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HT4100

Plasma Arc Cutting System

- Operation -

Instruction Manual

IM-166

(P/N 801660)

for Serial Numbers

beginning with

4100-000001

Revision 4 June, 1996

HYPERTHERM, Inc.

P.O. Box 5010

Hanover, New Hampshire 03755-5010

Tel.: (603) 643-3441

Fax: (603) 643-5352

HYPERTHERM HT and MAX are trademarks of Hypertherm, Inc. and may be

registered in the United States and/or other countries

Summary of Contents for HT4100

Page 1: ...HT4100 Plasma Arc Cutting System Operation Instruction Manual 801660 Rev 4 ...

Page 2: ...ing with 4100 000001 Revision 4 June 1996 HYPERTHERM Inc P O Box 5010 Hanover New Hampshire 03755 5010 Tel 603 643 3441 Fax 603 643 5352 Copyright 1996 Hypertherm Inc All Rights Reserved HYPERTHERM HT and MAX are trademarks of Hypertherm Inc and may be registered in the United States and or other countries ...

Page 3: ......

Page 4: ...anual Operation ATTENTION Genuine Hypertherm parts are the factory recommended replacement parts for your Hypertherm system Any damage caused by the use of other than genuine Hypertherm parts is not covered by the Hypertherm warranty ...

Page 5: ...HERM s specifications and in cases of designs processes formulae or combinations not developed or purported to be developed by HYPERTHERM HYPERTHERM agrees to indemnify protect and hold harmless Distributors and their customers against any and all liability or claims in any manner imposed upon or accruing against Distributors and their customers because of the use in or about the construction or o...

Page 6: ...2 3 HT4100 Master Power Supply 2 3 HT4100 Slave Power Supply 2 3 High Frequency HF Console 2 3 Remote Voltage Current V C Control 2 4 Gas Console 2 4 Motor Valve Console 2 4 Timer Counter 2 4 Water Chiller 2 5 Initial Height Sensing IHS 2 5 Specifications 2 6 System Requirements 2 6 HT4100 Power Supplies Master Slave 2 6 PAC610 Machine Torch 2 7 High Frequency Console 2 7 Switch Remote SR V C Cont...

Page 7: ...ble Remote PR V C Module 3 6 Timer Counter 3 8 Daily Start Up 3 9 Common Cutting Faults 3 10 Technical Questions 3 11 Cut Charts 3 11 Changing Consumable Parts 3 14 Removal and Inspection 3 14 Replacement 3 14 Changing the Water Tube 3 15 Routine Inspection and Cleaning 3 16 Power Supplies 3 16 Water Chiller 3 16 Interconnections 3 16 Section 4 STANDARDS INDEX 4 1 Standards Index 4 2 APPENDIX a 1 ...

Page 8: ...nsole Front Panel Controls and Indicators 3 5 Figure 3 4 Digital Remote DR V C Front Panel Controls and Indicators 3 7 Figure 3 5 Programmable Remote DR V C Front Panel Indicators 3 7 Figure 3 5ASwitch Remote SR V C Front Panel Controls and Indicators 3 7A Figure 3 6 Timer Counter Front Panel Controls and Indicators 3 8 Figure 3 7 Changing Consumable Parts 3 15 Figure 3 8 Changing the Water Tube 3...

Page 9: ... 2 Safety Instructions 1 4 Burn Prevention 1 4 Toxic Fume Prevention 1 5 Fire Prevention 1 5 Electric Shock Prevention 1 6 Explosion Prevention 1 7 Grounding 1 8 Safety Reminders 1 9 Standards Index 1 9 1 1 Section 1 SAFETY HT4100 Instruction Manual Operation ...

Page 10: ...sed to describe situ ations that require additional information The following formats are used for each Notes A note offers additional information such as an operating tip that aids the user in operating the plasma system Caution A caution describes a situation that may cause damage to the plasma system and offers advice to avoid or rectify the situation WARNING A warning describes a situation tha...

Page 11: ...protection NOISE CAN DAMAGE HEARING Wear correct ear protection FUMES AND GASES CAN INJURE YOUR HEALTH Keep your head out of the fumes Provide ventilation exhaust at the arc or both to keep the fumes and gases from your breathing zone and the general area If ventilation is inadequate use an approved respirator HEAT SPLATTER AND SPARKS CAUSE FIRE AND BURNS Do not cut near combustible material Do no...

Page 12: ...area not to look directly at the arc unless they wear a glasses goggles or helmet Prepare the cutting area in a manner that reduces the reflection and transmission of ultraviolet light Paint walls and other surfaces with dark colors to reduce reflection Install protective screens or curtains to reduce ultraviolet transmission To protect skin against burns caused by high intensity ultraviolet light...

Page 13: ...that have held toxic materials Clean such containers thoroughly before cutting Do not cut metal or painted metals containing zinc lead cadmium or beryl lium unless the operator or anyone else subjected to the fumes is wearing respiratory equipment or an air supplied helmet Fire Prevention Cutting with a plasma system produces hot metal sparks and slag Take the follow ing precautions against fire M...

Page 14: ... for primary wiring sizes and types Inspect the primary power cord frequently for damage or cracking of the cover Bare wiring can kill Do not use the system with a damaged power cord If a power cord is damaged replace it immediately Inspect the torch leads Replace if frayed or damaged Never operate the plasma system unless the power supply unit covers are in place Exposed power supply connections ...

Page 15: ...ed by trained repair techni cians Never use a regulator for any gas other than that for which it is intended Never use a regulator that leaks creeps excessively or is physically damaged in any way Never attempt to lubricate a regulator with oil or grease Handle and use compressed gas cylinders in accordance with safety standards published by the Compressed Gas Association CGA American Welding Soci...

Page 16: ...flow restriction Grounding Before operating the plasma system Be sure the power cord is plugged into a properly grounded outlet or that the power cord ground wire is properly connected to the ground in the disconnect box If installation of the plasma system involves connecting the power cord to the power supply ensure that the power cord ground wire is properly connected Conform to CSA standards b...

Page 17: ...ce This would be hazardous to the operator and other people in the area and prevents the proper cooling of the equipment Each Hypertherm plasma system is designed to be used only with specific Hypertherm torches Do not substitute other torches which could overheat and present a potentially dangerous situation to the operator and any personnel in the area STANDARDS INDEX The Standards Index contain...

Page 18: ... 4 Gas Console 2 4 Motor Valve Console 2 4 Timer Counter 2 5 Water Chiller 2 5 Initial Height Sensing IHS 2 5 Specifications 2 6 System Requirements 2 6 HT4100 Power Supplies Master Slave 2 6 PAC610 Machine Torch 2 7 High Frequency Console 2 7 Switch Remote SR V C Control 2 7 Digital Remote DR V C Control 2 8 Programmable Remote PR V C Control 2 8 Gas Console 2 9 Water Chiller 2 9 Motor Valve Cons...

Page 19: ...0 system system interconnect diagrams and accompanying drawings HT4100 Instruction Manual Operation 801660 This manual describes the controls and indicators for the system units explains how to start up and operate the HT4100 system contains cut chart tables gives instructions to remove and replace consumable parts and provides routine inspection and cleaning information HT4100 Instruction Manual ...

Page 20: ... in the Operation section of IM166 The following descriptions briefly describe the purpose and configuration of the major units which comprise the HT4100 System HT4100 Master Power Supply This unit houses two 100 amp 15kHz chopper power supplies to produce constant current DC output Also located in this unit is the Torch Height Control THC The power supply interconnects with the HF console IHS com...

Page 21: ...l switches Programmable Remote Includes the voltage and current displays No switches or potentiometers are included All functions are controlled by the guidance machinery computer This unit also interconnects with the computer interface Gas Console This unit houses solenoid valves for plasma and shield gas flow control as well as flowmeters for plasma and shield gas flow metering valves for plasma...

Page 22: ...ving this capabililty greatly increases the life of the nozzle and electrode The water chiller is a three phase power system that directly interfaces with the HF console See Water Supply Requirements in the Pre Installation section of this manual Initial Height Sensing IHS Optional This unit used with two inductive probes is designed to automatically detect the workpiece surface and index the torc...

Page 23: ...reflow HT4100 Power Supplies Master Slave Maximum OCV U0 275 VDC Maximum Output Current I2 400 amps Output Voltage U2 150 VDC Duty Cycle Rating X 100 Ambient Temperatures Duty Cycle Power supplies will operate between 14 and 104 F 10 and 40 C Power supplies operated in an ambient temperature above 86 F 30C may show some decrease in duty cycle Cooling Forced Air Class F Input Power U1 Input Voltage...

Page 24: ...as requirements Electrode coolant flow rate 1 4 gpm 5 3 l min Weight 3 1 2 pounds 1 59 kg High Frequency Console 073077 Dimensions and Weight Width 16 41 cm Height 16 3 4 42 cm Depth 13 3 4 35 cm Weight 75 pounds 34 kg Switch Remote SR V C Control 073053 Controls Start button Activates IHS if on and initializes pilot arc Stop button Deactivates main contactor in power supplies IHS On Off switch Tu...

Page 25: ...t adjust pot Adjusts arc cutting current and displays value on LEDs Control Range Current 100 to 400 Amps Voltage 100 to 200 Volts Control Resolution Current 10 Amps Voltage 5 Volts Dimensions and Weight Width 11 1 2 29 cm Height 3 7 6 cm Depth 13 3 8 34 cm Weight 5 pounds 5 oz 2 4 kg Programmable Remote PR V C Control 055004 Controls None Controlled through guidance machinery computer Control Ran...

Page 26: ...alve Console 073079 Dimensions and Weight Width 11 1 2 29 cm Height 6 15 8 cm Depth 8 20 cm Weight 18 pounds 8 2 kg Initial Height Sensing 053016 Input Power 120 VAC from power supply Air Pressure 20 psi 1 4 bar regulated shop air input to solenoid Dimensions and Weight Width 9 23 cm Height 4 5 11 cm Depth 11 1 2 29 cm Weight 13 pounds 6 kg Timer Counter 073057 Dimensions and Weight Width 6 1 2 16...

Page 27: ...te PR V C Module 3 6 Switch Remote SR V C Module 3 6A Timer Counter 3 8 Daily Start Up 3 9 Common Cutting Faults 3 10 Technical Questions 3 11 Cut Chart 3 11 Changing Consumable Parts 3 14 Removal and Inspection 3 14 Replacement 3 14 Changing the Water Tube 3 15 Routine Inspection and Cleaning 3 16 Power Supplies 3 16 Water Chiller 3 16 Interconnections 3 16 3 1 HT4100 Instruction Manual Operation...

Page 28: ...heated Master Transformer LED When off indicates that the master power supply main transformer has overheated RHF Interlock LED When off indicates that either or both remote HF console door interlock s is disengaged Slave Interlock LED When off indicates that the slave power supply microprocessor has malfunctioned Plasma Gas LED When off indicates that the plasma gas pressure is too low Spare LED ...

Page 29: ...on Figure 3 2 Slave Power Supply Front Panel Indicators Slave Transformer Master Transformer RHF Interlock Slave Interlock Plasma Gas Spare Coolant Flow LT2 PB1 LT1 PB2 LT2 LT1 AC ON Figure 3 1 Master Power Supply Front Panel Controls and Indicators ...

Page 30: ... gas preflow SHIELD O2 FM2 and N2 FM4 flowmeters In test preflow indicate the percentage of nitrogen and oxygen required for the shield preflow gas mixture SHIELD Preflow O2 MV3 and N2 MV6 metering valves Adjusts shield gas preflow Test Cut Flow This test position is used when setting the plasma and shield gas flow rates on the flowmeters for cutting conditions as specified in the Cut Charts on pa...

Page 31: ...OPERATION 3 5 HT4100 Instruction Manual Operation Figure 3 3 Gas Console Front Panel Controls and Indicators S1 S2 S3 MV5 MV2 MV3 MV6 MV4 MV1 FM2 FM4 FM3 FM1 ...

Page 32: ...age CURRENT Adjust Pot Adjusts the cutting arc current from 100 amps to 400 amps Values are chosen from the Cut Charts and depend on the type of metal to cut and metal thickness CURRENT LEDs Displays cutting current during cut sequence UP DOWN LEDs Indicates that torch height is being adjusted up or down Programmable Remote PR V C Module Fig 3 5 VOLTAGE LEDs Displays cutting voltage during cut seq...

Page 33: ...econd delay initializes the pilot arc followed by cutting arc transfer STOP Button Deactivates the main contactor shutting off DC power to the torch which shuts off the cutting arc VOLTAGE Adjust Pot Adjusts the cutting arc voltage from 100 to 200 volts Values are chosen from the Cut Charts and depend on the type of metal to cut and metal thickness The Torch Height Control constantly monitors the ...

Page 34: ...N 3 7 HT4100 Instruction Manual Operation Figure 3 4 Digital Remote DR V C Front Panel Controls and Indicators Figure 3 5 Programmable Remote PR V C Front Panel Indicators Voltage Adjust Pot Current Adjust Pot ...

Page 35: ...Instruction Manual Operation OFF OFF TEST START STOP Voltage Adjust Pot Current Adjust Pot INITIAL HEIGHT AUTO HEIGHT PLASMA ON ON RUN START STOP Figure 3 5A Switch Remote SR V C Front Panel Controls and Indicators 12 14 92 ...

Page 36: ...C TIME LCD Counter Indicates the cumulative time that the arc is on in hours ERRORS LCD Counter w Reset Indicates the number of times that the arc cut cycle ended before the programmed current ramp down time had elapsed This reading provides a direct correlation to the long life operation of the electrode the higher the reading the shorter the electrode life Reset Figure 3 6 Timer Counter Front Pa...

Page 37: ...sumables 3 Ensure that the torch is squared to the material Refer to the HT4100 Instruction Manual Installation P N 801650 for the torch alignment procedure 4 Set Test Preflow Run Test Cut Flow toggle switch S2 on the gas console to Run 5 Set the main disconnect switches for the master and slave power supplies and the water chiller to On 6 Turn the required oxygen and nitrogen gas supplies gases O...

Page 38: ...g valves MV2 and MV5 Test cut flow rates are specified in the Cut Chart on page 3 12 14 Set switch S2 to Run after the test preflow and test cut flow rates have been set 15 The system is now ready for operation COMMON CUTTING FAULTS Torch pilot arc will initiate but will not transfer Cause can be 1 Work cable connection on cutting table not making good contact 2 Malfunction in HT4100 system See HT...

Page 39: ...cutting is causing shortened consumable life TECHNICAL QUESTIONS Claims for defective merchandise All units shipped from Hypertherm undergo rigorous quality control testing However if your system does not function correctly 1 Recheck all pre installation and installation requirements and connections in HT4100 Instruction Manual Installation P N 801650 2 If you are unable to solve the problem call ...

Page 40: ... 5 5 8 16 3 4 19 7 8 22 1 25 1 1 8 28 5 1 1 4 32 1 3 8 35 1 1 2 38 0 70 0 60 0 60 0 60 0 60 0 60 0 60 0 60 0 60 0 60 0 60 200 260 260 280 300 300 300 300 300 300 300 125 130 135 145 150 150 155 155 155 155 155 06 1 5 1 8 3 1 8 3 3 16 5 3 16 5 3 16 5 3 16 5 3 16 5 3 16 5 3 16 5 3 16 5 160 4065 145 3680 105 2650 90 2280 80 2030 70 1780 55 1400 50 1270 45 1145 40 1015 35 890 30 0 30 0 30 0 30 0 30 0 ...

Page 41: ... from the current ring If the water tube appears damaged or loose see Changing the Water Tube on page 3 15 1 Replace the electrode by screwing it back into the torch head Use the electrode socket wrench to tighten down the electrode Do not overtighten 2 Prior to installing the swirl ring apply a light coating of silicone grease to both outside O rings As a guideline you should be able to feel the ...

Page 42: ...pairing cut quality However the retaining cap should be tightened by hand only Figure 3 7 Changing Consumable Parts 6 96 Changing the Water Tube Problems and causes you may find with a defective or improperly installed water tube Short electrode life Water tube not screwed in tightly Flow switch interlock shutting down the system Water flow restricted due to loose water tube Humming or rattling so...

Page 43: ...CLEANING Power Supplies The only routine inspection and cleaning necessary on the master and slave power supplies is to keep dust and foreign matter from inside the units This can be done by removing the covers and blowing out the units with compressed air Periodically inspect the units for cleanliness and clean as required In an excessively dirty environment perform this proce dure on a weekly ba...

Page 44: ...Section 4 STANDARDS INDEX In this section Standards Index 4 2 4 1 HT4100 Instruction Manual Operation ...

Page 45: ... 0 Welding and Cutting Containers Which Have Held Combustibles obtain able from the American Welding Society 550 LeJeune Road P O Box 351040 Miami FL 33135 8 NFPA Standard 51 Oxygen Fuel Gas Systems for Welding and Cutting obtainable from the National Fire Protection Association 470 Atlantic Avenue Boston MA 02210 9 NFPA Standard 70 1978 National Electrical Code obtainable from the National Fire P...

Page 46: ...espiratory Protection obtainable from the American National Standards Institute 1430 Broadway New York NY 10018 16 Canadian Electrical Code Part 1 Safety Standards for Electrical Installations obtainable from the Canadian Standards Association 178 Rexdale Boulevard Rexdale Ontario Canada M9W1R3 ...

Page 47: ... 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 IEC SYMBOLS USED ...

Page 48: ...nducting non interrupting state by some mechanical action such as flipping a switch cap Nozzle retaining cap Holds the swirl ring electrode and nozzle inside the torch capacitor A device that stores electric energy in the form of voltage cathode The negative side of a DC power source See anode consumable Electrode nozzle swirl ring and retaining cap CSA Canadian Standards Association A product sta...

Page 49: ...escribing the degree of protection an enclosure offers against entry of objects and water I1 Rated supply current The supply current to the power source at a rated cutting condition given U1 U2 and I2 I2 Rated output cutting current kerf Slit made in a workpiece by a cutting torch kilowatt Thousand kilo watts Measurement of electrical power LED Light Emitting Diode An electronic indicator lamp lin...

Page 50: ...n fault conditions swirl ring An insulating ring that separates the electrode from the nozzle and causes the air inside the plasma torch to swirl and aid in squeezing the arc transfer A pilot arc transfers to the work when the plasma arc leaves the surface of the nozzle and attaches to the work U0 Rated Open Circuit Voltage occuring at the rated input voltage U1 U1 Rated Supply Voltage The supply ...

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