Hypertherm HT4100 Instruction Manual
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Hypertherm HT4100 Instruction Manual

Hypertherm HT4100 Instruction Manual

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HT4100
®
Plasma Arc
Cutting System
- Operation -
Instruction Manual
801660 - Rev. 4

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  • Page 1 HT4100 ® Plasma Arc Cutting System - Operation - Instruction Manual 801660 - Rev. 4...
  • Page 2 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 4 WARRANTY ATTENTION Genuine Hypertherm parts are the factory-recommended replacement parts for your Hypertherm system. Any damage caused by the use of other than genuine Hypertherm parts is not covered by the Hypertherm warranty. HT4100 Instruction Manual: Operation...

  • Page 5: Patent Indemnity

    HYPERTHERM's written consent. This warranty shall not apply to any Product which has been mishandled, incorrectly installed, modified or assembled by you or any other person. HYPERTHERM shall be liable for breach of this warranty only if it receives written notice of such breach within the applicable warranty period specified herein above. THE FOREGOING SHALL CONSTITUTE THE SOLE REMEDY TO DISTRIBUTORS OR THEIR CUSTOMERS FOR ANY BREACH BY HYPERTHERM OF ITS WARRANTY.

  • Page 6: Table Of Contents

    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 ..............
  • Page 7 TABLE OF CONTENTS Section 3 OPERATION ..................3-1 Front Panel Controls and Indicators ............... 3-2 HT4100 Master Power Supply ................3-2 HT4100 Slave Power Supply ................3-2 Gas Console ..................... 3-4 Digital Remote (DR) V/C Module ..............3-6 Programmable Remote (PR) V/C Module ............3-6 Timer/Counter ....................
  • Page 8 Figure 3-5ASwitch Remote (SR) V/C Front Panel Controls and Indicators ..3-7A Figure 3-6 Timer/Counter Front Panel Controls and Indicators ......3-8 Figure 3-7 Changing Consumable Parts ............3-15 Figure 3-8 Changing the Water Tube ..............3-16 HT4100 Instruction Manual: Operation 12-14-92...
  • Page 9 Safety Instructions ................1-4 Burn Prevention ................1-4 Toxic Fume Prevention ..............1-5 Fire Prevention ................1-5 Electric Shock Prevention ............... 1-6 Explosion Prevention ..............1-7 Grounding ..................1-8 Safety Reminders ................1-9 Standards Index .................. 1-9 HT4100 Instruction Manual: Operation...

  • Page 10: Introduction

    A warning describes a situation that presents a physical danger to the operator, and offers advice to avoid or rectify the situation. Each type of warning displays an applicable danger symbol, ie. fire, explosion, electri- cal shock, etc. HT4100 Instruction Manual: Operation...
  • Page 11 • Do not have on your person any combustibles such as a butane lighter or matches. • Pilot arc can cause burns. Keep the torch nozzle away from yourself and others when the switch is depressed. • Wear correct eye and body protection. HT4100 Instruction Manual: Operation...

  • Page 12: Safety Instructions

    Flame-retardant clothing which covers all exposed areas. Cuffless trousers to prevent entry of sparks and slag. • Hold any hand torch away from your body when pressing the start button because the pilot arc may come on immediately. HT4100 Instruction Manual: Operation...

  • Page 13: Toxic Fume Prevention

    • Quench freshly cut metal or allow metal to cool before handling it or bringing it into contact with combustible materials. • Never use a plasma system to cut containers with potentially flammable materials inside. Such containers must be thoroughly cleaned prior to cutting. HT4100 Instruction Manual: Operation...

  • Page 14: Electric Shock Prevention

    Electric Shock Prevention All Hypertherm plasma systems use high voltage (up to 280 VDC) to initiate the plasma arc. Take the following precautions when operating the plasma system: • Keep your body and clothing dry.

  • Page 15: Explosion Prevention

    • Never move or transport a cylinder without the protective valve cover in place. • Never use a gas cylinder or its contents for any purpose other than that for which it is intended. • Never lubricate cylinder valves with oil or grease. HT4100 Instruction Manual: Operation...

  • Page 16: Grounding

    • Connect the work table to a good earth ground. Consult the U.S. National Electri- Work Grounding Electrode System cal Code, Article 250, Section H , or other appropri- Table ate national or local codes. Standards Index For additional information, refer to the in this manual. HT4100 Instruction Manual: Operation...

  • Page 17: Safety Reminders

    SAFETY SAFETY REMINDERS • All Hypertherm torches are designed with a safety interlock, which turns off the power supply when the retaining cap is loosened. • Never bypass or shortcut the safety interlocks on any of the plasma system units.

  • Page 18: Section 2 Introduction & Specifications

    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 ............

  • Page 19: Introduction

    This manual gives pertinent information for the pre-installation supply requirements, installation, and post-installation requirements for the HT4100 system. Also included in this manual are specifications of the components of the HT4100 system, system interconnect diagrams, and accompanying drawings. HT4100 Instruction Manual: Operation (#801660)

  • Page 20: General

    DC current to extend the life of the torch nozzle and electrode. The HT4100 system provides the user with capability of locating the power supply and the torch apart by a maximum of 300 feet (91 m). This is accomplished by adding a remote High Frequency (HF) Console.

  • Page 21: Remote Voltage/Current (V/C) Control

    Note: The motor valve console must be mounted 10 feet (3 m) from the torch. HT4100 Instruction Manual: Operation 1-93...

  • Page 22: Timer/Counter

    This unit is interfaced to the HT4100 Slave power supply. Water Chiller The water chiller for the HT4100 system is a refrigeration unit that is capable of reducing the water coolant temperature well below ambient air and water supply temperature.

  • Page 23: Specifications

    INTRODUCTION & SPECIFICATIONS SPECIFICATIONS System Requirements Power Requirements: Refer to HT4100 power supply specifications below: Gas Requirements: Plasma Gas Type .........Oxygen (O ), *Nitrogen (N Shield Gas Types .........Oxygen (O ), and Nitrogen (N ) mixture Gas Quality Oxygen ..........99.5% pure (liquid gas recommended) Nitrogen ..........99.995% pure (liquid gas recommended)

  • Page 24: Pac610 Machine Torch

    Cut Charts Plasma and Shield Gas Flow .......Refer to the in the Operation section of the HT4100 Instruction Manual: Operation (IM166) for specific gas requirements. Electrode coolant flow rate ......1.4 gpm (5.3 l/min) Weight ............3-1/2 pounds (1.59 kg)

  • Page 25: Digital Remote (Dr) V/C Control

    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 ............12-1/2" (31.8 cm) Weight ............5 pounds-5 oz. (2.4 kg) HT4100 Instruction Manual: Operation...

  • Page 26: Gas Console

    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" (16.5 cm) Height ............2-1/2" (6.4 cm) Depth ............8-5/8" (22 cm) Weight ............3 lbs (1 kg) HT4100 Instruction Manual: Operation 1-96...
  • Page 27 Section 3 OPERATION In this section: Front Panel Controls and Indicators ............ 3-2 HT4100 Master Power Supply ............3-2 HT4100 Slave Power Supply............3-2 Gas Console ................... 3-4 Digital Remote (DR) V/C Module............ 3-6 Programmable Remote (PR) V/C Module ........3-6 Switch Remote (SR) V/C Module ..........

  • Page 28: Front Panel Controls And Indicators

    OPERATION FRONT PANEL CONTROLS AND INDICATORS HT4100 Master Power Supply (Fig. 3-1) POWER • ON (1) Pushbutton/indicator switch (PB1/LT1) Activates the power supply and its control circuits. Indicator lights when power up is complete. • OFF (0) Pushbutton switch (PB2) Shuts the power supply down.
  • Page 29 OPERATION HT4100 Instruction Manual: Operation...

  • Page 30: Gas Console

    (MV5) metering valves - Adjusts shield gas test cut flow. Run - This position enables the contactor and the subsequent firing of the arc after the gas flow rates have been set in the Test Preflow and Test Cut Flow positions. HT4100 Instruction Manual: Operation...

  • Page 31: Figure 3-3 Gas Console Front Panel Controls And Indicators

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

  • Page 32: Digital Remote (Dr) V/C Module

    Programmable Remote (PR) V/C Module (Fig. 3-5) • VOLTAGE LEDs Displays cutting voltage during cut sequence. • CURRENT LEDs Displays cutting current during cut sequence. • UP/DOWN LEDs Indicates that torch height is being adjusted up or down. HT4100 Instruction Manual: Operation...

  • Page 33: Switch Remote (Sr) V/C Module

    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. HT4100 Instruction Manual: Operation 3-6A 12-14-92...

  • Page 34: Figure 3-4 Digital Remote (Dr) V/C Front Panel Controls And Indicators

    OPERATION Voltage Adjust Pot Current Adjust Pot Figure 3-4 Digital Remote (DR) V/C Front Panel Controls and Indicators Figure 3-5 Programmable Remote (PR) V/C Front Panel Indicators HT4100 Instruction Manual: Operation...

  • Page 35: Figure 3-5Aswitch Remote (Sr) V/C Front Panel Controls And Indicators

    OPERATION Voltage Adjust Pot Current Adjust Pot START STOP START STOP INITIAL HEIGHT AUTO HEIGHT PLASMA TEST Figure 3-5A Switch Remote (SR) V/C Front Panel Controls and Indicators HT4100 Instruction Manual: Operation 3-7A 12-14-92...

  • Page 36: Timer/Counter

    This reading provides a direct correlation to the long-life operation of the electrode; the higher the reading, the shorter the electrode life. Reset Reset ERRORS ARC TIME STARTS Figure 3-6 Timer/Counter Front Panel Indicators HT4100 Instruction Manual: Operation...

  • Page 37: Daily Start-Up

    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.

  • Page 38: Common Cutting Faults

    Torch pilot arc will initiate, but will not transfer. Cause can be: Work cable connection on cutting table not making good contact. Malfunction in HT4100 system. See HT4100 Instruction Manual: Maintenance (#801670). The torch initial height is set too high.

  • Page 39: Technical Questions

    HT4100 system to be successful in plasma arc cutting. The HT4100 provides a wide travel speed operating window: usually ± 10 ipm (± 254mm/min) on most materials. The...
  • Page 40 HT4100 Operating Data (Cut) Charts Mild Steel - 300 Amp Cutting Plasma / O & N Shield Electrode Nozzle Retaining Cap Nozzle Swirl Ring PAC610 Torch 120103 120096 (cw) 120108 (cw) 020721 120107 120116 (ccw) 120115 (ccw) Preflow Cut Flow...

  • Page 41: Changing Consumable Parts

    (as a guideline for amount of silicone, see step 2 above). Insert the nozzle into the torch and tighten by hand. Use the nozzle wrench to tighten the nozzle snugly. Do not overtighten. HT4100 Instruction Manual: Operation 3-14 3-94...

  • Page 42: Changing The Water Tube

    If you suspect a problem with the water tube, you may need to replace it. 1. Disconnect power supply from power source. Changing Consumable Parts 2. Remove all consumables from torch (see - pg. 3-14). HT4100 Instruction Manual: Operation 3-15 6-96...

  • Page 43: Routine Inspection And Cleaning

    3. Look for any damage or bends in the water tube. 4. Remove and replace the water tube by using the water tube wrench (027347) supplied by Hypertherm - Fig. 3-8. When installing water tube, do not over tighten! Snug down by hand only.
  • Page 44 Section 4 STANDARDS INDEX In this section: Standards Index ..................4-2 HT4100 Instruction Manual: Operation...

  • Page 45: Section 4 Standards Index

    American Welding Society Standard AWS F4.1, ration for Welding and Cutting of Containers and Piping That Have Held Hazardous Sub- stances , obtainable from the American Welding Society, 550 LeJeune Road, P.O. Box 351040, Miami, FL 33135. HT4100 Instruction Manual: Operation...

  • Page 46: Standards Index

    , obtainable from the American National Standards Institute, 1430 Broadway, New York, NY 10018. Safety Standards for Electrical Installations Canadian Electrical Code Part 1, , obtainable from the Canadian Standards Association, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W1R3. HT4100 Instruction Manual: Operation...

  • Page 47: Appendix

    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. HT4100 Instruction Manual: Operation...

  • Page 48: Glossary

    Fundamental property of atoms that atoms can have their electrons pulled away ("ionized") and then the electrons can move about in metals or gases. An atom missing one or more electrons is called an ion. Both electrons and ions can move about in gases. HT4100 Instruction Manual: Operation...
  • Page 49 A plasma arc that attaches to the torch nozzle rather than the work. plasma An electrically charged gas is said to be "ionized". A cloud of ionized gas together with its electrons is called "plasma." HT4100 Instruction Manual: Operation...
  • Page 50 Measurement of electrical power. The ability to heat the work equivalent to a current of one ampere times an electrical force of one volt. work(piece) The object to be cut. Duty cycle at a given U and I HT4100 Instruction Manual: Operation...

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