlocks:
coolant pump is activated.)
Push and hold
ON button (PB1)
CR2 (120V relay) on Power
Distribution Board (PCB1) closes.
120VAC to
M2, M3, M4 (Power Supply
Fans) M5-M8 (Power Supply Heat
Exchange Fans) PCB2 (Power Supply-µP
Control Board)
First 5 interlocks
listed above
satisfied
?
Yes
CR3 (240V relay) on Power Distribution Board (PCB1) closes.
240VAC to
M1 (Power Supply Coolant
Pump)
Correct Interlock Problem
No
All STATUS LEDs on
PCB5 (Interlock Display
Board) are extinguished.
Release ON button (PB1)
System initialization
is complete.
MAINTENANCE
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Initial Checks
Before tracking down specific problems, it is good practice to do a visual check, and verify proper voltages are present at the power source, transformer and power distribution board.
1. Place the line disconnect switch in the off position.
2. Using a Phillips head screwdriver, remove the top plate, two side plates, front plate, and rear plate.
3. Inspect the interior of the power supply for discoloration on pc boards, or other apparent damage. If a component or module is obviously defective upon visual inspection, remove and replace it before testing. Refer to Section 6 to identify parts and part numbers.
4. If no damage is apparent, place the line disconnect switch in the on position.
5. Measure the voltage at TB1 between L1, L2 and L3. Refer to Figure 5-2 for detail of TB1. The voltage between any two of the three points at TB1 should be equal to your supply voltage. If there is a problem at this point, disconnect the main power and check connections, power cable, and fuses at the line disconnect switch. Repair and/or replace defective component(s) if necessary.
WARNING
SHOCK HAZARD: Always use caution when servicing a power supply when it is plugged in and the covers are removed. Dangerous voltages exist within the power supply which could cause injury or death.
Measure the voltage for the 400 volt CE power supplies between the U, V and W terminals of TB1 in the EMI filter located on the top of the power supply. Refer to the appendix section.
Figure 5-2 Primary Power Measurement Location – HT2000LHF
WARNING
There is line voltage at the contactor if the line disconnect switch is in the ON position, even if the ON (l) pushbutton on the HT2000 power supply has not been pressed. Use extreme care when measuring primary power in this area. Voltages present at the terminal block and contactor can cause injury or death!
MAINTENANCE
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Figure 5-3 Power Distribution Board PCB1
6. Measure the voltage at Power Distribution Board PCB1. Refer to Figure 5-3 for detail of PCB1. Look on the board for fuses F1-F4. Measurements between each fuse and chassis ground should be as follows:
F1: 24VAC F2: 120VAC F3: 240VAC F4: 120VAC
If voltages are not present, or incorrect at one or more of these points, disconnect the power and troubleshoot PCB1 fuses and associated pins, connectors and wiring between power distribution board connector REC1 and transformer secondary T1. Refer to Section 6 for location of T1.
Also, check the main power circuit breaker CB1 and associated wiring and connections between T1 and points L1 and L2.
Repair and/or replace defective component(s) if necessary.
F2F4F3 F1
MAINTENANCE
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Troubleshooting
The troubleshooting section is presented by following normal operational sequence.
Before troubleshooting for specific problems, be sure that the unit passes Initial Checks as outlined earlier in this section.
WARNING
SHOCK HAZARD: Always use caution when servicing a power supply when the covers are removed. Dangerous voltages exist within the power supply which could cause injury or death. If questions or problems arise during servicing, call the Hypertherm Technical Services Department listed at the front of this manual.
1. The green POWER ON pushbutton switch PB1 is pressed, but the fans are not operating and the green POWER ON indicator does not illuminate.
1.1. The POWER ON (I) PB1 pushbutton is defective.
Check that the switch is operating correctly. The POWER ON switch is normally open.
1.2. The POWER OFF (0) PB2 pushbutton is defective.
Check that the switch is operating correctly. The POWER OFF switch is normally closed.
1.3. No jumper for PB2A and PB2B at TB5.
TB5 terminals 1&2 and 4&5 need a jumper if there is no optional remote I/O cable for switching the power supply on and off.
1.4. Associated wiring not making good contact.
Check wiring and repair or replace, if necessary.
2. The green POWER ON pushbutton switch PB1 is pressed, the POWER ON indicator illuminates, but the fans are not running.
2.1. CR2 on the power distribution board PCB1 is defective.
Check that CR2 switches when the POWER ON pushbutton is pressed. See Figure 5-3 for location of CR2. If CR2 is defective, replace PCB1.
2.2. Connector from the power distribution board is not seated securely.
Check pins, connectors and associated wiring for continuity. Repair or replace, if necessary.
3. The green POWER ON pushbutton switch PB1 is pressed, the fans are operating, but the green POWER ON indicator does not illuminate.
3.1. Pushbutton PB1 was not held down for a long enough
period of time.
Press and hold PB1 for a minimum of 5 seconds.
3.2. Relay CR1 on the power distribution board is defective.
Check that CR1 switches when the POWER ON pushbutton is pressed. See Figure 5-3 for location of CR1. If CR1 is defective, replace PCB1.
Problem Possible Causes / Solutions
MAINTENANCE
HySpeed HT2000LHF Instruction Manual 5-7
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4. The green POWER ON indicator is illuminated, the START command is given and the DC ON indicator is illuminated, but there is no high frequency and no pilot arc.
4.1. There is no spark between the spark gap electrodes.
Clean (with emery cloth), align and reset the electrode gaps to .020" (0.51 mm), if necessary. The electrode surfaces between the gaps should be flat. If the surfaces are rounded, replace and reset the gap.
• Inspect the high voltage transformer T3 in the power supply for signs of overheating. See Figure 6-7 for location of T3 . Replace T3 if it is overheating.
• Check for 120VAC at T3 after the START command is given.
• If there is no 120VAC at T3, use wiring diagrams in Section 7 to check pins, connectors and associated wiring from T3 to relay board PCB4. If connections are OK, there may be a problem with either PCB4 or PCB2.
• If there is 120VAC at T3 , shut down the system and remove capacitors C4, C5 and C6. (See Figure 6-7 for location of C4, C5 and C6) Restart the system and look for a faint spark across the gaps.
• If a spark is not observed at the gaps, replace T3. If there is a spark, shut down system, and replace capacitors C4, C5 and C6. (Always replace all the capacitors.)
4.2. There is no high frequency at the torch.
Check for a shorted torch, or loose lead connections. Replace the torch or tighten the lead connections.
Problem Possible Causes / Solutions
3.3. One or more of the STATUS LEDs remains illuminated,
indicating a fault condition. To troubleshoot STATUS fault conditions, see Status LED Troubleshooting later in this section.
5. The green POWER ON indicator is illuminated, the torch START command is given and the DC ON indicator illuminates, and there is high frequency, but there is no pilot arc.
5.1. Pilot arc relay CR1 is not closing.
See if the CR1 relay contacts close after the START command is given. See Figure 6-7 for location of CR1. If CR1 does not close:
• With an AC voltmeter across the relay, see if 120VAC is coming from PCB4 after the START command is given.
• If there is no 120VAC, check connectors, terminals, pins, and associated wiring to PCB4.
• If wiring is OK, there is a problem either with PCB4 or PCB2.
MAINTENANCE
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Problem Possible Causes / Solutions
5.2. Pilot arc relay CR1 is defective.
If there is
120VAC across the relay (see previous steps),
and CR1 does not close, replace CR1.
5.3. Main contactor (CON1) or PCB4 is defective.
• With an AC voltmeter, see if there is 120VAC at contactor CON1 after the START command is given. If there is no 120VAC, check pins, connectors and associated wiring from CON1 to PCB4.
• If wiring is OK, PCB4 or PCB2 may be defective.
• If there is 120VAC at CON1 as described above, measure the voltage between secondary terminals of the main transformer T2 after the START command is given. The voltage between any two of the three points connected to each chopper input should be equal to about 200VAC.
If there is no voltage at any of the above points, replace CON1.
If there is voltage at some but not all of the above points, check wiring and connections to and from T2. If wiring checks out OK, return to Initial Checks section and repeat steps 1-5.
5.4. Choppers are defective or not functioning.
See Chopper Module Test Procedure later in this section.
6. The unit stops cutting during cut, or cuts poorly.
6.1. The work cable is not connected or it is broken.
Connect or repair the work cable.
6.2. Arc not transferring to workpiece.
Check the work cable connection to the workpiece. Good contact must be made in order for the arc to transfer.
6.3. There is insufficient air or gas pressure.
Check the gas inlet pressures and the plasma and shield gas pressures in TEST and RUN modes as specified in the
Cut Charts.
6.4. Torch is getting insufficient current.
Check the arc current setting in the Cut Charts for the type and thickness of metal you are cutting.
6.5. The power supply has overheated.
Shut down the system and wait for the power supply to cool down. If the power supply will not restart, see Status LED Troubleshooting guide later in this section.
6.6. Choppers are defective or not functioning.
See Chopper Module Test Procedure later in this section.
MAINTENANCE
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Problem Possible Causes / Solutions
Status LED Troubleshooting
Be certain that the power supply has been through the Initial Checks as outlined earlier in this section before troubleshooting STATUS LEDs.
When any one of the STATUS LEDs illuminates, there is a fault condition that must be corrected in order for the HT2000LHF power supply to become operational. See Section 7 in this manual for reference.
1. INTERLOCK LED illuminated: This LED should never illuminate. Call the Technical Services department listed in the front of this manual if this LED illuminates.
2. TRANSFORMER LED illuminated: 2.1. Main Transformer T2 or one of the choppers is overheating.
This LED will extinguish when the main transformer (T2) is operating in a normal temperature range (under 165° C (329° F)) and choppers CH1 and CH2 are also operating in a normal temperature range (under 82° C (180° F)).
• Check the temperature switches (normally closed).
• Check pins, connectors and wiring to temperature switches.
• Leave the fans running, and try restarting the unit after one hour. If LED still illuminates, one of the choppers or the main transformer may need to be replaced.
3. COOLANT LEVEL LED illuminated: 3.1. Coolant level is low.
This LED will extinguish when a proper coolant level in the coolant reservoir is maintained. Level switch LS1 is located in the coolant reservoir, and will open when it senses that coolant level is too low.
• Check the coolant level.
• If the coolant level is adequate, check to see if LS1 switch is closed.
• Check connections and wiring from LS1 to PCB1.
Repair and/or replace defective component(s), if necessary.
MAINTENANCE
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6
Problem Possible Causes / Solutions
5. PLASMA GAS LED illuminated: 5.1. Plasma gas pressure is too low.
This LED will extinguish when PS1 and/or PS2 in the gas console senses plasma gas pressure of 80 psi (5.5 bar) or greater.
• Verify that the plasma gas supply is set to 120 psi (8.3 bar) as defined in the Specifications section of this manual.
• Verify that all plasma gas connections are secure, and that there are no leaks in any hoses connected to the gas console.
5.2. Pressure switches PS1 and/or PS2 not functioning.
These switches are normally open, and close when plasma gas pressure is at or above 80 psi (5.5 bar). After PS1 and PS2 are closed (in O2mode) or PS1 is closed (in N2mode), the Plasma Gas LED extinguishes.
• Using the wiring diagrams, check pins, connectors and wiring from the power distribution board (PCB1) to PS1 and PS2.
Repair and/or replace defective component(s), if necessary.
4. SHIELD GAS/CAP LED illuminated: 4.1. Shield gas pressure is too low.
This LED will extinguish when shield gas pressure of 12 psi (0.83 bar) or greater is sensed by PS3 (located in the power supply).
• Check to see that the shield gas supply is set to 90 psi (6.2 bar) as defined in the Specifications section of this manual.
• Verify that all shield gas connections are secure, and that there are no leaks in any hoses connected to the power supply or gas console.
4.2. Torch cap not tightened securely.
If the torch retaining cap is not tightened securely, or there is debris in the retaining cap, the shield gas may escape and cause pressure switch PS3 to remain open.
• Listen at the torch for a hissing sound during startup.
• Remove the retaining cap and check for debris or O-ring damage. Clean or replace, if necessary. See Changing
Consumable Parts in the Operation section.
4.3. Pressure switch PS3 in the power supply is not functioning.
PS3 is normally open, and closes when shield gas pressure is 12 psi (0.83 bar) or greater.
• Using the wiring diagrams, check pins, connectors and wiring from the power distribution board (PCB1) to PS3.
Repair and/or replace defective component(s), if necessary.
MAINTENANCE
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Problem Possible Causes / Solutions
6. COOLANT TEMP LED illuminated: 6.1. Coolant is too hot.
This LED will extinguish when temperature switch TS2 senses that the temperature of coolant in the coolant reservoir is under 160° F (71° C).
• Check to see if the water coolant is above 160° F (71° C).
• Check to see if TS2 (located in the coolant reservoir) is open. TS2 is normally closed, and is opened when a temperature above 160° F (71° C) is reached.
• Using the wiring diagrams, check pins, wires and connections from TS2 to PCB1.
Repair and/or replace defective component(s), if necessary.
7. COOLANT FLOW LED illuminated: 7.1. Coolant flow is restricted.
This LED will extinguish when flowswitch FS1 senses a coolant flow of at least 0.5 gpm (1.9 lpm) to the torch. FS1 is a normally open switch that closes when a flow greater than 0.5 gpm (1.9 lpm) is sensed. See Coolant Flow Test Procedure later in this section to troubleshoot coolant flow problems.
Note: Coolant flow LED illuminates when the line disconnect switch is turned ON because coolant reservoir pump M2 is not activated until the power supply POWER ON (PB1) is pressed.
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Chopper Module Test Procedure
Note: Take voltages with a digital multimeter capable of storing min. and max. readings.
1. Turn all power to the power supply OFF. Disconnect the mating receptacles in the power supply to disable the high frequency transformer T3. See Figure 6-7 for location of T3.
2. Remove large fuses F1 and F2. Check to see if the fuses are open.
3. Place the positive lead to the + side of the bridge and the negative lead to the – side of the bridge. See Figure 5-4. Note that actual connection points are hidden by cap support bracket in Figure 5-4.
4. Turn power to the power supply ON, and start the system up. After the START command has been given, check the voltage. The input to the chopper at these points should be about +280 VDC. If the input is OK and corresponding fuse F1 or F2 was blown, replace the chopper module. If there is no +280 VDC input, check input to bridge for shorts. Also, check contactor (CON1), connections and associated wiring to the contactor. Repair and/or replace defective component(s) if necessary.
5. If the voltage from above step is +280 VDC and corresponding fuse is not blown, check output of CH1 by placing the positive lead of the voltmeter at point + WORK on the chopper module (wire #48A) and negative lead at point - TORCH (wire #39A). (Check the output of CH2 by placing the leads of the voltmeter at the corresponding points on the other chopper module.)
6. Turn the system on and press the START command. After the START command has been given, check the voltage. If the output from each chopper at these points is +280 VDC, then the choppers are OK.
7. If the chopper does not output +280 VDC, check to see if the LED1 logic power light is illuminated. If LED1 is extinguished, check if 120V is going to JP6. If there is no 120V at JP6, check wiring back to the power distribution board. Repair or replace defective component(s), if necessary. Also check to see if LED3 is turning green when enabled (normal condition). If LED1 is illuminated and LED3 is red when enabled (fault condition), then make sure that JP9 is seated properly.
8. If the chopper still does not output 280V after completing step 7, there may be a problem with the control signal or the chopper module. The chopper drive signal comes through the analog board PCB3 as an analog level from 0 to +8 VDC, which varies the duty cycle and subsequent output current of the chopper. These analog signals are on pins 3&4 REC1 of PCB3 for CH1, and 5&6 REC1 for CH2.
WARNING
SHOCK HAZARD: Use extreme care when working near the chopper modules. The large chopper capacitors store large amounts of energy in the form of electric voltage. Even if the power is off, dangerous voltages exist at the capacitor terminals, on the chopper, and the diode heatsinks. Never discharge capacitors with a screwdriver or other implement…explosion, property damage and/or personal injury will result.
MAINTENANCE
HySpeed HT2000LHF Instruction Manual 5-13
6
To determine if there is a problem with the chopper modules or with control board PCB2 or analog board PCB3, proceed as follows:
• Ensure that the high frequency is still disabled (see step 1).
• Disconnect PL3.1 from REC1 on PCB3.
• Place voltmeter across the output of the chopper and press the START command.
• If the voltmeter reads +280 VDC, then replace either control board PCB2 or analog board PCB3.
• If the voltmeter reads 0 volts, then replace the corresponding chopper module CH1 or CH2.
Figure 5-4 Chopper Module – Front View
Bridge (+)
- TORCH
+ WORK
Bridge (–)
LED3
LED1
JP9
JP6
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