Hypertherm HT2000LHF Instruction Manual Download

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MAINTENANCE

HySpeed HT2000LHF

Instruction Manual

5-5

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.

Summary of Contents for HT2000LHF

Page 1: ...200 Volt Plasma Arc Cutting System Instruction Manual 803040 Revision 7 HySpeed HT2000LHF ...

Page 2: ...0V power supplies 3 03 Changed spec on coolant 3 04 Added power specs for 440V 3 11 Added note referencing DC relay kit part number 4 10 Added line referencing cutting techniques 4 33 4 36 Adding cutting techniques 6 04 Added 440V control xfrmr 6 05 Added 440V power xfrmr 6 09 Changed p n of items 6 and 7 for new pressure switch 6 13 Added 015049 to parts list 6 16 Changed figure title to HT2000 C...

Page 3: ...Added note to Water Muffler cable stating that it cannot be used with the stainless torch 4 11 Changed index to cut chart and consumables to include new electrode and swirl ring 4 12 4 29 Updated cut charts with new electrode swirl ring and clearer cutting capacities 5 02 Removed old style pump clamp from drawing 6 05 New part number for valve SV7 6 08 Added kits for pump and motor replacement 6 0...

Page 4: ...Mild Steel 100A cutting cut chart 5 05 New power distribution PCB graphic added fuse 5 14 Added error code for phase loss 6 02 New firmware rev 6 06 New graphic of chopper with phase loss board new phase loss board 6 16 Changed some quantities in consumable parts kit 7 01 Uprevved wiring diagrams to E i 02 Added j1 to grounding requirements in index i 04 Added phase loss to index j 01 New system g...

Page 5: ......

Page 6: ...l P N 803040 Revision 7 November 2013 Copyright 2013 Hypertherm Inc All Rights Reserved Hypertherm HT HyLife HySpeed and LongLife are trademarks of Hypertherm Inc and may be registered in the United States and or other countries Hypertherm Inc Hanover NH USA www hypertherm com ...

Page 7: ...blic of Singapore 65 6 841 2489 Tel 65 6 841 2490 Fax 65 6 841 2489 Technical Service Hypertherm UK Ltd 9 Berkeley Court Manor Park Runcorn Cheshire England WA7 1TQ 44 1928 579 074 Tel 44 1928 579 604 Fax France 15 Impasse des Rosiers 95610 Eragny France 00 800 3324 9737 Tel 00 800 4973 7329 Fax Hypertherm S r l Via Torino 2 20123 Milano Italia 39 02 725 46 312 Tel 39 02 725 46 400 Fax 39 02 725 4...

Page 8: ...nnection 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 au thorized by a person who is competent to assess whether the changes will increase the ris...

Page 9: ...erm 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 ...

Page 10: ...ité 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...

Page 11: ...STALLATION 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 Plac...

Page 12: ...onsole 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 Concersions 4 10 Cut Chart and Consumable Parts Index 4 11 Changing Consumable Parts 4 31 Removal and Inspection 4 31 Replacem...

Page 13: ...upply 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 HT2...

Page 14: ...eed 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 ...

Page 15: ...TABLE OF CONTENTS viii Hyspeed HT2000LHF Instruction Manual 6 ...

Page 16: ...n 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 ...

Page 17: ... 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...

Page 18: ... 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 N...

Page 19: ...rdant 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...

Page 20: ...s 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...

Page 21: ...cutting path 2 3 Wear complete body protection 3 Electric shock from torch or wiring can kill Protect yourself from electric shock 3 1 Wear insulating gloves Do not wear wet or damaged gloves 3 2 Insulate yourself from work and ground 3 3 Disconnect input plug or power before working on machine 4 Breathing cutting fumes can be hazardous to your health 4 1 Keep your head out of the fumes 4 2 Use fo...

Page 22: ...vention 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 Sécurit...

Page 23: ...e 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 ...

Page 24: ...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 alimentati...

Page 25: ...sées 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 ...

Page 26: ...e 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 pe...

Page 27: ... peut être fatal Se protéger contre les risques de chocs électriques 3 1 Porter des gants isolants Ne pas porter de gants mouillés ou abîmés 3 2 S isoler de la surface de travail et du sol 3 3 Débrancher la prise ou la source de courant avant de manipuler l équipement 4 L inhalation des vapeurs produites par le coupage peut être dangereuse pour la santé 4 1 Garder le visage à l écart des vapeurs 4...

Page 28: ...ure 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 auto...

Page 29: ...al 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 Sh...

Page 30: ...mps 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 k...

Page 31: ...al 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 ...

Page 32: ...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 Fig...

Page 33: ... 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...

Page 34: ...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 carri...

Page 35: ...mmends 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 flexibl...

Page 36: ...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 co...

Page 37: ...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 ele...

Page 38: ...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 ef...

Page 39: ...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 1 pushbutton on the power supply has not been pressed As a common safety practice ALWAYS verify that the line disconnect switch...

Page 40: ... 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 ...

Page 41: ...upply 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 ...

Page 42: ...al 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 ...

Page 43: ...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 12304...

Page 44: ...een 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 Signal...

Page 45: ...t 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 Brow...

Page 46: ...ltage 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 ...

Page 47: ...as 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...

Page 48: ... 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 ...

Page 49: ...ee 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 clust...

Page 50: ...h 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 P...

Page 51: ...e 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 Conne...

Page 52: ...rom 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 ...

Page 53: ...racket 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 ...

Page 54: ...N 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 mai...

Page 55: ...tages 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 percent age 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 oxyge...

Page 56: ...utting 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...

Page 57: ... 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 e...

Page 58: ...r 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 ...

Page 59: ... 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 poi...

Page 60: ...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 elect...

Page 61: ... from the Cut Charts for the type and thickness of metal to cut PLASMA N2 Air O2 SHIELD N2 Air psi psi psi DC N2 Air O2 O2 PLASMA Cut Flow PreFlow PreFlow 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...

Page 62: ... 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 o...

Page 63: ...utting 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 ...

Page 64: ...20837 020608 020607 020415 Ap A 100 Air Air 020448 120837 020611 020607 120547 4 27 100 H35 N2 020448 120837 020611 020607 020415 Ap A 40 Air Air 020688 020423 020689 020613 120667 4 28 200 O2 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 N2 020485 120837 020615 020607 020415 Ap A BEVEL CUT...

Page 65: ... 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 O2 Plasma 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...

Page 66: ...es superior cut speed minimum dross minimum surface nitriding and excellent weldability Above Water 1 4 6 5 45 64 0 70 1 8 3 1 4 6 125 145 3700 0 5 315 8 5 3 62 4 79 6 0 280 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 ...

Page 67: ...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...

Page 68: ... 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 N2 Plasma CO2 Shield This gas combination may be used when cut edge quality and surface nitriding are less important Electrode life is extended when using this combi...

Page 69: ... 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 cu...

Page 70: ...5 Mild Steel 100 amps O2 Plasma 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 ...

Page 71: ...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...

Page 72: ...7 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 inle...

Page 73: ... 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 N2 Plasma 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 combin...

Page 74: ...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 N2 Plasma CO2 Shield 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 ...

Page 75: ...30 110 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 inle...

Page 76: ... 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...

Page 77: ...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 pressu...

Page 78: ...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 N2 Plasma 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 pressur...

Page 79: ... 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 N2 Plasma CO2 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 pres...

Page 80: ...0 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...

Page 81: ...0 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...

Page 82: ...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 O2 Plasma 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...

Page 83: ...ma 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 ...

Page 84: ...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 s...

Page 85: ...th 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 ...

Page 86: ...be 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 o...

Page 87: ...top 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 part...

Page 88: ...utting 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 T...

Page 89: ...2 shield 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 O2 in the O2 N2 shield 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 m...

Page 90: ...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 Tor...

Page 91: ...e 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...

Page 92: ...lay 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 CR3 240V relay on Power Distribution Board PCB1 closes 240VAC to M1 Power Supply Coolant Pump All STATUS LEDs on PCB5 Interlock Display Board are extinguished Correct Interlock Problem Correct Interlock Problem First 5 interlocks listed above sat...

Page 93: ...e 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 remo...

Page 94: ... 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 b...

Page 95: ... 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 distri...

Page 96: ...cation 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 Poss...

Page 97: ...nnections 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 ...

Page 98: ...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 t...

Page 99: ... 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 t...

Page 100: ... 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 se...

Page 101: ...acing 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 extinguishe...

Page 102: ...equency 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 ...

Page 103: ...hing the Error Code LED on the control board The power supply front cover must be removed to observe control board PCB2 and the Error Code LED see Figure 6 1 for location of PCB2 and Figure 5 5 for location of Error Code LED on PCB2 The Error Code LED will blink on for 5 seconds and off for 5 seconds with a 2 second gap before repeating the blinking sequence The number of blinks between the 2 seco...

Page 104: ...orch 1 Find a clean 1 gallon 3 8 liter container 2 Locate the two coolant hoses that come off of the cathode block at the rear of the power supply black hoses one with a green tape band and one with a red tape band See Fig 5 6 3 Remove the torch coolant return hose black hose with the red band from the cathode block 4 Place the red banded hose into the 1 gallon container WARNING Push the OFF 0 but...

Page 105: ... either with the flow switch or the particulate filter Remove the filter element and re connect the coolant hose to the cathode block on the rear of the power supply Start the power supply If the COOLANT FLOW LED remains illuminated replace the flow switch If the LED does not illuminate replace the filter element Verify Flow Rate to Torch 1 Press the power supply OFF 0 button and place the main di...

Page 106: ...mmends draining the torch coolant from the power supply and torch before transporting the system After this draining procedure a small amount of coolant will remain in the system pump and valves For this reason Hypertherm also recommends that a suitable ratio of propylene glycol be purged through the system prior to draining if the system will experience extremely cold temperatures Note that Hyper...

Page 107: ... to the power supply 5 Disconnect the torch coolant supply hose black hose with the green band from the rear of the power supply See Fig 5 6 6 Blow clean dry oil free air at 80 120 psi 5 5 8 3 bar into the torch coolant supply hose until coolant stops flowing into the reservoir 7 Drain or siphon remaining coolant from the reservoir as in step 3 8 Unscrew the coolant filter housing from the rear of...

Page 108: ...vacuum Clean torch threads and current ring Verify cooling fans are working properly Verify proper coolant level Monthly Date Completed Jan Feb March April May June July Aug Sept Oct Nov Dec Inspect for loose wire connections Inspect contacts on main contactor for wear Inspect pilot arc relay for pitting Verify proper operation of coolant flow switches Perform coolant flow test Check gas console p...

Page 109: ...MAINTENANCE 5 20 HySpeed HT2000LHF Instruction Manual 7 ...

Page 110: ...HySpeed HT2000LHF Instruction Manual 6 1 6 Section 6 PARTS LIST Introduction See Section 3 Installation and appendices A and C to find part numbers for cables and hoses ...

Page 111: ...ing 1 75 MTG X 1 37 ID 3 6 008245 Bushing 7 8 Hole X 11 16 ID 1 7 041764 PCB Assy HT2000LHF Control PCB2 1 8 041276 PCB Assy HT2000 Anlg PCB3 1 9 041246 PCB Assy Relay HD1070 HT2000 PCB4 1 001566 Panel HT2000 Front Filter 1 001567 Cover HT2000 Front Filter Panel 1 027441 Filter 24 X 24 X 2 Fiberglass air 1 029697 HT2000 THC SA Items not shown in Figure 6 1 Used only in HT2000LHF power supplies wit...

Page 112: ...re 6 2 HT2000LHF Power Supply THC Assembly Part Item Number Description Designator Qty 129331 Contr Pnl SA HT2000LHF 1 1 001661 Pnl HT2000LHF Cont 1 2 005151 Lamp holder 1 3 005149 Bulb 120VAC LT2 1 4 005089 Lens White for 005088 1 5 041536 PC BD Assy Intlk Dsply 200 4001 PCB12 1 6 009063 Diode Ind LED Amber 7 7 002278 Cover HT2000 Cont Panel SA 1 8 005121 Pushbutton 2 NO Green Illumin PB1 LT1 1 9...

Page 113: ...0V 3φ φ 50 60Hz T1 1 4 129312 Cont Transformer SA 480V 3φ φ 60Hz T1 1 4 029404 Cont Transformer SA 600V 3φ φ 60Hz T1 1 5 041534 PC BD Assy Power Distribution PCB1 1 008322 Fuse 8A 250V 1 4 X 1 1 4 Slow F1 F2 F3 3 6 014080 Inductor 4mh 100A L1 1 7 004262 Plate Lift MAX100 80 1 001601 Plate CE LVD Lift Eye 1 001602 Gasket CE LVD Lift Eye 1 See Appendix D for location of 029316 on 400V CE power suppl...

Page 114: ...000V 2 7 008317 Fuse Semiconductor 125A 250V F1 1 8 008317 Fuse Semiconductor 125A 250V F2 1 9 014111 Transformer 30KW 200V 3φ 50Hz T2 1 9 014097 Transformer 30KW 208V 3φ 60Hz T2 1 9 014078 Transformer 30KW 240V 480V 3φ 60Hz T2 1 9 014088 Transformer 30KW 400V 3φ 50Hz T2 1 9 014158 Transformer 30KW 440V 460V 3φ 50 60Hz T2 1 9 014082 Transformer 30KW 600V 3φ 60Hz T2 1 10 005102 Thermostat 160 C 6 A...

Page 115: ...Chopper SA CH1 1 005199 Temperature Switch 82 C TSW1 1 2 129118 CH130 CE LVD Chopper SA CH2 1 005199 Temperature Switch 82 C TSW2 1 3 008509 Bushing 1 75 MTG X 1 37 ID 3 4 041564 PCB Assy Phase Loss Detection Circuit 1 HT2000LHF Power Supply Front Wall Inside Figure 6 6 HT2000LHF Power Supply Front Wall Inside 1 3 2 2 4 ...

Page 116: ...p 12 TB4 1 8 008134 Terminal Strip 8 TB5 1 9 008447 Receptacle 23 37 Std Sex 1X6 1X5 2 10 008208 Receptacle 23 37 Rev Sex 1X1 1X2 1X7 1X4 4 11 008201 Receptacle 17 14 Rev Sex 1X9 1X3 2 12 008210 Receptacle 11 4 Rev Sex 1X10 1 13 129284 Shield SA HT2000LHF Shield Sense 1 129285 HF I O PNL SA HT2000 LHF 1 14 009349 Coil Assembly 200A High Frequency T4 1 109077 Spark Gap Assembly HT2000LHF SG1 1 15 0...

Page 117: ... 1 10 029324 Heat Exchanger SA MAX200 1 027978 Heat Exchanger Water Air M5 M6 1 11 129383 Valve SA HT2000 Power Supply 1 006046 Valve Sol 240V 3 8 NPT NC V1 1 129252 Water Pump SA 1 12 128385 Kit Motor 1 3 HP Carbon 230 50 60 M1 1 13 128384 Kit Pump 70 GPH Positive Displace 1 031122 Coupler Pro Pump Motor 1 129285 HF I O PNL SA HT2000 LHF 1 14 004314 Block 200 Cathode 1 Item is not shown in Figure...

Page 118: ... Valve Ndl 1 8 FPT 125 Orf MV3 1 18 006064 Valve Ndl 1 8 FPT 125 Orf MV4 1 19 011053 Flowmeter 7 8 GPM 44 CFH FM1 1 011058 Fltube w Float BP 8 Flt 0 10 SC Cal 2 011008 Shield Plastic for 011053 or 011056 011081 Flowmeter Float Stop 20 011053 Flowmeter 7 8 GPM 44CFH FM2 1 011058 Fltube w Float BP 8 Flt 0 10 SC Cal 2 011008 Shield Plastic for 011053 or 011056 011081 Flowmeter Float Stop 21 022008 Ga...

Page 119: ...r 1 9 001137 FR HT400 DR PR ST V C Mdl LS 1 10 001138 FR HT400 DR PR ST V C Mdl RS 1 029302 Filter PNL PCB SA DR SR V C 1 11 009871 Potentiometer 500 Ohm 10 turn 2 12 008175 Receptacle Shell Size 13 9 1 13 008176 Pin 20 24 AWG Type III 6 14 041070 PC BD Assy Opto Iso 1 15 041187 PC BD Assy Dig Sta V C MAX200 1 16 004116 Heatsink DR PR SR V C 1 17 042059 IC LM340AK 5 0 1 18 009274 Capacitor 2600 UF...

Page 120: ...2 Transf mer DR PR SR V C 1 5 004119 Bracket Mtg DR PR V C 1 002122 Encl Assy PR V C 1 6 001139 PL HT400 PR V C MDL FR 1 7 001131 Flg HT400 DR PR V C MDL Fr 1 8 001137 FR HT400 DR PR ST V C Mdl LS 1 9 001138 FR HT400 DR PR ST V C Mdl RS 1 029089 Filter PNL PCB SA PR V C 1 10 008175 Receptacle Shell 13 9 Size 1 11 008176 Pin 20 24 AWG Type III 22 12 008193 Recp CPC 17 16 Standard Sex 12 13 041070 P...

Page 121: ... 008071 Strain Relief 1 2 X 375 500 1 5 008175 Receptacle Shell Size 13 9 1 6 008176 Pin 20 24 AWG Type III 7 7 008186 Socket 20 24 AWG Type III 8 8 008210 Receptacle 11 4 2 9 009041 Filter AC 1 Amp 1B3 1 10 024038 Hose Assy 4 x 7 1 11 041043 PC BD Assy UW IHS 1 12 041023 Power Source IHS 1 13 008094 Terminal Strip 8 1 Initial Height Sensing Control Console Figure 6 12 Initial Height Sensing Contr...

Page 122: ...fold 1 2 011005 Flowmeter 0 10 SC BT 8 w valve FM1 1 3 024143 Hose Assy 4 X 9 1 029831 Manifold SA 073109 H35 Manifold 1 4 005046 Pressure Switch 0 200 1 4FPT PS1 1 5 006009 Solenoid Valve 200 1 4FPT 120V NC SV5 1 023702 Cable HT2000 H35 Manifold Press Sw 1 6 008195 CACLP CPC Size 11 1 7 008205 Pin 18 16 AWG Type III CRP 4 8 008807 Receptacle Shell CPC 11 4 14X1 1 9 047055 Cable 18 2 TW PR Unshiel...

Page 123: ... 2 8 027275 Meter Elapsed Time LCD 1 003140 Relay 120VAC DP AU Cont 2 Items are not shown in Figure 6 14 Part Item Number Description Designator Qty 073045 Remote Current Control Console 1 001068 Enclosure DCC PCC MAX200 RCC 1 2 001339 Panel MAX200 RCC Front 1 3 001340 Panel MAX200 RCC Rear 1 4 005123 Thumbwheel Switch MAX200 1 5 008176 Pin 24 20 AWG Type III CRP 7 6 008193 Receptacle Shell CPC 17...

Page 124: ...Hyspeed 200A 1 220239 Shield Hyspeed 200A 1 220237 Nozzle Hyspeed 200A 1 220235 Electrode Hyspeed 200A 1 220236 Swirl Ring Hyspeed 200A 1 Hyspeed consumables are for cutting mild steel with Oxygen at 200A only Part Item Number Description Designator Qty 128369 HT2000LHF Stainless Steel Machine Torch Assy with Valve Cluster 1 020041 Torch Mounting Sleeve 2 Generic 1 2 120356 HT2000 S S Torch Main B...

Page 125: ...bleStarter 001285 Box Gray Plastic 1 1 220239 Shield Hyspeed 200A 1 2 220242 Nozzle Retaining Cap with IHS tab HySpeed 200A 1 3 220237 Nozzle Hyspeed 200A 3 5 220236 Swirl RIng Hyspeed 200A 1 7 220235 Electrode HySpeed 200A 3 027055 Lubricant Silicon 1 4 Oz Tube 1 804560 Quick Set up Card HT2000 HySpeed 1 1 2 5 3 4 Figure 6 17 HySpeed HT2000 Starter Consumable Parts ...

Page 126: ...le 100A 055 O2 2 4 020608 Nozzle 200A 086 Air N2 H35 3 4 020611 Nozzle 100A 059 Air 3 5 220236 Swirl RIng Hyspeed 200A 1 6 020607 Swirl Ring Air N2 H35 1 6 020613 Swirl Ring Air 1 6 020679 Swirl Ring Air N2 1 7 220235 Electrode HySpeed 200A 3 7 120667 Electrode HT2000 200A Oxy LL 2 7 020415 Electrode N2 H35 2 7 120547 Electrode HT2000 100A LL 2 8 020963 Water Tube PAC200T 2000 Electd Cool 1 027055...

Page 127: ...Nozzle 100A 059 Air 3 5 120833 Swirl Ring HT2000 O2 1 6 020607 Swirl Ring Air N2 H35 1 6 020613 Swirl Ring Air 1 6 020679 Swirl Ring Air N2 1 7 120667 Electrode HT2000 200A O2 LL 5 7 020415 Electrode N2 H35 5 7 120547 Electrode HT2000 100A LL 3 8 020963 Water Tube PAC200T 2000 Electd Cool 1 027055 Lubricant Silicon 1 4 Oz Tube 1 027194 Wrench Nozzle 3 4 1 027524 Wrench Nozzle 1 1 044027 O Ring Bun...

Page 128: ...Shield HT2000 Extended 2 2 120837 Nozzle Retaining Cap with IHS tab 1 3 120259 Nozzle HT2000 200A Oxygen Extended 5 4 120833 Swirl Ring HT2000 O2 2 5 120258 Electrode HT2000 Extended 5 6 120257 Water Tube Electd Cool Extended 1 027055 Lubricant Silicon 1 4 Oz Tube 1 027194 Wrench Nozzle 3 4 1 044027 O Ring Buna N 2 027347 Tool Water Tube Removal 1 Figure 6 20 HT2000 Beveling Consumable Parts 1 2 5...

Page 129: ...ve 3 way 120VAC 1 8FPT SV7 1 6 5 129118 CH130 Chopper SA CH1 CH2 1 6 6 009684 Res 4 Ohm 420W R6A R6B 1 6 7 003021 Relay 120VAC NO SPST CR1 1 6 7 009349 Coil Assembly 200A HF T4 1 6 7 009975 Cap 1400pF 20kV C4 C5 C6 3 6 7 004061 Electrode Sprk Gap 1 8 x 1 6 3 6 7 129150 HV Transformer SA 6kV T3 1 6 7 029202 Current Sensor Assembly CS1 1 6 7 129618 Switch Level SA 1 2 NPT LS1 1 6 8 029323 Switch Tem...

Page 130: ... axis of each sheet Lining up the coordinates will bring you to the source or destination blocks similar to a road map When referencing components to the wiring diagrams designations may appear to be repeated Eg C1 appears on sheet 2 in the wiring diagrams in 2 locations Sections of the power supply on that page are outlined with a dotted box and a label Within different sections the same designat...

Page 131: ...terlock Fan Feedthru LC Filter AC DC supply Fuse Ground Clamp Ground Chassis Ground Earth IGBT Inductor LED Light Pin Plug PNP Transistor Potentiometer Push Button Normally Closed MOV Push Button Normally Open Receptacle Relay Coil Relay Normally Closed Relay Normally Open Relay Solid State AC Relay Solid State DC Relay Solid State Dry SCR Shield Shunt Spark Gap Switch Flow Resistor ...

Page 132: ...re Transformer Coil Valve Solenoid Voltage Source Zener Diode VAC Source Triac Switch Pressure Normally Closed Switch Pressure Normally Open Switch 1 Pole 1 Throw Switch 1 Pole 2 Throw Switch 1 Pole 1 Throw Center Off Switch Temperature Normally Closed Switch Temperature Normally Open Time Delay Closed NC Off Time Delay Open NO Off Time Delay Open NC On Terminal Block Torch HyDefinition ...

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Page 134: ...7 5 7 Figure 7 1 HT2000LHF Coolant Flow Diagram ...

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Page 156: ...lve status for N2 timing chart N2 or Air Cutting Mode Component Idle Cutflow Preflow SV1A OFF OFF OFF SV1B ON ON ON SV2 OFF OFF ON SV3 OFF OFF OFF SV4A OFF ON OFF SV4B OFF OFF ON SV5 OFF ON ON SV6 OFF ON ON SV7 ON ON ON ...

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Page 158: ...Cutting Mode Component Idle Cutflow Preflow SV1A ON ON ON SV1B OFF OFF OFF SV2 OFF OFF ON SV3 OFF OFF ON SV4B OFF OFF ON SV4B OFF OFF ON SV5 OFF ON ON SV6 OFF ON ON SV7 ON ON ON Solenoid valve status for O2 timing chart ...

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Page 160: ...Cutting Mode Component Idle Cutflow Preflow SV1A ON ON ON SV1B OFF OFF OFF SV2 OFF OFF ON SV3 OFF OFF ON SV4B OFF OFF ON SV4B OFF OFF ON SV5 OFF ON ON SV6 OFF ON ON SV7 ON ON ON Solenoid valve status for O2 timing chart ...

Page 161: ...asma gas flow rate in Test Preflow mode Preflow plasma gas flow rate percentages are specified in the Argon Hydrogen Cut Charts FM1 Indicates the argon hydrogen plasma gas flow rate Flow rates for argon hydrogen are specified in the Argon Hydrogen Cut Charts Figure a 1 Argon Hydrogen Manifold Front Panel Controls and Indicators Argon Hydrogen Manifold FRONT PANEL CONTROLS and INDICATORS Fig a 1 In...

Page 162: ...old to Power Supply 1 Connect the receptacle end of the argon hydrogen cable to the cable connection point on the argon hydrogen manifold Figure a 2 2 Connect the other end of the cable to TB4 smaller terminal strip on the inside rear panel of the power supply Match up wires 102 103 13 and 14 to wires already connected to the strip Connect the two shield wires to points labeled as PE protective ea...

Page 163: ...ft 12 4 m 024443 50 ft 15 m 024467 75 ft 23 m 1 Turn all plasma and shield gas supply tanks OFF 2 Disconnect the 4X1 end of the valve cluster cable from the power supply off valve cable 3 Disconnect the plasma gas hose that comes from the torch and goes to SV5 4X1 end of the valve cluster cable disconnect from the power supply off valve cable Plasma gas hose disconnect at this point Figure a 4 Con...

Page 164: ...and threaded connector 015049 to the torch plasma gas hose 5 Attach one end of the argon hydrogen plasma gas torch lead to the plasma gas torch lead connection located on the front of the argon hydrogen manifold Figure a 4 6 Attach the other end of the argon hydrogen plasma gas torch lead to the 015049 connector Plasma gas torch lead connection 015049 connector Torch plasma gas hose Argon hydrogen...

Page 165: ...depth exceeds 044 inch 1 1 mm Wipe the current ring in the torch with a clean paper towel or Q tip see Figure 4 7 Refer to the Argon Hydrogen Cut Charts to choose the correct consumables for your cutting needs 2 Replace the consumable parts Refer to Changing Consumable Parts in Section 4 for detailed information on replacing consumables 3 Ensure that the torch is squared to the material Refer to S...

Page 166: ...gas console to Test Preflow Verify that the argon hydrogen supply regulator reads 120 psi 8 2 bar 2 Look at the flowmeter FM1 on the argon hydrogen manifold and set the Preflow plasma gas flow rate by referring to the Argon Hydrogen Cut Charts and turning the argon hydrogen flowmeter adjust knob MV1 3 Look at the shield gas pressure gauge PG3 on the gas console and set to the Argon Hydrogen Cut Ch...

Page 167: ...9 connector and connect the plasma hose from the torch to SV5 See Figures a 3 and a 4 6 Remove the nitrogen supply hose from the shield supply connection of the gas console 7 Connect the nitrogen supply hose to the N2 connection of the gas console See Figure a 6 8 Connect the shield gas supply hose to the shield supply connection of the gas console See Gas Console Connections in Section 3 9 Reconn...

Page 168: ...als 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 Argon Hydrogen Cut Chart and Consumable Parts Index Plasma Gas Retaining Swirl Metal Amps Shield Gas Shield Cap Nozzle Ring Electrode Page Stainless Steel Stainless Steel Aluminum Aluminum 200 H35 N2 0206...

Page 169: ... 200 amps H35 Plasma N2 Shield Argon Hydrogen Manifold 073109 Required This gas combination Hypertherm recommends a mixture of 35 hydrogen and 65 argon for the plasma gas gives maximum thickness cutting capability minimum dross levels minimum amount of surface contamination excellent weldability and excellent cut quality on thicknesses greater than 1 2 On thicknesses less than 1 2 excessive dross ...

Page 170: ... 145 25 630 1 0 Stainless Steel 100 amps H35 Plasma N2 Shield Argon Hydrogen Manifold 073109 Required This gas combination Hypertherm recommends a mixture of 35 hydrogen and 65 argon for the plasma gas gives good cut speed but may result in excessive dross Some surface nitriding and surface oxidation of alloying elements can occur 1 inch 25 4 mm 1 scfh 28 316 liter hour 1 psi 0689 bar 6 895 KPa No...

Page 171: ... 1 25 5 16 8 155 40 1000 1 1 4 32 5 16 8 165 26 660 1 1 2 38 5 16 8 170 18 460 1 3 4 44 5 16 8 180 12 300 2 50 5 16 8 185 7 180 Aluminum 200 amps H35 Plasma N2 Shield Argon Hydrogen Manifold 073109 Required This gas combination Hypertherm recommends a mixture of 35 hydrogen and 65 argon for the plasma gas gives maximum thickness cutting capability excellent cut quality and excellent weldability El...

Page 172: ...3 8 10 1 8 3 1 4 6 145 60 1530 0 5 1 2 12 1 8 3 150 50 1280 Aluminum 100 amps H35 Plasma N2 Shield Argon Hydrogen Manifold 073109 Required This gas combination Hypertherm recommends a mixture of 35 hydrogen and 65 argon for the plasma gas gives good cut speed low dross levels and is very economical 1 inch 25 4 mm 1 scfh 28 316 liter hour 1 psi 0689 bar 6 895 KPa Notes Set plasma gas inlet pressure...

Page 173: ...t Flow Pressure Setting Pressure Pressure H35 H35 psi amps psi psi 1 psi 0689 bar 6 895 KPa 29 29 50 200 120 90 81 8 SCFH Stainless Steel or Aluminum Gouging 200 amps H35 Plasma N2 Shield Argon Hydrogen Manifold 073109 Required Hypertherm recommends a mixture of 35 hydrogen and 65 argon for the plasma gas 020607 Swirl ring 020415 Electrode 020615 Nozzle 120837 Retaining cap 020485 Shield ...

Page 174: ...APPENDIX A ARGON HYDROGEN CUTTING AND GOUGING a 14 HySpeed HT2000LHF Instruction Manual 6 ...

Page 175: ...1 Toxicological Information b 4 Section 12 Ecological Information b 5 Section 13 Disposal Considerations b 5 Section 14 Transport Information b 5 Section 15 Regulatory Information b 5 Section 16 Other Information b 5 Benzotriazole COBRATEC Safety Data Section I b 7 Section II Ingredients b 7 Section III Physical Data b 7 Section IV Fire and Explosion Hazard Data b 8 Section V Health Hazard Data b ...

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Page 180: ...b 6 Figure b 1 Freezing Point of Propylene Glycol Solution of Propylene Glycol Temperature F 70 60 50 40 30 20 10 0 10 20 30 40 0 10 20 30 40 50 60 ...

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Page 185: ...en Upper Limit Sw Sig 5 3 Black Upper Limit Sw Com 9 5 Shield Drain 11 9 Black AC Power 14 8 White AC Power 7 Shield Drain 7 Key 8X2 8X3 8X4 8X5 Color Signal 4 A Red Power 15 VDC 2 B Black Common 1 C Clear Signal 3 Braid Shield 14 Part No Length 023859 25 ft 7 6m 023860 50 ft 15m 023861 75 ft 23m 023862 100 ft 30 5m 023863 150 ft 46m 023864 200 ft 61m IHS Sensor cables IHS to Inductor Probes The t...

Page 186: ...LHF Instruction Manual 6 Figure c 1 Initial Height Sensing Connections AIR CYLINDER TORCH MOUNTING SUBASSEMBLY TORCH TYPICAL SWIVEL FITTING IHS CONTROL MODULE 20 PSI REGULATED SHOP AIR TORCH LIFTER TYPICAL 14D 14A 14B 14C 14 UPPER LIMIT SWITCH AND CABLE 67 4 S 1 TB ...

Page 187: ... switch that opens when the lever is up when the torch fully retracts Install the upper limit switch behind the torch lifter as in Figure c 1 Caution Follow the cable installation procedure below to avoid electromagnetic interference problems with the torch lead set 1 Use a shielded twisted pair of 22 24 gauge wire stranded Use Belden 8761 2 At the upper limit switch connect the common wire black ...

Page 188: ...82 Bracket IND Sensor UW IHS 1 2 004083 Bracket IND IHS Torch Mounting 1 3 015005 Adapter 1 4 NPT x 4 1 4 027024 Cylinder IND Sensor UW IHS 1 5 005074 Inductive Sensor Assembly 2 020044 Clevis Torch Mounting Bracket 1 Item is not shown in Figure c 2 Figure c 2 Inductive IHS Torch Mounting Assembly with Interconnecting Leads for IHS Assembly Interconnecting Leads for the Inductive IHS System Torch ...

Page 189: ...LHF Instruction Manual d 1 6 Appendix D ELECTROMAGNETIC COMPATIBILITY General This appendix will enable a qualified electrician to install the power cable to the EMI filter on the 400V CE power supplies 073235 073236 ...

Page 190: ...le to the EMI filter first and then connect the other end to the line disconnect switch Power Supply 1 Locate the EMI filter on the top rear of the power supply see Figure d 1 2 Unscrew the 4 filter cover screws and remove the cover to access the input voltage connections at TB1 see Figure d 2 3 Insert the power cable through the strain relief see Figure d 1 4 Connect leads L1 to U L2 to V and L3 ...

Page 191: ...nal or local electrical codes This work should be performed only by qualified licensed personnel See Power Requirements and Line Disconnect Switch on page 3 4 Figure d 3 Power Cable Connections to TB1 WARNING There is line voltage at the filter even if the ON 1 pushbutton on the HT2000 power supply has not been pressed As a common safety practice ALWAYS verify that the line disconnect switch is in...

Page 192: ... 1 001558 Enclosure Hyspeed HT2000 CE Electronic Filter 1 2 001559 Cover Hyspeed HT2000 CE Top 3 008489 Bushing 1 97 ID X 2 5 Hole Black Snap 1 4 008610 Strain Relief 1 1 2NPT 1 5ID 2 Screw 1 5 029316 TB1 Input Power SA 200 2000 4X00 HD 1 6 109036 Filter 60A 440VAC 3PH 2 Stage Electronic 1 7 109040 Filter Mounting Bracket for 109036 1 1 3 2 4 5 6 7 Figure d 4 Hyspeed HT2000LHF EMI Filter Parts ...

Page 193: ...parts life will be shortened which increase production costs To optimize both consumables life and cut quality Hypertherm recommends a three stage filtering process for compressor air for removing contaminants from the air supply 1 The first stage of filtering should remove at least 99 of all particles and liquids 5 microns and larger in size 2 The second stage should be a coalescing type filter t...

Page 194: ...APPENDIX E AIR FILTERS e 2 Hyspeed HT2000LHF Instruction Manual 6 ...

Page 195: ...ing free hydrogen buildup is to install an aeration manifold on the floor of the water table to replenish the oxygen content of the water Making an Aeration Manifold Make an aeration manifold with two inch 50 mm PVC tubing with one inch 25 mm distribution lines connected to it Drill 1 8 inch 3 mm holes every six inches 150 mm in the distribution lines Cap the ends of the distribution lines and ins...

Page 196: ...APPENDIX F AERATION MANIFOLD FOR CUTTING ALUMINUM f 2 Hyspeed HT2000LHF Instruction Manual 6 ...

Page 197: ...rrent AC Plasma cutting torch AC input power connection The terminal for the external protective earthed conductor A chopper based power source Anode work clamp Temperature switch Pressure switch Plasma torch in the TEST position cooling and cutting gas exiting nozzle The power is on The power is off Volt amp curve ...

Page 198: ...APPENDIX G IEC SYMBOLS g 2 Hyspeed HT2000LHF Instruction Manual 6 ...

Page 199: ...er cord and the line disconnect switch Equipment Grounding All accessory modules that receive power from the plasma power supply must also use the power supply s ground either by connection to the PE terminal of the power supply or by direct connection to the equipment ground conductor Each module should have only one connection to ground to avoid ground loops If any enclosure is grounded to the w...

Page 200: ...local codes Place the supplementary ground rod within 20 ft 6 m of the worktable according to national or local codes If any module is grounded to the work table the work table must be grounded to the power supply or the configuration must be changed to comply with applicable national and local electrical codes A ferrite choke can be placed in the conductor between the work table ground rod and th...

Page 201: ...nection Configuration Note Configuration may vary for each installation and may require a different ground scheme Plasma Power Supply PE PE PE PE Power Cord Ground Ferrite Choke Supplementary Grounding Rod Gas Console Other Equipment receiving power from the plasma power supply Ignition Console Work Table ...

Page 202: ... is acceptable to daisy chain the grounds for the gas console and other equipment to the ignition console The ignition console should NOT be daisy chained through the other components to the work table Plasma Power Supply PE PE Power Cord Ground Ferrite Choke Supplementary Grounding Rod Gas Console Other Equipment receiving power from the plasma power supply Ignition Console Work Table PE PE ...

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