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Hypertherm HT4001 Instruction Manual

Hypertherm HT4001 Instruction Manual

Plasma arc cutting system
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Table of Contents

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    • Section 1A Sécurité
    • Danger Avertissement Précaution
      • Risque D'explosion Argon-Hydrogène Et Méthane
      • Détonation de L'hydrogène Lors du Coupage de L'aluminium
      • Les Chocs Électriques Peuvent Être Fatals
    • Identifier Les Consignes de Sécurité
    • Le Coupage Peut Provoquer un Incendie Ou Une Explosion
    • Suivre Les Instructions de Sécurité
    • Les Chocs Électriques Peuvent Ê T Re Fatals
      • Le Coupage Peut Produire des Vapeurs Toxiques
      • Prévention des Chocs Électriques
      • L'arc Plasma Peut Provoquer des Blessures Ou des Brûlures
    • L'arc Plasma Peut Provoquer des Blessures Ou des Brû L Ures
      • Mise À la Masse Et À la Terre
      • Les Rayons de L'arc Peuvent Brûler Les Yeux Et la Peau
    • Les Rayons de L'arc Peuvent Brû L er Les Yeux Et la Peau
      • Torches À Allumage Instantané
      • Sécurité des Bouteilles de Gaz Comprimé
      • Les Bouteilles de Gaz Comprimé Peuvent Exploser en Cas de Dommages
      • Le Bruit Peut Provoquer des Problèmes Auditifs
      • Pacemakers Et Prothéses Auditives
    • Pacemakers Et Prothèses Auditives
    • Un Arc Plasma Peut Endommager Les Tuyaux Gelés
      • Étiquette de Sécurité
      • Section 2 DESCRIPTION & SPECIFICATIONS
      • Description
      • Description & Specifications
        • HT4001 Power Supply
        • Remote High Frequency (RHF) Console
        • Gas Console
        • Motor Valve Console
        • Remote Voltage/Current (V/C) Control - Optional
        • Timer/Counter - Optional
        • Water Chiller - Optional
        • Initial Height Sensing (IHS) - Optional
        • H-401 Slave Power Supply - Optional
        • Water Muffler - Optional
      • Specifications
        • System Requirements
        • HT4001 Power Supply
        • HT4001 Power Supply with Slave
      • IEC Symbols Used

    • Figure 2-1 Overall Dimensions - HT4001 Power Supply

    • Figure 2-3 PAC620 Bevel Torch Assembly with Dimensions
      • PAC620 Machine Torches
      • Remote High Frequency Console
      • Digital Remote (DR) V/C Control (077012
      • Programmable Remote (PR) V/C Control (077013
      • Gas Console
      • Motor Valve Console

    • Figure 2-2 PAC620 Standard Torch Assembly with Dimensions

    • Figure 2-8 Mounting Dimensions - Initial Height Sensing
      • Initial Height Sensing
      • Timer/Counter
      • Water Chiller
      • H-401 Power Supply
      • Water Muffler

    • Section 3 PRE-INSTALLATION
      • Introduction
      • Gas Requirements
      • Water Supply Requirements
      • Grounding Requirements
      • Power Requirements
        • Line Disconnect Switch
        • Power Cables
        • Positioning the Power Supplies
      • Transformer Configurations

    • Figure 3-1 240V Transformer

    • Figure 3-2 480V Transformer

    • Figure 3-3 200V Transformer

    • Figure 3-4 380V Transformer

    • Figure 3-5 400V Transformer

    • Figure 3-6 415V Transformer

    • Figure 3-7 575V Transformer

    • Figure 3-8 600V Transformer
      • Connecting the Power

    • Figure 3-9 Power Cable Connections
      • Torch Lifter Requirement
      • Optional Equipment
        • Water Muffler
        • Initial Height Sensing (IHS)

    • Section 4 INSTALLATION
      • Upon Receipt
      • Claims
      • Module Grounding and Grounding Checks
      • Noise Levels (Decibels)

    • Figure 4-1 Noise Levels (Decibels)
      • System Units Placement

    • Figure 4-2 Typical HT4001 System Component Placement for Gantry Cutter
      • HT4001 Interconnection Reference Map

    • Figure 4-3 HT4001 Interconnect System Diagram with IHS, Water Muffler and Slave
      • Power Supply Connections
      • Positive Lead Connection - PS to Work Table

    • Figure 4-5 RHF Cable Connections - PS to RHF Console

    • Figure 4-6 Gas Console Cable Connection - PS to Gas Console

    • Figure 4-7 Machine Interface I/O Cable Connection - PS to Computer Interface

    • Figure 4-8 Machine Interface V/C Cable Connection - PS to Computer Interface

    • Figure 4-9 Remote Serial and V/C Cables - PS to Remote V/C
      • Figure 4-10 Timer/Counter Cable and IHS Cable Connections - PS to T/C; PS to IHS

    • Figure 4-11 Water Muffler Connections - PS to Water Muffler
      • RHF Console Connections
        • Figure 4-12 RHF Connections to Water Chiller and Gas Console
        • Figure 4-13 RHF Connections to Torch - Shielded Leads
      • Gas Console Connections
        • Figure 4-14 Gas Console Connections - Gas Console to Gas Supplies; Gas Console to Torch
        • Figure 4-15 Gas Console Connections - Gas Console to Motor Valve Console
      • Motor Valve Console Connections
      • Figure 4-16 Motor Valve Console to Torch Connections
      • Initial Height Sensing Connections
        • Figure 4-17 Initial Height Sensing Connections
        • Figure 4-18 Initial Height Sensing Upper Limit Switch Connections
      • Optional Power Supply Connections
      • Figure 4-19 Hold Cable Connections to TB3
      • Mounting the Machine Torch
      • Torch Alignment

    • Section 5 OPERATION
      • Controls and Indicators
      • HT4001 Power Supply Front Panel
      • HT4001 Power Supply Rear Panel Control
        • Figure 5-1 Power Supply Front Panel Indicators
        • Figure 5-3 Gas Console Front Panel Controls and Indicators
      • Digital Remote (DR) V/C Module
      • Figure 5-4 Digital Remote (DR) V/C Front Panel Controls and Indicators
      • Programmable Remote (PR) V/C Module
      • Timer/Counter
      • Figure 5-5 Programmable Remote (PR) V/C Front Panel Indicators
      • Pre-Operation System Checkout
      • Final Torch Adjustment
      • Figure 5-8 Torch with Inductive Probes
      • Daily Start-Up
        • Figure 5-9 Gas Console Reference - Daily Startup
        • Cutting Techniques
        • How to Get Better Cut Quality
        • Dross Conditions
        • Shape of Cut Surface
        • How to Get Longer Consumable Life
        • How to Get Better Pierces
        • How to Increase Cutting Speed
        • Common Cutting Faults
        • Cut Charts
        • Technical Questions
        • Cut Chart and Consumable Parts Index
        • Changing Consumable Parts
        • Removal and Inspection
        • Replacement
        • Figure 5-10 Changing Consumable Parts
        • Changing the Water Tube
        • Figure 5-11 Changing the Water Tube
      • Section 6 PARTS LIST
      • Introduction
      • Finding Part Numbers
      • HT4001 Interconnection Reference Map
      • HT4001 Power Supply
      • Gas Console
      • Motor Valve Console
      • IHS Console
        • Figure 6-1 HT4001 Power Supply - Outside Front Panel
        • HT4001 Power Supply
        • Figure 6-2 HT4001 Power Supply - Inside Front Panel
        • Figure 6-3 HT4001 Power Supply - Front Bail
        • Figure 6-4 HT4001 Power Supply - Rear Bail
        • Figure 6-5 HT4001 Power Supply - Inside Floor
        • Figure 6-6 HT4001 Power Supply - Rear Wall Inside
        • Figure 6-7 HT4001 Power Supply - Rear Wall Outside
        • Figure 6-8 Remote High Frequency Console
        • Remote High Frequency Console
        • Figure 6-9 Gas Console
        • Gas Console
        • Figure 6-10 Motor Valve Console
        • Motor Valve Console
        • Figure 6-11 Remote V/C - Digital (DR) Control Module
      • Remote V/C - Programmable (PR) Control Module
        • Figure 6-13 IHS Console
        • IHS Console
      • Timer/Counter
      • Positive Lead - PS to Work Table and PS to Slave
        • Figure 6-18 Gas Console Cable - PS to Gas Console
        • Figure 6-21 Remote Serial Cable - PS to Remote V/C
        • Figure 6-24 IHS Interface Cable - PS to IHS
        • Figure 6-27 Cooling Hose Set - RHF Console to Water Chiller
        • Figure 6-29 Shielded Torch Leads - RHF Console to Torch
        • Figure 6-31 Nitrogen Supply Hose - Gas Console to Nitrogen Supply
        • Figure 6-34 Cut Flow Gas Hose - Gas Console to Motor Valve Console
        • Figure 6-37 Air Hose Assembly - IHS Module to Inductive Sensor Air Cylinder
        • Figure 6-40 Hold Cable - PS to Second HT4001 Power Supply
      • PAC620 Machine Torch Assembly
      • Torch Mounting Bracket
      • Consumable Parts Kits
        • Figure 6-45 Consumable Parts - PAC620 400A Bevel
        • Figure 6-46 Consumable Parts - PAC620 760A Standard
        • Figure 6-47 Consumable Parts - PAC620 760A Bevel
      • Recommended Spare Parts
        • Power Supply
        • Remote High Frequency Console
        • Gas Console
      • IHS System and Components
      • IHS Leads Packages and Components

    • Section 7 MAINTENANCE
      • Introduction
      • Routine Maintenance
        • Torch and Torch Leads
        • Power Supplies
        • Gas Console
        • Motor Valve Console
        • Remote HF Console
      • HT4001 Initialization and Sequence of Operation
      • Power Distribution Board PCB1
      • Initial Checks
        • Figure 7-1 Primary Power Measurement Location - HT4001
        • Figure 7-2 Power Distribution Board PCB1
      • Troubleshooting
      • STATUS LED Troubleshooting
      • Figure
      • Chopper Module Test Procedure
      • Figure 7-3 Chopper Module - Front View
      • Relay Board PCB4 Status Indicators
      • Relay Board PCB4 in O 2 Test Preflow
      • Relay Board PCB4 in N
        • Test Cut Flow
      • Relay Board PCB4 in N
      • Figure 7-9 Relay Board PCB4 in RUN Mode
      • Error Codes
      • Torch Coolant Draining

    • Appendix A H-401 Power Supply as Slave
      • H-401 Slave Modification
      • Current Setpoint PCB Installation
      • Current Setpoint PCB Connections
        • Figure A-1 Current Setpoint PCB Installation
        • Figure A-2 Current Setpoint PCB Connections
        • H-401 Slave Connections
          • Figure A-4 H-401 Power Cable Connections
          • Figure A-5 Slave Cable - HT4001 Power Supply to H-401 Slave Power Supply
        • HT4001 Power Supply to Work Table and RHF Console

    • Appendix B AERATION MANIFOLD
      • Aeration Manifold for Plasma Cutting Aluminum

    • Appendix C Electromagnetic Compatibility
      • EMC Introduction
      • General
        • Figure C-2 HT4001 Power Supply with EMI Filter Cover off
        • Figure C-3 Power Cable Connections to TB5
      • EMI Filter Parts List

    • Appendix D Power Cable Installation for 200/220V Power Supplies
      • General
        • Figure D-2 HT4001 Power Supply with Terminal Box Cover off
        • Figure D-3 Power Cable Connections to TB5

    • Appendix E Benzotriazole Safety Data

    • Appendix F System Grounding
      • Figure F-1 Recommended Ground Connection Configuration
      • Figure F-2 Alternate Ground Connection Configuration

    • Standards Index

    • Section 8 WIRING DIAGRAMS
      • Wiring Diagrams
      • Power Supply

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HT4001
®
Plasma Arc
Cutting System
Instruction Manual
802000 – Revision 15
EN50199
EN60974-1

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Summary of Contents for Hypertherm HT4001

  • Page 1 HT4001 ® Plasma Arc Cutting System Instruction Manual 802000 – Revision 15 EN50199 EN60974-1...
  • Page 2 IM200 Rev 14 to 15 9/18/01 Changed Page Description 1.1-1a.6 Updated safety sections Updated addresses on subsidiary page Page 1...
  • Page 3 IM200 Rev 13 to 14 5/25/2000 Changed Page Description 4.07 new graphic of center bail with new relay 4.12 new signals for remote on/off 4.13 added graphic TB4 with note about jumper 4.37 new TB4 graphic 6.10 New graphic of power supply rear bail 6.11 part number addition for on/off relay 8.05...
  • Page 4 401 power supply 7.23 new graphic of chopper a.02 changed slave modification because of HDR 401 power supply a.03-11 changed slave modification because of HDR 401 power supply 8.10 of 14 updated 401 wiring diagram portion of HT4001 schematic Page 3...
  • Page 5 IM200 Rev 11 to 12 2/1/99 Changed Page Description 0.01 uprevved because of new 340A electrodes 5.20,21 & 26 changed 340A electrodes 6.01 Fixed TOC 6.06 & 07 Removed 4 diodes from rear of front panel 6.42, 44 & 46 changed pn of 340A electrode 6.47 removed diodes from recommended spare parts...

  • Page 6: Bumped Page

    IM200 Rev 10 to 11 7/24/98 Changed Page Description 3.04 & 4.03 Added reference to grounding appendix 5.13 Clarified setting current 5.14 & 15 bumped page 6.47 Corrected PCB2 and firmware part numbers 7.13 New graphic of power distribution board, fuse f4 7.24-27 Updated LEDs on Relay board f.01-04...
  • Page 7 IM200 Rev 9 to 10 4/15/98 Changed Page Description 0.01 Uprevved to 10 - 4/15/98 with serial #4001-000805 4.36 Changed name of cable because serial i/o board is no longer required. 6.04 New graphic of power supply front panel 6.05 Changed p/n of relay pcb, control board pcb, and firmware.
  • Page 8 3/27/98 Changed Page Description IM200 Rev 8 to 9 3.04 Added note about voltage needing to be within 15% 4.07 & 6.08 New graphic of start circuit II 6.05 New rev firmware 6.09 New part no. for start circuit II 6.14 New graphic of in-rush protection circuit 6.15...
  • Page 9 IM200 Rev 7 to 8 1/16/98 Changed Page Description 0.01 Uprevved to 8 - 1/15/98 with serial #≈715 0.06 Added 2 new figure #s 0.07-.10 bumped page 2.01 Repaginated due to additional pages 2.05 Added power factor 2.07 Added figures of torches with dimensions 2.08-.14 bumped page 4.08,10 &...
  • Page 10 IM200 Rev 6 to 7 11/1/97 Changed Page Description 0.01 Uprevved to 7 - implement 11/1 with serial#603 2.06 Added 440/480 power supply numbers 3.04 Added 440V current and fuse specs 3.05 Added 440V cable size recomendation 3.09 Added 440V Transformer picture 4.04 Added torque specification 6.11...
  • Page 11 IM200 Rev 5 to 6 8/15/97 Changed Page Description 7.03 added note to check contactor contacts 7.04 & 05 bumped page 0.01 Uprevved to 6 - implement 8/15 with serial#539 0.02 Changed customer service tel. # 3.11 Changed light...contactor to lights...contactors 4.02 Changed customer service tel.
  • Page 12 IM200 Rev 4 to 5 4/14/97 Changed Page Description 5.25&26 Changed 120468, 120469 to 120470, 120471 2.05,3.02,5.09& Added tolerance to gas pressures 6.10 &.11 Removed resistor, cap from I/O panel 6.21 Added 011081 float stop 6.42-45 removed qtys from consumable parts list 6.46 removed non-ce retaining caps from CE consumable parts kits 6.47...
  • Page 13 IM200 Rev 3 to 4 12/20/96 Changed Page Description 0.01 Uprevved due to LVD changes, 360A Beveling consumables, Kip valves 0.03 updated TOC with new safety sections 0.04 changed page of changing consumable parts 1.01-1a.04 new safety section 2.02 removed reference to CE compliance 2.06 removed 380 and 415VAC references 3.11...
  • Page 14 September, 2001 Hypertherm, Inc. Hanover, NH USA www.hypertherm.com © Copyright 2001 Hypertherm, Inc. All Rights Reserved Hypertherm, HyDefinition, HT, HyLife, LongLife, MAX, PAC and Powermax are trademarks of Hypertherm, Inc., and may be registered in the United States and/or other countries...
  • Page 15 63457 Hanau-Wolfgang, Deutschland 49 6181 58 2100 Tel 49 6181 58 2134 Fax 49 6181 58 2123 (Technical Service) Hypertherm Singapore Pte Ltd No. 19 Kaki Bukit Road 2 K.B. Warehouse Complex Singapore 417847, Republic of Singapore 65 841 2489 Tel...
  • Page 16 WARRANTY ATTENTION The 380/415V CE power supply complies with the EMC European standard EN50199. Information about this standard, and other line filtering information pertaining to this power supply, is located in Appendix C of this manual. HT4001 Instruction Manual 1-96...
  • Page 17 LIMITATION OF LIABILITY GENERAL In no event shall Hypertherm be liable to any person or entity for any incidental, consequential, indirect, or Hypertherm, Inc. warrants that its Products shall be free punitive damages (including but not limited to lost...

  • Page 18: Table Of Contents

    Description ............................2-2 Specifications ........................... 2-5 IEC Symbols Used ......................... 2-13 Section 3 PRE-INSTALLATION ....................3-1 Introduction ............................3-2 Gas Requirements ........................... 3-2 Water Supply Requirements ......................3-3 Grounding Requirements ......................... 3-4 Power Requirements ........................3-4 HT4001 Instruction Manual 11-96...
  • Page 19 Remote V/C - Programmable (PR) Control Module ..............6-27 IHS Console ..........................6-29 Timer/Counter .......................... 6-30 HT4001 Cables, Leads, Torch Leads and Hoses ..............6-31 PAC620 Machine Torch Assembly ................... 6-41 Torch Mounting Bracket ......................6-41 Consumable Parts Kits ......................6-42 Recommended Spare Parts ....................
  • Page 20 IHS Leads Packages and Components ................... 6-48 Section 7 MAINTENANCE ......................7-1 Introduction ..........................7-2 Routine Maintenance ......................... 7-3 HT4001 Initialization and Sequence of Operation ..............7-5 Initial Checks ..........................7-11 Troubleshooting ........................7-14 STATUS LED Troubleshooting ....................7-20 Chopper Module Test Procedure ..................... 7-22 Relay Board PCB4 Status Indicators ..................
  • Page 21 Figure 4-2 Typical HT4001 System Component Placement for Gantry Cutter ............. 4-4 Figure 4-3 HT4001 Interconnect System Diagram with IHS, Water Muffler and Slave ..........4-5 Figure 4-4 Negative Lead and Pilot Arc Lead Connections - PS to RHF Console Positive Lead Connection - PS to Work Table ....................
  • Page 22 Changing Consumable Parts ........................5-33 Figure 5-11 Changing the Water Tube ......................... 5-34 Figure 6-A HT4001 Interconnect Reference Map with IHS, Water Muffler and Slave ..........6-3 Figure 6-1 HT4001 Power Supply - Outside Front Panel ..................... 6-4 Figure 6-2 HT4001 Power Supply - Inside Front Panel ....................
  • Page 23 Air Hose Assembly - IHS Module to Inductive Sensor Air Cylinder ............6-39 Figure 6-38 Inductive IHS Torch Mounting Assembly ....................6-39 Figure 6-39 IHS Sensor Cables - IHS Module to IHS Probes ..................6-39 HT4001 Instruction Manual viii 1-98...
  • Page 24 Figure a-4 H-401 Power Cable Connections ........................ a-7 Figure a-5 Slave Cable - HT4001 Power Supply to H-401 Slave Power Supply ............a-9 Figure a-6 Slave Connections - HT4001 Power Supply to H-401 Slave Power Supply HT4001 Power Supply to Work Table and RHF Console ................a-11 Figure b-1 Aeration Manifold ............................
  • Page 25 TABLE OF CONTENTS Figure d-2 HT4001 Power Supply with Terminal Box Cover Off ................... d-3 Figure d-3 Power Cable Connections to TB5 ....................... d-4 Figure f-1 Recommended Ground Connection Configuration ..................f-2 Figure f-2 Alternate Ground Connection Configuration ....................f-3...
  • Page 26 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 Hypertherm Plasma Systems...

  • Page 27: Recognize Safety Information

    • Install an aeration manifold on the floor of the water closed container. table to eliminate the possibility of hydrogen • Do not cut containers that have held combustible detonation. Refer to the Appendix section of this materials. manual for aeration manifold details. Hypertherm Plasma Systems 11-98...

  • Page 28: Electric Shock Can Kill

    • Provide a disconnect switch close to the power grounding conductor first. supply with properly sized fuses. This switch allows • Each Hypertherm plasma system is designed to be the operator to turn off the power supply quickly in used only with specific Hypertherm torches. Do not an emergency situation.

  • Page 29: A Plasma Arc Can Cause Injury And Burns

    Work Table Connect the work table to an earth power cord ground. Fasten the retaining nut tightly. ground, in accordance with appropriate national or • Tighten all electrical connections to avoid excessive local electrical codes. heating. Hypertherm Plasma Systems 4-99...

  • Page 30: Compressed Gas Equipment Safety

    Protection Association, 470 Atlantic Avenue, Boston, MA 02210 Hazardous Substances, American Welding Society 10. OSHA, Safety and Health Standards, 29FR 1910 550 LeJeune Road, P.O. Box 351040, Miami, FL 33135 U.S. Government Printing Office, Washington, D.C. 20402 Hypertherm Plasma Systems 11-98...

  • Page 31: Warning Lable

    Use welding helmet with correct shade of filter. Wear complete body protection. Become trained and read the instructions before working on the machine or cutting. Do not remove or paint over (cover) 110212 warning labels. Hypertherm Plasma Systems 8-99...

  • Page 32: Section 1A Sécurité

    Les bouteilles de gaz comprimé peuvent exploser en cas de dommages............1a-5 Le bruit peut provoquer des problèmes auditifs ....................1a-5 Pacemakers et prothèses auditives ......................1a-5 Un arc plasma peut endommager les tuyaux gelés ..................1a-5 Étiquette de sécurité .............................1a-6 Hypertherm Systèmes plasma 1a-1 2/12/01...

  • Page 33: Identifier Les Consignes De Sécurité

    • Ne pas couper de récipients contenant des matières Se référer à l’annexe du manuel pour plus de combustibles. renseignements sur les collecteurs d’aération. 1a-2 Hypertherm Systèmes plasma 2/12/01...

  • Page 34: Les Chocs Électriques Peuvent Être Fatals

    Ce dispositif permet à • Chaque système plasma Hypertherm est con ç u pour ê t re l’opérateur d’arr ê t er rapidement la source de courant en utilisé uniquement avec des torches Hypertherm cas d’urgence.

  • Page 35: L'arc Plasma Peut Provoquer Des Blessures Ou Des Brûlures

    Bien serrer l’écrou de retenue. Table de travail Raccorder la table de travail à la terre, • S’assurer que toutes les connexions sont bien serrées conformément aux codes de sécurité locaux ou nationaux pour éviter la surchauffe. appropriés. 1a-4 Hypertherm Systèmes plasma 2/12/01...

  • Page 36: Sécurité Des Bouteilles De Gaz Comprimé

    LES TUYAUX GELÉS • Se tenir le plus loin possible de la source de courant. Les tuyaux gelés peuvent ê t re endommagés ou éclater si l'on essaie de les dégeler avec une torche plasma. Hypertherm Systèmes plasma 1a-5 2/12/01...

  • Page 37: Étiquette De Sécurité

    6. Se former à la technique du coupage et lire les instructions avant de manipuler l’équipement ou de procéder au coupage. 7. Ne pas retirer ou peindre (recouvrir) les étiquettes de sécurité. 1a-6 Hypertherm Systèmes plasma 2/12/01...

  • Page 38: Section 2 Description & Specifications

    Water Muffler - Optional ..............2-4 Specifications ..................2-5 System Requirements ..............2-5 HT4001 Power Supply..............2-5 HT4001 Power Supply with Slave ..........2-5 PAC620 Machine Torches .............. 2-7 Remote High Frequency Console ..........2-8 Digital Remote (DR) V/C Control ............ 2-9 Programmable Remote (PR) V/C Control ........

  • Page 39: Description

    Five nozzle sizes produce high-quality cuts throughout the range of cut thicknesses. The plasma gases used with the HT4001 system are oxygen, for cutting mild steel, and nitrogen, for cutting stainless steel, aluminum and other non-ferrous materials. The following descriptions briefly describe the purpose and configuration of the HT4001 System components.

  • Page 40: Gas Console

    • Voltage and current displays. No switches or potentiometers included. All functions controlled by the guidance machinery computer. Current Remote - Used with HT4001 systems without THC. Includes: • Thumbwheel switch for setting cutting current. Note: See IM191 RCC Installation for more information on the Current Remote.

  • Page 41: Timer/Counter - Optional

    Water Chiller - Optional The water chiller for the HT4001 system is a refrigeration unit capable of reducing the water supply temperature and increasing the water pressure to the RHF console. Reducing the water temperature greatly increases the life of the nozzle and elec- trode.

  • Page 42: Specifications

    DESCRIPTION & SPECIFICATIONS SPECIFICATIONS System Requirements Power Requirements: Refer to HT4001 Power Supply specifications below: Gas Requirements: Plasma Gas Types ..........Oxygen (O ), Nitrogen (N Gas Quality Oxygen ............99.5% Nitrogen ............99.995% Oxygen Gas Inlet Pressure ......... 120 psi +/- 10 psi (8.3 bar +/- 0.7 bar) Nitrogen Gas Inlet Pressure ........

  • Page 43: Figure 2-1 Overall Dimensions - Ht4001 Power Supply

    ), 3Ø, 60 Hz @ 89A (I 600 VAC (U ), 3Ø, 60 Hz @ 86A (I Figure 2-1 Overall Dimensions - HT4001 Power Supply Dimensions and Weight: Width ..............34" (863 mm) Maximum Height ..........51" (1295 mm); 63" (1600 mm) on CE units and 200/220V units Maximum Depth ..........

  • Page 44: Figure 2-2 Pac620 Standard Torch Assembly With Dimensions

    15.37" (390 mm) 6.02" (153 mm) 9.35" (238 mm) 2.5" (64 mm) 0.62" (16 mm) 1.88" 0.4" (48 mm) 2" 1.98" 1.2" (10 mm) (51 mm) (50 mm) (30 mm) Figure 2-3 PAC620 Bevel Torch Assembly with Dimensions HT4001 Instruction Manual 1-98...

  • Page 45: Remote High Frequency Console

    Width (Max.) ............14.63" (372 mm) Height ..............16.75" (425 mm) Depth ..............16.00" (406 mm) Weight ..............75 lbs (34 kg) 16.00" 12.38" 13.63" 14.63" 5/16" dia.(4) Figure 2-4 Mounting Dimensions (bottom view) - RHF Console HT4001 Instruction Manual 1-98...

  • Page 46: Digital Remote (Dr) V/C Control (077012

    Depth (Max,) ............12.50" (318 mm) Weight ..............5 lbs - 5 oz. (2.4 kg) 11.40" 10.50" .45" 1.20" 6.50" 5" 11.65" 7/32" dia. (4) (Programmable Remote V/C Control Shown) Figure 2-5 Mounting Dimensions (bottom view) - Remote V/C Control HT4001 Instruction Manual 1-98...

  • Page 47: Gas Console

    Height ..............4.25" (110 mm) Depth ..............8" (200 mm) Weight ..............14 lbs (6.3 kg) 11.50" 10.75" 10.25" 8" 7" 6" 5/16" dia. (4) Figure 2-7 Mounting Dimensions (bottom view) - Motor Valve Console 2-10 HT4001 Instruction Manual 1-98...

  • Page 48: Figure 2-8 Mounting Dimensions - Initial Height Sensing

    Width ..............6.50" (165 mm) Height ..............2.50" (64 mm) Depth ..............8.50" (220 mm) Weight ..............3 lbs (1 kg) 5/32" dia. (4) 6.50" 3.38" .50" 6.25" " 1.70 8.50" Figure 2-9 Mounting Dimensions (bottom view) - Timer/Counter HT4001 Instruction Manual 2-11 1-98...

  • Page 49: Water Chiller

    Weight ..............6 lbs (2.7 kg) Pump Dimensions and Weight: Width ..............11" (280 mm) Height ..............19" (480 mm) Depth ..............17" (430 mm) Weight ..............85 lbs (38.6 kg) Refer also to Water Muffler Instruction Manual (801730). 2-12 HT4001 Instruction Manual 4-00...

  • Page 50: Iec Symbols Used

    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. HT4001 Instruction Manual 2-13 1-98...
  • Page 51 Power Cables ................. 3-5 Positioning the Power Supplies ............. 3-6 Transformer Configurations ..............3-7 Connecting the Power ..............3-11 Torch Lifter Requirement ..............3-12 Optional Equipment ................3-12 Water Muffler ................3-12 Initial Height Sensing (IHS) ............3-13 HT4001 Instruction Manual...

  • Page 52: Section 3 Pre-Installation

    If questions arise at any time, call Technical Service listed in the front of this manual or your authorized Hypertherm distributor. GAS REQUIREMENTS The HT4001 system requires a supply gas purity of 99.995% for nitrogen and 99.5% for oxygen. The customer must supply the source gas. Hypertherm recommends using liquid gas containers.

  • Page 53: Water Supply Requirements

    A corrosion inhibitor can be added to the water in the water table to extend the life of the table and the workpiece. When using the water muffler system with the HT4001, special filtering of the water table water is necessary. See Optional Equipment - Water Muffler on page 3-12 for details.

  • Page 54: Grounding Requirements

    PRE-INSTALLATION GROUNDING REQUIREMENTS Properly ground the HT4001 system for personal safety and to prevent emission of high-frequency interference. See Appendix F for system grounding requirements. Connect the worktable to a high-quality earth ground from within 20 feet (6 m) of the table.

  • Page 55: Line Disconnect Switch

    Power Cables Wire sizes vary based on the distance of the receptacle from the main box. HT4001 Power Supplies The wire sizes listed below are taken from the National Electric Code 1990 handbook, table 310.16. Use a 4-conductor (3 conductor w/ground) input power cable with a conductor temperature rating of 60°...

  • Page 56: Positioning The Power Supplies

    3. Do not place any filter device over the air intake locations. This reduces cooling efficiency and VOIDS THE WARRANTY. HT4001 Instruction Manual...

  • Page 57: Transformer Configurations

    PRE-INSTALLATION TRANSFORMER CONFIGURATIONS Three-phase input ØA ØB ØC Figure 3-1 240V Transformer Three-phase input ØA ØB ØC Figure 3-2 480V Transformer HT4001 Instruction Manual...

  • Page 58: Figure 3-3 200V Transformer

    PRE-INSTALLATION TRANSFORMER CONFIGURATIONS (cont.) ØA ØC ØB Figure 3-3 200V Transformer ØA ØB ØC Figure 3-4 380V Transformer HT4001 Instruction Manual 10-95...

  • Page 59: Figure 3-5 400V Transformer

    PRE-INSTALLATION TRANSFORMER CONFIGURATIONS (cont.) ØB ØA ØC ØB ØA ØC Figure 3-5 400V Transformer Figure 3-6 415V Transformer ØA ØB ØC Figure 3-6a 440V Transformer HT4001 Instruction Manual 11-97...

  • Page 60: Figure 3-7 575V Transformer

    PRE-INSTALLATION TRANSFORMER CONFIGURATIONS (cont.) ØA ØB ØC Figure 3-7 575V Transformer ØC ØA ØB Figure 3-8 600V Transformer HT4001 Instruction Manual 3-10...

  • Page 61: Connecting The Power

    ON. These indicators are a warning that there is line voltage at the contactors even if the circuit breaker on the HT4001 power supply is OFF. As a common safety practice, ALWAYS verify that the line disconnect switch is in the OFF position before installing, disconnecting or servicing in these areas.

  • Page 62: Torch Lifter Requirement

    Attach the filter to the pump with approximately four feet of 3/4 inch I.D. #12 hose. The customer may supply his/her own water pump and water hose or purchase a pump with or without hose through Hypertherm. Please refer to water muffler system part numbers listed on the following page, and water muffler instruction manual 801730 for further information.

  • Page 63: Initial Height Sensing (Ihs)

    Power Requirements The customer must provide the power cable for the water-muffler pump. The pumps provided by Hypertherm take a three-phase input. Part numbers and corresponding voltages are listed below. Input current information is provided on the motor data plate. Present pump systems all draw less than 20 amps. Select cable sizes accordingly.
  • Page 64 Claims ....................4-2 Module Grounding and Grounding Checks ........4-3 Noise Levels (Decibels) ..............4-3 System Units Placement..............4-4 HT4001 Interconnection Reference Map ..........4-5 Power Supply Connections..............4-6 RHF Console Connections ............... 4-22 Gas Console Connections ..............4-26 Motor Valve Console Connections............ 4-30 Initial Height Sensing Connections ...........

  • Page 65: Section 4 Installation

    Claims for damage during shipment — If your unit was damaged during shipment, you must file a claim with the carrier. Hypertherm will furnish you with a copy of the bill of lading upon request. If you need additional assistance, call our Customer Service group at 1-800-737-2978.

  • Page 66: Module Grounding And Grounding Checks

    • Ensure the power cord ground wire is properly connected to the ground in the line disconnect box. • Ensure the power cord ground wire is properly connected to the HT4001 power supply chassis. Refer to Connecting the Power in the Pre-Installation section of this manual.

  • Page 67: System Units Placement

    • See Section 2 for mounting dimensions of all units. • Ground all external modules in the HT4001 system to earth. • To prevent leaks in the system, tighten all gas and water connections to the following specifications: Gas or water...

  • Page 68: Ht4001 Interconnection Reference Map

    Shielded torch leads 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 Cables Slave requirements , etc. Reference to installation steps Figure 4-3 HT4001 Interconnect System Diagram with IHS, Water Muffler and Slave HT4001 Instruction Manual...

  • Page 69: Power Supply Connections

    Negative Lead - PS to Remote High Frequency (RHF) Console Pass the negative 2 lead through one of the 2" bushings in the lower rear of the HT4001 power supply and connect to the lower bar (-) on the center bail rear as shown in Fig. 4-4.

  • Page 70: Positive Lead Connection - Ps To Work Table

    Start Circuit Assembly - (on Center Bail Front) Work Table Cathode Block Inductor Coil RHF Console RHF Console Figure 4-4 Negative Lead and Nozzle Lead Connections - PS to RHF Console Positive Lead Connection - PS to Work Table HT4001 Instruction Manual 5-00...
  • Page 71 SV6/Inj. H BLACK SV6/Inj. H WHITE SHIELD FS2/Flow SW BLACK FS2/Flow SW GREEN SHIELD FS1/Flow SW BLACK PS1/Pressure SW BLUE SHIELD S1,S2/Door Intlk BLACK S1,S2/Door Intlk YELLOW SHIELD BROWN Pilot Arc Relay BLACK SHIELD ORANGE BLACK SHIELD HT4001 Instruction Manual 1-98...

  • Page 72: Figure 4-5 Rhf Cable Connections - Ps To Rhf Console

    INSTALLATION Power Supply NEGATIVE (-) NOZZLE WATER RHF Console Figure 4-5 RHF Cable Connections - PS to RHF Console HT4001 Instruction Manual 6-96...
  • Page 73 SV2, SV3/O Preflow BROWN SHIELD SV1A/Plasma O SV1A/Plasma O GREEN SHIELD SV1B/Plasma O BLACK SV1B/Plasma O ORANGE SHIELD PS1, PS2/Plasma Pressure PS1, PS2/Plasma Pressure WHITE SHIELD S3, Increase/Decrease S3. Increase/Decrease BROWN SHIELD Spare Spare BLUE SHIELD HT4001 Instruction Manual 4-10 1-98...

  • Page 74: Figure 4-6 Gas Console Cable Connection - Ps To Gas Console

    INSTALLATION Power Supply Gas Console Figure 4-6 Gas Console Cable Connection - PS to Gas Console HT4001 Instruction Manual 4-11 12-96...
  • Page 75 ∞ Signals are AC relays. DC relays are available as an option from Hypertherm by ordering kit: 128404 †WARNING When installing or servicing the HT4001, AC or DC line voltages may be present on the UP, DOWN and TRANSFER signals even if the power supply line disconnect switch is OFF. Make certain that all line disconnect switches relating to the HT4001 system are OFF during installation and when servicing.

  • Page 76: Figure 4-7 Machine Interface I/O Cable Connection - Ps To Computer Interface

    **Move jumper to TB4 terminals 2&3 to enable a remote ON/OFF switch 24 VAC AUXILIARY (INTER- LOCKED WITH AUTO STOP) Power Supply Machine Computer Interface Figure 4-7 Machine Interface I/O Cable Connection - PS to Computer Interface HT4001 Instruction Manual 4-13 5-00...
  • Page 77 POWER SUPPLY CONNECTIONS (CONT.) Machine Interface V/C Cable - PS to Machine Interface Note: If HT4001 system uses the digital remote V/C unit to set voltage and current, skip this step. The machine interface V/C cable is used only with the programmable remote.

  • Page 78: Figure 4-8 Machine Interface V/C Cable Connection - Ps To Computer Interface

    INSTALLATION Power Supply Machine Computer Interface Figure 4-8 Machine Interface V/C Cable Connection - PS to Computer Interface HT4001 Instruction Manual 4-15...
  • Page 79 INSTALLATION POWER SUPPLY CONNECTIONS (CONT.) See IM191 RCC Installation for installation of Remote Current Control to HT4001. 9 Remote Serial Cable - PS to Remote V/C Connect this cable from the power supply to either the digital or programmable remote.

  • Page 80: Figure 4-9 Remote Serial And V/C Cables - Ps To Remote V/C

    INSTALLATION Power Supply Digital Remote Programmable Remote Figure 4-9 Remote Serial and V/C Cables - PS to Remote V/C HT4001 Instruction Manual 4-17...
  • Page 81 11 Timer/Counter Cable - PS to Timer/Counter Pass the timer/counter cable through one of the 2" bushings in the lower rear of the HT4001 power supply and connect to TB3. TB3 is located on the inside rear wall of the power supply.

  • Page 82: Figure 4-10 Timer/Counter Cable And Ihs Cable Connections - Ps To T/C; Ps To Ihs

    INSTALLATION Power Supply TB3 - Power Supply IHS Module 11 X 1 Timer/Counter Figure 4-10 Timer/Counter Cable and IHS Cable Connections - PS to T/C PS to IHS HT4001 Instruction Manual 4-19 10-98...
  • Page 83 PS End Pump End 1X10 Part No. Length 023866 50 ft (15 m) 023867 75 ft (23 m) 023868 100 ft (31 m) SIGNAL END (1X10) COLOR Black Water Muffler Coil White AC Neutral Green Ground HT4001 Instruction Manual 4-20 1-98...

  • Page 84: Figure 4-11 Water Muffler Connections - Ps To Water Muffler

    INSTALLATION Power Supply Figure 4-11 Water Muffler Connections - PS to Water Muffler HT4001 Instruction Manual 4-21...

  • Page 85: Rhf Console Connections

    024261 11.5 ft (3.5 m) 024036 35 ft (10.5 m) 024345 75 ft (23 m) 024037 40 ft (12.2 m) 024346 100 ft (30.5 m) 024130 12 ft (3.6 m) 024132 14 ft (4.2 m) HT4001 Instruction Manual 4-22 1-96...

  • Page 86: Figure 4-12 Rhf Connections To Water Chiller And Gas Console

    INSTALLATION NEGATIVE (-) NOZZLE TORCH WATER WATER OUT WATER IN RHF Console RHF Console RETURN DISCHARGE Water Chiller Gas Console Figure 4-12 RHF Connections to Water Chiller and Gas Console HT4001 Instruction Manual 4-23 12-96...
  • Page 87 028509 15 ft (4.5 m) 028514 40 ft (12 m) 028510 20 ft (6 m) 028515 45 ft (13.5 m) 028511 25 ft (7.5 m) 028516 50 ft (15 m) 028512 30 ft (9 m) HT4001 Instruction Manual 4-24 6-96...

  • Page 88: Figure 4-13 Rhf Connections To Torch - Shielded Leads

    Cathode Block Green Brass Ring RHF Console RHF Console Pilot Arc Lead- Connection THREADED END INSULATING SLEEVE Green to Green White to White Torch Red to Red Figure 4-13 RHF Connections to Torch - Shielded Leads HT4001 Instruction Manual 4-25 7-96...

  • Page 89: Gas Console Connections

    024036 35 ft (10.5 m) 024345 75 ft (23 m) 024261 11.5 ft (3.5 m) 024037 40 ft (12.2 m) 024346 100 ft (30.5 m) 024130 12 ft (3.6 m) 024132 14 ft (4.2 m) HT4001 Instruction Manual 4-26 11-97...

  • Page 90: Figure 4-14 Gas Console Connections - Gas Console To Gas Supplies; Gas Console To Torch

    INSTALLATION Gas Console Gas Supplies INSULATING SLEEVE Left-hand fitting to left-hand fitting Torch Figure 4-14 Gas Console Connections - Gas Console to Gas Supplies Gas Console to Torch HT4001 Instruction Manual 4-27 12-96...
  • Page 91 60 ft (18 m ) SV5 Plasma Off Black SV5 Plasma Off 023649 35 ft (10.5 m) 023654 75 ft (23 m) Ground Shield MV1 Decrease Black 120VAC Neut. Brown Ground Shield MV1 Increase Ground Shield HT4001 Instruction Manual 4-28 12-96...

  • Page 92: Figure 4-15 Gas Console Connections - Gas Console To Motor Valve Console

    INSTALLATION Gas Console Motor Valve Console Figure 4-15 Gas Console Connections - Gas Console to Motor Valve Console HT4001 Instruction Manual 4-29 12-96...

  • Page 93: Motor Valve Console Connections

    4-38. Plasma-Off Off Valve cable Plasma Plasma lead off-valve lead Function Motor Valve Wire Color Off-Valve Conn. Plasma Off & Vent Black Drain Ground Clear Part No. Length 129158 14 ft (4 m) 4-30 HT4001 Instruction Manual 11-97...

  • Page 94: Figure 4-16 Motor Valve Console To Torch Connections

    INSTALLATION Motor Valve Console INSULATING SLEEVE Plasma off-valve lead connections TORCH BODY Figure 4-16 Motor Valve Console to Torch Connections HT4001 Instruction Manual 4-31 12/95...

  • Page 95: Initial Height Sensing Connections

    2 ft (.6 m) 023869 40 ft (12 m) Part No. Length 023889 2 ft (.6 m) 023870 40 ft (12 m) Function IHS End Color Probe End Power (+15 VDC) Common Black Signal Clear Shield Braid 4-32 HT4001 Instruction Manual 2-95...

  • Page 96: Figure 4-17 Initial Height Sensing Connections

    INSTALLATION AIR CYLINDER INDUCTIVE IHS CONTROL PROBES MODULE TORCH MOUNTING BRACKET TORCH LIFTER SWIVEL FITTING TORCH (TYPICAL) 20 PSI REGULATED SHOP AIR Figure 4-17 Initial Height Sensing Connections HT4001 Instruction Manual 4-33...
  • Page 97 4. Route the cable through the strain relief to connect the cable wires to 1TB. 5. Connect the shield drain wire (uninsulated) to 1TB-10 (#S). This connects the cable shield to the HT4001 frame. The shield drain must not touch the IHS module case.

  • Page 98: Figure 4-18 Initial Height Sensing Upper Limit Switch Connections

    INSTALLATION UPPER LIMIT SWITCH AND CABLE IHS CONTROL MODULE TORCH LIFTER Figure 4-18 Initial Height Sensing Upper Limit Switch Connections HT4001 Instruction Manual 4-35...

  • Page 99: Optional Power Supply Connections

    OPTIONAL POWER SUPPLY CONNECTIONS 29 Hold cable - PS to Second HT4001 Power Supply When using a multi-torch system, the hold cable interfaces the two HT4001 power supplies. Make connections at TB3 on both supplies. TB3 is located on the inside rear wall of the HT4001 power supply.

  • Page 100: Figure 4-19 Hold Cable Connections To Tb3

    INSTALLATION 24 VAC AUXILIARY (INTER- LOCKED WITH AUTO STOP) Figure 4-19 Hold Cable Connections to TB3 HT4001 Instruction Manual 4-37 5-00...

  • Page 101: Mounting The Machine Torch

    Figure 4-20 Mounting the Machine Torch (with IHS probes) Figure 4-21 Torch Alignment (without IHS probes) Torch Alignment To guarantee the torch is at right angles to the workpiece, align the torch with a square at 0° and 90°. See figure 4-21. 4-38 HT4001 Instruction Manual...

  • Page 102: Section 5 Operation

    In this section: Controls and Indicators ............... 5-2 HT4001 Power Supply Front Panel ..........5-2 HT4001 Power Supply Rear Panel Control ........5-2 Gas Console ................... 5-4 Digital Remote (DR) V/C Module............ 5-6 Programmable Remote (PR) V/C Module ........5-7 Timer/Counter .................

  • Page 103: Controls And Indicators

    When illuminated, indicates that the coolant flow to the electrode is inadequate. • PLASMA GAS LED When illuminated, indicates that the plasma gas pressure is inadequate. HT4001 Power Supply Rear Panel Control (Fig. 5-2) POWER • UP Position (1) In this position, AC is sent to the control transformer, turning the power supply on.

  • Page 104: Figure 5-1 Power Supply Front Panel Indicators

    OPERATION STATUS RHF DOOR TRANSFORMER COOLING WATER PLASMA GAS Figure 5-1 Power Supply Front Panel Indicators Figure 5-2 Power Supply Rear Panel Circuit Breaker HT4001 Instruction Manual...
  • Page 105 O Injection flow meter (FM3) - Indicates the percentage of injection water flow as indicated in the Cut Charts . • O Injection metering valve (MV4) - Adjusts injection water flow as indicated in the Cut Charts . HT4001 Instruction Manual...

  • Page 106: Figure 5-3 Gas Console Front Panel Controls And Indicators

    OPERATION HYPERTHERM (FM1) (FM2) (FM3) (PG1) (S1) (PG2) (PG3) (MV2) (MV3) (MV4) (MV1) (S2) HT4001 Figure 5-3 Gas Console Front Panel Controls and Indicators HT4001 Instruction Manual 6-95...

  • Page 107: Digital Remote (Dr) V/C Module

    CURRENT LEDs Displays cutting current. • UP / DOWN LEDs Indicates that torch height is being adjusted up or down. Voltage Adjust Pot Current Adjust Pot Figure 5-4 Digital Remote (DR) V/C Front Panel Controls and Indicators HT4001 Instruction Manual...

  • Page 108: Programmable Remote (Pr) V/C Module

    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 STARTS ARC TIME ERRORS Figure 5-6 Timer / Counter Front Panel Indicators HT4001 Instruction Manual...

  • Page 109: Pre-Operation System Checkout

    Safety section. Turn main disconnect switches to the HT4001 power supply and water chiller OFF before proceeding. The following procedure is for an HT4001 system with a water chiller, an IHS system with upper limit switch, and a Digital Remote (DR) V/C control module.
  • Page 110 Cut Charts. 11. Set S2 to Test Cut Flow . Set the cut flow rate on the O or N flow meters using the MV1 metering valve. Select the test cut flow rates from the Cut Charts. HT4001 Instruction Manual 3-97...
  • Page 111 DOWN indicator light on the V/C module will go off and the probes will retract. At this point, set initial height to OFF and depress the STOP button. You are now ready for Final Torch Adjustment. HT4001 Instruction Manual 5-10...

  • Page 112: Final Torch Adjustment

    Press the STOP button to terminate the plasma arc. Verify that the UP indicator lights and the torch retracts to the upper limit switch. HT4001 Instruction Manual 5-11...
  • Page 113 If all pre- installation and installation directives have been followed and you are still experiencing difficulty with the system, feel free to call Hypertherm's Field Service group at 1-800-643-9878. HT4001 Instruction Manual...

  • Page 114: Daily Start-Up

    Before operating this system, you must read the Safety section thoroughly! Wear proper clothing. Your cutting environment must meet requirements outlined in the Safety section. Turn main disconnect switches to the HT4001 power supply and water chiller OFF before proceeding.

  • Page 115: Figure 5-9 Gas Console Reference - Daily Startup

    14. Verify that there is a uniform conical water pattern at the front of the torch. If the pattern is irregular, shut the power supply down at the main disconnect switch and check the nozzle and swirl ring. Replace with new parts, if worn or damaged. HT4001 Instruction Manual 5-14 6-98...

  • Page 116: Cutting Techniques

    How to Get Better Cut Quality In order to get the best cut quality, verify that the HT4001 system is set up according to the Daily Start-Up procedure. The three major components of cut quality are: cut angle, dross, and shape of cut surface.

  • Page 117: Dross Conditions

    Maintain the correct torch height and cut speed to keep the cut face straight. 1. Concave cut face (bevel on inside) • Caused by standoff distance being too low. Increasing the arc voltage will increase the standoff distance and straighten the cut face. HT4001 Instruction Manual 5-16...

  • Page 118: How To Get Longer Consumable Life

    Program the lead out when the drop part is the one wanted, but do not program the lead out into the drop part. • Use a chain cut, if possible. • Purge the gas lines before cutting. HT4001 Instruction Manual 5-17...

  • Page 119: How To Get Better Pierces

    Long consumable life is difficult to achieve when cutting plate that is magnetized or becomes magnetized easily. Call Hypertherm's Technical Service department (1-800-643-9878) if you suspect the type of metal you are cutting causes shortened consumable life.

  • Page 120: Common Cutting Faults

    Short consumable life - See How to Get Longer Consumable Life on page 5-17. 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. Re-check all pre-installation and installation requirements and connections.

  • Page 121: Cut Chart And Consumable Parts Index

    CE regulations. Cap removal tool (004732) must be used to put on and remove the retaining caps. Part numbers for the CE retaining caps are indicated in the cut charts. HT4001 without Slave - CUT CHART AND CONSUMABLE PARTS INDEX Consum.
  • Page 122 HT4001 without Slave PAC620 Torch - Standard Consumables Mild Steel - Oxygen Plasma Retaining Cap Nozzle Swirl Ring Electrode 020579 (Vect) 020623 (cw) 020086 (cw) 020663 020246 (Vesp) 120015 (ccw) 020392 (ccw) 260A 120466 - CE (Vect) 120630 Water Tube - Standard...
  • Page 123 HT4001 without Slave PAC620 Torch - Standard Consumables Mild Steel - Nitrogen Plasma Retaining Cap Swirl Ring Nozzle Electrode 020039 (cw) 020579 (Vect) 020089 020082 020246 (Vesp) 020042 (ccw) (.120 in/3 mm) Water Tube - Standard 020990 120466 - CE (Vect)
  • Page 124 HT4001 without Slave PAC620 Torch - Standard Consumables Stainless Steel - Nitrogen Plasma Swirl Ring Retaining Cap Nozzle Electrode 020039 (cw) 020579 (Vect) 020089 020082 020042 (ccw) 020246 (Vesp) (.120 in/3 mm) Water Tube - Standard 020990 120466 - CE (Vect)
  • Page 125 HT4001 without Slave PAC620 Torch - Standard Consumables Aluminum - Nitrogen Plasma Retaining Cap Swirl Ring Nozzle Electrode 020579 (Vect) 020039 (cw) 020089 020082 020042 (ccw) 020246 (Vesp) (.120 in/3 mm) Water Tube - Standard 020990 120466 - CE (Vect)
  • Page 126 HT4001 without Slave PAC620 Torch - Beveling Consumables Mild Steel - Oxygen Plasma Nozzle Retaining Cap Swirl Ring Electrode 120384 (cw) 120390 (Vect) 020623 (cw) 260A 120385 (ccw) 120391 (Vesp) 120015 (ccw) 020975 Water Tube - O Bevel 120470 - CE (Vect)
  • Page 127 HT4001 without Slave PAC620 Torch - Beveling Consumables Mild Steel - Oxygen Plasma Nozzle Retaining Cap Swirl Ring Electrode 120384 (cw) 120390 (Vect) 120460 (cw) 340A 120385 (ccw) 120391 (Vesp) 120461 (ccw) 120836 Water Tube - O Bevel 120470 - CE (Vect)
  • Page 128 HT4001 without Slave PAC620 Torch - Beveling Consumables Mild Steel or Stainless Steel - Nitrogen Plasma Retaining Cap Nozzle 120390 (Vect) 120386 Swirl Ring 120391 (Vesp) (.120 in/3 mm) 020039 (cw) Electrode 020042 (ccw) 020968 Water Tube - N Bevel...
  • Page 129 HT4001 without Slave PAC620 Torch - Beveling Consumables Aluminum - Nitrogen Plasma Retaining Cap Nozzle 120390 (Vect) 120386 Swirl Ring 120391 (Vesp) (.120 in/3 mm) 020039 (cw) Electrode 020042 (ccw) 020968 Water Tube - N Bevel 120387 020991 120470 - CE (Vect) (.166 in/4.2 mm)
  • Page 130 Note: If arc does not transfer when set at twice the torch standoff (in the case of thick metal being cut at high current). gradually lower the initial height of the torch until transfer occurs. HT4001 Instruction Manual 5-29 11-96...
  • Page 131 Note: If arc does not transfer when set at twice the torch standoff (in the case of thick metal being cut at high current), gradually lower the initial height of the torch until transfer occurs. HT4001 Instruction Manual 5-30 11-96...
  • Page 132 Set initial torch height (before piercing) to approximately twice the Torch Standoff distance for the material you are cutting. Note: If arc does not transfer when set at twice the torch standoff (in the case of thick metal being cut at high current). gradually lower the initial height of the torch until transfer occurs. HT4001 Instruction Manual 5-31...
  • Page 133 Set initial torch height (before piercing) to approximately twice the Torch Standoff distance for the material you are cutting. Note: If arc does not transfer when set at twice the torch standoff (in the case of thick metal being cut at high current). gradually lower the initial height of the torch until transfer occurs. HT4001 Instruction Manual 5-32...

  • Page 134: Changing Consumable Parts

    Do not use an excessive amount of grease. Too much grease will plug the swirl ring ports, causing improper gas flow during operation. HT4001 Instruction Manual 5-33 11-96...

  • Page 135: Figure 5-10 Changing Consumable Parts

    Unless using the CE cap tool for CE retaining caps, the retaining cap should be tightened by hand only. Retaining Cap Nozzle Electrode Swirl Ring Water Tube Torch Main Body Current Ring O-Ring Figure 5-10 Changing Consumable Parts HT4001 Instruction Manual 5-34 11-96...

  • Page 136: Changing The Water Tube

    - Fig. 5-11. When installing water tube, do not overtighten! Snug down by hand only. WARNING Always disconnect the power supply from the main power source before inspecting or changing the torch parts. Figure 5-11 Changing the Water Tube HT4001 Instruction Manual 5-35 11-96...
  • Page 137 Remote V/C - Programmable (PR) Control Module ..........6-27 IHS Console ......................6-29 Timer/Counter ...................... 6-30 HT4001 Cables, Leads, Torch Leads and Hoses ..........6-31 PAC620 Machine Torch Assembly ..............6-41 Torch Mounting Bracket ..................6-41 Consumable Parts Kits..................6-42 PAC620: HT4001 without Slave, Standard .............

  • Page 138: Section 6 Parts List

    Find the system component reference number or letter in the diagram, and find the same reference number or letter in the parts list. Components with many parts (such as the HT4001 power supply) are additionally broken down to major components and subassemblies.

  • Page 139: Ht4001 Interconnection Reference Map

    1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 Cables Slave requirements , etc. Reference to parts in Parts List Figure 6-A HT4001 Interconnect Reference Map with IHS, Water Muffler and Slave HT4001 Instruction Manual...

  • Page 140: Figure 6-1 Ht4001 Power Supply - Outside Front Panel

    PARTS LIST Figure 6-1 HT4001 Power Supply - Outside Front Panel HT4001 Instruction Manual 4-98...

  • Page 141: Ht4001 Power Supply

    PARTS LIST HT4001 Power Supply A : Outside Front Panel Part Item Number Description Designator Qty. 001451 Panel, HT4001 Power Supply 027080 Fan 225 CFM 120VAC 50/60Hz 027080 Fan 225 CFM 120VAC 50/60Hz 027080 Fan 225 CFM 120VAC 50/60Hz 027080...

  • Page 142: Figure 6-2 Ht4001 Power Supply - Inside Front Panel

    PARTS LIST Figure 6-2 HT4001 Power Supply - Inside Front Panel HT4001 Instruction Manual 2-99...
  • Page 143 PARTS LIST HT4001 Power Supply A : Inside Front Panel Part Item Number Description Designator Qty. 129160 CH100-CE/LVD Chopper SA 129160 CH100-CE/LVD Chopper SA 129160 CH100-CE/LVD Chopper SA 129160 CH100-CE/LVD Chopper SA 041564 PCB Assy:Phase Loss Det. Circuit PCB21 HT4001 Instruction Manual...

  • Page 144: Figure 6-3 Ht4001 Power Supply - Front Bail

    PARTS LIST Figure 6-3 HT4001 Power Supply - Front Bail HT4001 Instruction Manual 3-98...
  • Page 145 PARTS LIST HT4001 Power Supply A : Front Bail (Wall) Part Item Number Description Designator Qty. 008317 Fuse: 125A 250V 008317 Fuse: 125A 250V 008317 Fuse: 125A 250V 008317 Fuse: 125A 250V 129349 HT4001 Start Circuit SA II 009739 Diode:1000V 100A...

  • Page 146: Figure 6-4 Ht4001 Power Supply - Rear Bail

    PARTS LIST Figure 6-4 HT4001 Power Supply - Rear Bail 6-10 HT4001 Instruction Manual 5-00...
  • Page 147 PARTS LIST HT4001 Power Supply A : Rear Bail (Wall) Part Item Number Description Designator Qty. 001456 Bail: HT4001 Power Supply 041534 PCB Assy: Power Dist. PCB1 041377 PCB Assy: 9251 Iso-Amp PCB11 029903 Control Xfrmr SA: 200-220V/50Hz 029905 Control Xfrmr SA: 240-480V/60Hz...

  • Page 148: Figure 6-5 Ht4001 Power Supply - Inside Floor

    PARTS LIST Figure 6-5 HT4001 Power Supply - Inside Floor HT4001 Instruction Manual 6-12...
  • Page 149 PARTS LIST HT4001 Power Supply A : Inside Floor Part Item Number Description Designator Qty. 001450 Base: HT4001 Power Suppy 014173* Transformer: HT4001 80kW 200/3/50 014172** Transformer: HT4001 80kW 480/3/60 014174*** Transformer: HT4001 80kW 380-415/3/50 014175**** Transformer: HT4001 80kW 575-600/3/60...

  • Page 150: Figure 6-6 Ht4001 Power Supply - Rear Wall Inside

    PARTS LIST Figure 6-6 HT4001 Power Supply - Rear Wall Inside HT4001 Instruction Manual 6-14 3-98...
  • Page 151 PARTS LIST HT4001 Power Supply A : Rear Wall Inside Part Item Number Description Designator Qty. 003152 Circuit Breaker: 3 P, 5A 600V 24V-TC 029887 Harness: HT4001 Power Supply 008073 Terminal Board: 16-Term 008079 Terminal Board: 12-Term 008210 Receptacle Shell: CPC 11-4 Rvs Sex...

  • Page 152: Figure 6-7 Ht4001 Power Supply - Rear Wall Outside

    PARTS LIST Figure 6-7 HT4001 Power Supply - Rear Wall Outside HT4001 Instruction Manual 6-16 6-95...
  • Page 153 PARTS LIST HT4001 Power Supply A : Rear Wall Outside Part Item Number Description Designator Qty. 001452 Panel, HT4001 Power Supply Rear 001457 Enclosure: HT4001 Contactor 003116 Contactor: 170A 3Ø 120VAC Coil CON1 003172 Contactor:HT4001 250A IEC CON1 008052 Strain relief: 2" NPT Basket...

  • Page 154: Figure 6-8 Remote High Frequency Console

    PARTS LIST NEGATIVE (-) WATER Located behind item 41 TORCH Figure 6-8 Remote High Frequency Console 6-18 HT4001 Instruction Manual 7-96...

  • Page 155: Remote High Frequency Console

    Remote High Frequency Console B (077010) Part Item Number Description Designator Qty. 077010 HT4001 RHF Console 001466 Encl: HT4001 RHF CSL 004078 Shld Adptr:200/400/500/HD1070 005100 Switch, Door Interlock S1, S2 008082 Bshg: 1/2 ID X 5/8 Hole 008212 Strainrlf: 1/2NPT X .197-.354 008482...

  • Page 156: Figure 6-9 Gas Console

    PARTS LIST HYPERTHERM HT4001 20 21 22 Figure 6-9 Gas Console 6-20 HT4001 Instruction Manual 12-96...

  • Page 157: Gas Console

    Description Designator Qty. 073216 HT4001 Gas Console III 001335 Encl: HT400X/2000 Gas Csl 129089 Front Pnl SA HT4001 Gas Csl III 001463 Pnl:HT4000 Gas Cnsl II Front 004117 Cap:Needle Valve 005042 Tgl Sw: SP MOM ON/OFF/ON 005181 Tgl Sw: DPDT Maint ON/NONE/ON...

  • Page 158: Figure 6-10 Motor Valve Console

    PARTS LIST 9 10 15 16 15 16 2A 2B 14 17 14 17 Figure 6-10 Motor Valve Console 6-22 HT4001 Instruction Manual 12-96...

  • Page 159: Motor Valve Console

    Motor Valve Console D (073214) Part Item Number Description Designator Qty. 073214 HT4001 Motor Valve Console 002218 Encl: 2000/400X Mtr Valve Csl 006109 Sol Valve: 150# Manif 120V 2-Way NC SV4A 006109 Sol Valve: 150# Manif 120V 2-Way NC SV4B 006063 Mtr Valve: Elec 1/8FPT .125 orf...

  • Page 160: Figure 6-11 Remote V/C - Digital (Dr) Control Module

    PARTS LIST 10 11 Figure 6-11 Remote V/C - Digital (DR) Control Module HT4001 Instruction Manual 6-24...
  • Page 161 IC: Regulator +5V 1.5A 009274 Capacitor, 2600 UF 15VDC 008097 Terminal, 1/16 Pnl Swg Mt 008098 Terminal, 1/16 Pnl Prs Mt 041076 PC BD Assy Rem Volt Disp 041077 PC BD Assy Rem Curr Disp HT4001 Instruction Manual 6-25 12-96...

  • Page 162: Remote V/C - Programmable (Pr) Control Module

    PARTS LIST Figure 6-12 Remote V/C - Programmable (PR) Control Module HT4001 Instruction Manual 6-26...
  • Page 163 Terminal, 1/16 Pnl Swg Mt 041371 PC BD Assy: 750A PR V/C 004116 Heatsink, DR/PR SR V/C 009274 Capacitor, 2600 UF 15VDC 042059 IC: Regulator +5V 1.5A 008097 Terminal, 1/16 Pnl Swg Mt 008098 Terminal, 1/16 Pnl Prs Mt HT4001 Instruction Manual 6-27 1-95...

  • Page 164: Figure 6-13 Ihs Console

    PARTS LIST Figure 6-13 IHS Console HT4001 Instruction Manual 6-28...

  • Page 165: Ihs Console

    024038 Hose Assy, 1/4 Blk #4 x 7" 041043 PC BD Assy Ind-IHS 041023 Power Source, IHS/PCC Xmtr 008094 Terminal Strip (8) * See also page 6-47 for breakdown of IHS system and leads components HT4001 Instruction Manual 6-29 1-95...

  • Page 166: Timer/Counter

    Pin:24-20 AWG Type III + CRP 008193 RCPT Shell:CPC 17-16 Std Sex 11X1 027274 Counter, Self Powered LCD 027275 Meter, Self Powered ET – 003140 Relay:120VAC DP AU Cont STARTS ARC TIME ERRORS 11 X 1 Figure 6-14 TImer/Counter HT4001 Instruction Manual 6-30...

  • Page 167: Positive Lead - Ps To Work Table And Ps To Slave

    75 ft (22.9 m) 123029 170 ft (51.9 m) 023766 100 ft (30.5 m) 023768 200 ft (61 m) 123065 110 ft (33.6 m) 023769 300 ft (91.5 m) Figure 6-17: PS/RHF Cable - PS to RHF Console 6-31 HT4001 Instruction Manual 1-98...

  • Page 168: Figure 6-18 Gas Console Cable - Ps To Gas Console

    125 ft (38.1 m) 023853 35 ft (10.7 m) 023857 150 ft (45.8 m) 023854 50 ft (15.3 m) 023858 200 ft (61 m) Figure 6-20: Machine Interface V/C Cable - PS to Machine Interface HT4001 Instruction Manual 6-32 4-97...

  • Page 169: Figure 6-21 Remote Serial Cable - Ps To Remote V/C

    125 ft (38.1 m) 023791 50 ft (15 m) 023794 150 ft (46 m) 023792 75 ft (23 m) 123027 170 ft (51.9 m) 023793 100 ft (30.5 m) Figure 6-23: TImer/Counter Cable - PS to Timer/Counter 6-33 HT4001 Instruction Manual 4-97...

  • Page 170: Figure 6-24 Ihs Interface Cable - Ps To Ihs

    Figure 6-25: Water Muffler Air Control Cable - PS to Water Muffler Air Control Box 1X10 Part No. Length 023866 50 ft (15.3 m) 023867 75 ft (22.9 m) 023868 100 ft (30.5 m) Figure 6-26: Water Muffler Pump Cable - PS to Water Muffler Pump HT4001 Instruction Manual 6-34 4-97...

  • Page 171: Figure 6-27 Cooling Hose Set - Rhf Console To Water Chiller

    12 ft (3.7 m) 024258 50 ft (15.3 m) 024132 14 ft (4.3 m) 024179 53 ft (16.2 m) 024033 15 ft (4.6 m) Figure 6-28: Injection Water Hose - RHF Console to Gas Console 6-35 HT4001 Instruction Manual 4-97...

  • Page 172: Figure 6-29 Shielded Torch Leads - Rhf Console To Torch

    85 ft (25.9 m) 024470 180 ft (54.9 m) 024206 100 ft (30.5 m) 024333 200 ft (61 m) 024481 110 ft (33.6 m) Figure 6-30: Oxygen Supply Hose - Gas Console to Oxygen Supply HT4001 Instruction Manual 6-36 4-97...

  • Page 173: Figure 6-31 Nitrogen Supply Hose - Gas Console To Nitrogen Supply

    60 ft (18.3 m) 024309 30 ft (9.2 m) 024357 75 ft (22.9 m) 024322 35 ft (10.7 m) 024358 100 ft (30.5 m) Figure 6-33: Preflow Gas Hose - Gas Console to Motor Valve Console 6-37 HT4001 Instruction Manual 4-97...

  • Page 174: Figure 6-34 Cut Flow Gas Hose - Gas Console To Motor Valve Console

    Hose Assy: 1/4 Blue Part No. Length Hose Assy: 3/16 129158 14 ft (4.3 m) RH 'A' 60" Blue RH 'A' 10' Figure 6-36: Motor Valve Console Lead Assembly - Motor Valve Console to Torch HT4001 Instruction Manual 6-38 4-97...

  • Page 175: Figure 6-37 Air Hose Assembly - Ihs Module To Inductive Sensor Air Cylinder

    Length 023888 2 ft (.6 m) 023869 40 ft (12.2 m) Part No. Length 023889 2 ft (.6 m) 023870 40 ft (12.2 m) Figure 6-39: IHS Sensor Cables - IHS Module to IHS Probes HT4001 Instruction Manual 6-39 4-97...

  • Page 176: Figure 6-40 Hold Cable - Ps To Second Ht4001 Power Supply

    25 ft (7.6 m) 023344 150 ft (45.8 m) 023342 50 ft (15.3 m) Figure 6-40: Hold Cable - PS to Second HT4001 Power Supply Part No. Length 123377 25 ft (7.6 m) Figure 6-41: Slave Cable - PS to H-401 Slave...

  • Page 177: Pac620 Machine Torch Assembly

    PAC620 Standard Torch Main Body 020990 Water Tube:400/600/170 Electdcool 020663 Electrode: O2 020623 Swirl Ring: O2 020086 Nozzle: .099 O2 020579 Ret Cap:PAC620 Standard (Vectra) TORCH MOUNTING BRACKET 020046 Torch Mounting Bracket (2") with Clevis 6-41 HT4001 Instruction Manual 6-96...

  • Page 178: Consumable Parts Kits

    PARTS LIST CONSUMABLE PARTS KITS PAC620 Consumable Kit: HT4001 without Slave, Standard Figure 6-44 Consumable Parts - PAC620 400A Standard Part Item Number Description 028825 PAC620 Parts Kit: HT4001 w/o Slave, Standard 020663 Electrode: O2, 260A 120630 Electrode: O2, 340A...

  • Page 179: Figure 6-45 Consumable Parts - Pac620 400A Bevel

    PARTS LIST PAC620 Consumable Kit: HT4001 without Slave, Bevel Figure 6-45 Consumable Parts - PAC620 400A Bevel Part Item Number Description 028826 PAC620 Parts Kit: HT4001 w/o Slave, Bevel 020968 Electrode: PAC620 Bev N2 020975 Electrode: PAC620 Bev O2 020039...

  • Page 180: Figure 6-46 Consumable Parts - Pac620 760A Standard

    PARTS LIST CONSUMABLE PARTS KITS (cont.) PAC620 Consumable Kit: HT4001 with Slave, Standard Figure 6-46 Consumable Parts - PAC620 760A Standard Part Item Number Description 028827 PAC620 Parts Kit: HT4001 w/ Slave, Standard 020285 Electrode: N2 020663 Electrode: O2, 260A...

  • Page 181: Figure 6-47 Consumable Parts - Pac620 760A Bevel

    PARTS LIST PAC620 Consumable Kit: HT4001 with Slave, Bevel Figure 6-47 Consumable Parts - PAC620 760A Bevel Part Item Number Description 028828 PAC620 Parts Kit: HT4001 w/ Slave, Bevel 020968 Electrode: PAC620 Bev N2 020975 Electrode: PAC620 Bev O2 020039 Swirl Ring: N2, .120/.166/.187...
  • Page 182 PARTS LIST CONSUMABLE PARTS KITS (cont.) PAC620 Consumable Kit: HT4001 CE without Slave, Standard Part Number Description 128130 PAC620 Parts Kit: HT4001 CE w/o Slave, Standard 020663 Electrode: O2, 260A 120630 Electrode: O2, 340A 020082 Electrode: N2, 400A 020039 Swirl Ring: N2, .120/.166/.187...

  • Page 183: Recommended Spare Parts

    LT1,LT2 027080 Fan: 225CFM 120VAC 50/60 Hz M1-M4,M6 027079 Fan: 450-550 CFM 120VAC 50/60 Hz M5, M7 041588 PCB Assy: HT4001 Control Board II PCB2 081038 Firmware: HT4001 041246 PCB Assy: 2000/HD Relay PCB4 041359 PCB Assy: HT4001 750A THC Mother...

  • Page 184: Ihs System And Components

    Ind. IHS Ind. IHS Ind. IHS Ind. IHS Ind. IHS Ind. IHS Sensor Cables Sensor Cables Sensor Cables Sensor Cables Sensor Cables Sensor Cables 40 Ft 40 Ft 40 Ft 40 Ft 40 Ft 40 Ft HT4001 Instruction Manual 6-48 12-96...

  • Page 185: Section 7 Maintenance

    Power Supplies................7-3 Gas Console ..................7-4 Motor Valve Console ............... 7-4 Remote HF Console ................ 7-4 HT4001 Initialization and Sequence of Operation........ 7-5 Initial Checks ..................7-11 Troubleshooting.................. 7-14 STATUS LED Troubleshooting ............7-20 Chopper Module Test Procedure ............7-22 Relay Board PCB4 Status Indicators ..........

  • Page 186: Introduction

    MAINTENANCE INTRODUCTION The HT4001, and all Hypertherm plasma systems, undergo rigorous testing prior to shipment and should require little maintenance if proper installation and operation procedures are followed. In this section are: routine maintenance procedures, initialization and sequence of operation flowcharts, an initial checks procedure, a troubleshooting guide to aid in servicing the HT4001 system including a troubleshooting guide for the STATUS indica- tors, a chopper module test procedure and a description of the relay board status LEDs.

  • Page 187: Routine Maintenance

    MAINTENANCE ROUTINE MAINTENANCE The HT4001 system is designed to require little regular maintenance under normal use. The following maintenance checks, are suggested to keep your system in top running condition. Torch and Torch Leads (See also Torch Coolant Draining at the end of this section) Inspection Inspect the torch and torch leads on a routine basis.

  • Page 188: Gas Console

    • Open the cover and inspect the interior. Check all cables and hoses for wear and damage. Check for loose connections, look for areas of discoloration due to overheating. Check for plumbing leaks. HT4001 Instruction Manual 5-97...

  • Page 189: Ht4001 Initialization And Sequence Of Operation

    HT4001 INITIALIZATION AND SEQUENCE OF OPERATION On the following page is a flowchart outlining the system initialization during proper HT4001 operation. This flowchart details system functioning from the time the power supply circuit breaker is turned ON, up to the ready state.

  • Page 190: Power Distribution Board Pcb1

    Isolation PCB (PCB11) Terminal strip TB4 (If Slave in System) - Serial I/O PCB (PCB10) Start Circuit PCB (PCB14) µP Control Board (PCB2) STATUS LEDs on Interlock Display Board (PCB5) are extinguished: System initialization is now complete. HT4001 Instruction Manual 11-96...
  • Page 191 SV5 near torch (Plasma Off), SV6 in RHF Console (Injection Water) ON; SV4 in Motor Valve Console (Preflow/Operate) OFF (closed); Gas and water flow. In Gas Console, adjust Preflow Plasma gas (with MV2 (N2) and/or MV3 (O2)) and Injection Water (with MV4). Page 7 - 8 HT4001 Instruction Manual...
  • Page 192 (with S3 on Gas Console) MV1 (Plasma Motor Valve) in Motor Valve Console activated. Select RUN (with S2 on Gas Console) All valves OFF (except SV1 if in N2 mode). Gas and water stop flowing. Page 7 - 9 HT4001 Instruction Manual...
  • Page 193 IHS Installed? Y e s detect plate surface, and retract. CON1 and CON2 in HT4001 power supply (Contactors) close; CR1 in HT4001 power supply (Pilot Arc relay) closes; LT2 (DC Power) light ON; SV2 (N2 Preflow), SV3 (O2 Preflow) ON (open);...
  • Page 194 SCRs OFF (if slave is in system) SV4 (Preflow/Cut Flow) OFF; SV5 (Plasma Off) OFF; SV6 (Water Injection) OFF; Machine Motion stops. Water Muffler Water Muffler Y e s pump OFF. installed? SV6 (Shield On) OFF; Sequence complete. HT4001 Instruction Manual 7-10 8-97...

  • Page 195: Initial Checks

    For the 400 volt CE power supplies, measure the voltage between the U, V and W terminals of TB5 in the EMI filter located on the top of the HT4001 power supply. Refer to Appendix C. Also refer to the wiring diagram in Section 8, if required.

  • Page 196: Figure 7-1 Primary Power Measurement Location - Ht4001

    ON. These indicators are a warning that there is line voltage at the contactors even if the circuit breaker on the HT4001 power supply is OFF. Use extreme care when measuring primary power in these areas. Voltages present at the terminal block and...

  • Page 197: Figure 7-2 Power Distribution Board Pcb1

    PCB1 fuses and associated pins, connectors and wiring between power distribution board connector REC1 and control transformer secondary T1. Also, check wiring and connections between T1, CB1, CON1, and L1 and L2. Repair and/or replace defective component(s) if necessary. HT4001 Instruction Manual 7-13 7-98...

  • Page 198: Troubleshooting

    SHOCK HAZARD: Always use caution when servicing a power supply when the covers are removed. Dangerous voltages exist within the power supply which could cause injury or death. If questions or problems arise during servicing, call the Hypertherm Technical Services Department at 1-800-647-9878. Move circuit...
  • Page 199 6. Cannot adjust gas to proper level. Check and repair any kinks in hosing line. 6.2. Leak in gas hose. Check for and repair/replace leaking hose. 6.3. Supply hose inner diameter is too small. Use larger diameter hose. HT4001 Instruction Manual 7-15 11-96...
  • Page 200 Console. If wiring is OK, check for 120VAC when activating switch. If there is no 120VAC, check voltage/wiring from S3 to power distribution board (PCB1). Repair and/or replace defective component(s). 10. No injection water flow. See problem 7. HT4001 Instruction Manual 7-16...
  • Page 201 • If a spark is not observed at the gaps, replace T1. If there is a spark, shut down system, and replace capacitors C5A and C5B. (Always replace the capacitors in pairs). HT4001 Instruction Manual 7-17 11-96...
  • Page 202 3 of 13 in the wiring diagrams). The voltage between any two of the three points for each chopper should be equal to 200VAC. If there is no voltage at any of the above points, replace CON1. HT4001 Instruction Manual 7-18 3-98...
  • Page 203 14.7. Choppers are defective or not functioning. See Chopper Module Test Procedure later in this section. 14.8. Input voltage has dropped below 15% of nominal value. See Error Codes later in this section and Power Require- ments in Section 3. HT4001 Instruction Manual 7-19 3-98...

  • Page 204: Status Led Troubleshooting

    When one of the STATUS LEDs illuminates, there is a fault condition that must be corrected in order for the HT4001 power supply to become operational. If more than one LED illuminates, the system has multiple interlock problems that must be corrected.
  • Page 205 Check wiring, cables and connectors from REC3 of PCB1 to pins 14&15 of gas console cable receptacle. If wiring is OK, and inlet gas pressure is OK, PS1 and/or PS2 may need to be replaced. Repair and/or replace defective component(s), if necessary. HT4001 Instruction Manual 7-21 4-99...

  • Page 206: Figure

    See Figure 7-3. Note that actual connection points are hidden by cap support bracket in Figure 7-3. Turn power to the HT4001 ON, and start system up. After the START command has been given, check voltage. The input to the chopper at these points should be about +360 VDC. If the input is OK and corresponding fuse F1, F2, F3 or F4 is blown, replace the chopper module.

  • Page 207: Figure 7-3 Chopper Module - Front View

    If the voltmeter reads 0 volts, then replace the chopper module. 3φ Input Bridge (+) Bridge (–) PL3.9 PL3.5 PL3.6 PL3.7 LED1 REC9 REC5 REC6 REC7 LED3 (-) TORCH (+) WORK Figure 7-3 Chopper Module - Front View Figure 7-3A Analog PCB3 HT4001 Instruction Manual 7-23 4-00...

  • Page 208: Relay Board Pcb4 Status Indicators

    Slave 400A Arc On +12 VDC Plasma Preflow (SV4B in MV Csl) Error Counter Start Counter PA Relay CON1 (in HT4001) (CR1 in HT4001) (in HT4001) Output Figure 7-4 Relay Board PCB4 Status Indicators Enable HT4001 Instruction Manual 7-24 6-98...

  • Page 209: Relay Board Pcb4 In O 2 Test Preflow

    Plasma Preflow Plasma N (SV6 in RHF Csl) (SV5 near torch) (SV2/SV3 in Gas Csl.) (SV4B in MV Csl) (SV1B in Gas Csl) +12 VDC Output Enable Figure 7-6 Relay Board PCB4 in N Test Preflow HT4001 Instruction Manual 7-25 6-98...

  • Page 210: Test Cut Flow

    Cutflow RHF Inj. Wtr Plasma N (SV5 near torch) (SV4A in MV Csl) (SV6 in RHF Csl) (SV1B in Gas Csl) +12 VDC Figure 7-8 Relay Board PCB4 in N Test Cut Flow Output Enable HT4001 Instruction Manual 7-26 6-98...

  • Page 211: Figure 7-9 Relay Board Pcb4 In Run Mode

    (SV1A in Gas Csl) Slave On (when in use) Arc On +12 VDC CON1 Slave 400A Start Counter Output (in HT4001) (in HT4001) (when in use) Enable Figure 7-9 Relay Board PCB4 in RUN Mode HT4001 Instruction Manual 7-27 6-98...

  • Page 212: Error Codes

    Disconnected terminals at connector PL2.5 will give the torch 10 seconds of postflow gas. If the terminals are connected together, the torch will have no postflow gas. ERROR CODE LED PLASMA START LED PL2.5 Figure 7-10 HT4001 Control Board Error Code LED Location HT4001 Instruction Manual 7-28 3-98...
  • Page 213 Fourteen blinks indicates that there is a software program error. Fifteen blinks indicates that the input voltage has dropped below 15% of the nominal value. Eg: Input voltage for a 480V power supply drops below 408V. Figure 7-11 HT4001 Error Codes HT4001 Instruction Manual 7-29 3-98...

  • Page 214: Torch Coolant Draining

    If the torch needs to be changed or transported, follow this procedure for draining the torch coolant from the torch and torch leads. 1. Disconnect all power to the HT4001 system. 2. Disconnect the torch leads from the RHF console, motor valve console and gas console.

  • Page 215: Appendix A H-401 Power Supply As Slave

    APPENDIX A H401 POWER SUPPLY AS SLAVE In this Appendix: H401 Slave Modification ..............a-2 H401 Slave Connections ..............a-6 Connecting the Power ..............a-6 HT4001 Instruction Manual...

  • Page 216: H-401 Slave Modification

    H401 SLAVE MODIFICATION A PC board assembly must be added to the stock H401 power supply so that it can interface as a slave for the HT4001 system. Kit 128315 contains the necessary components to make this change: Part No.

  • Page 217: Current Setpoint Pcb Installation

    APPENDIX A Current Setpoint PCB 041366 H401 Power Supply Rear H401 Terminal Strip 123377 Cable H401 Center Wall Note: Locations of current setpoint PCB and H401 terminal strip are approximate. Figure a-1 Current Setpoint PCB Installation HT4001 Instruction Manual 4-00...
  • Page 218 Removing H401 Surge-Injection Circuit You must disable the surge-injection circuit in the H401 supply so that it can be used as a slave with the HT4001. 1. Remove wires 108 and 107 from the power supply circuit. Wires are located either on the floor of the power supply or on the rear center wall of the power supply between the surge injection circuit.

  • Page 219: Figure A-2 Current Setpoint Pcb Connections

    7 and 8 as shown. From 129375 wire harness From Slave Cable 123377 11 12 13 14 15 16 Figure a-3a H401 Terminal Strip Connections Remove wire 107 Remove wire 108 Figure a-3b Removing H401 Surge Injection Circuit HT4001 Instruction Manual 6-00...

  • Page 220: H-401 Slave Connections

    2. Connect the power cord leads to the line disconnect switch following local and applicable electrical codes. WARNING The line disconnect switch must remain in the OFF position during the rest of the installation of the H401 power supply. HT4001 Instruction Manual 4-00...

  • Page 221: Figure A-4 H-401 Power Cable Connections

    APPENDIX A C10A C10B Figure a-4 H401 Power Cable Connections - Center Wall Rear HT4001 Instruction Manual 4-00...
  • Page 222 APPENDIX A H401 SLAVE CONNECTIONS (cont.) Slave Cable - HT4001 Power Supply to H401 Power Supply - Fig. a-5 • Connect the 1X8 end of the slave cable to the 1X8 connector on the HT4001 power supply. Part No. Length 123377 25 ft (7.6 m)

  • Page 223: Figure A-5 Slave Cable - Ht4001 Power Supply To H-401 Slave Power Supply

    APPENDIX A Power Supply REC1 Current Setpoint PCB in H401 Power Supply - See pg. a-4 for more details of connections. Figure a-5 Slave Cable - HT4001 Power Supply to H401 Slave Power Supply HT4001 Instruction Manual 4-98...
  • Page 224 APPENDIX A H401 SLAVE CONNECTIONS (cont.) When using the H401 Slave, a positive and negative lead must connect the HT4001 to the H401. Two 25-foot cables (023136) come with the 077011 kit for this purpose. Also, an additional positive lead must run from the positive bus bar in the HT4001 power supply to the work table, and an additional negative lead must run from the negative bus bar in the HT4001 power supply to the cathode block of the RHF console.

  • Page 225: Ht4001 Power Supply To Work Table And Rhf Console

    33 To work table – HT4001 Power Supply H401 RHF Console Power Supply Figure a-6 Slave Connections - HT4001 Power Supply to H401 Slave Power Supply/ HT4001 Power Supply to Work Table and RHF Console HT4001 Instruction Manual a-11 4-00...

  • Page 226: Appendix B Aeration Manifold

    APPENDIX B Appendix B AERATION MANIFOLD In this section: Aeration Manifold for Plasma Cutting Aluminum .........b-2 Introduction ..................b-2 Making an Aeration Manifold ............b-2 HT4001 Instruction Manual...

  • Page 227: Aeration Manifold For Plasma Cutting Aluminum

    Connect the manifold to a shop air line. Set a pressure regulator to obtain a steady stream of bubbles. Aeration Manifold Distribution Lines Regulated air in Figure b-1 Aeration Manifold HT4001 Instruction Manual...

  • Page 228: Appendix C Electromagnetic Compatibility

    Appendix C ELECTROMAGNETIC COMPATIBILITY (EMC) In this section: EMC Introduction ................c-2 General ....................c-3 Power Cable ..................c-3 Connect Power Cable ................. c-3 Power Supply ................. c-3 Line Disconnect Switch ..............c-5 EMI Filter Parts List ................c-6 HT4001 Instruction Manual...

  • Page 229: Emc Introduction

    Computer and other control equipment. plasma cutting installation may be Cutting Cables d. Safety critical equipment, for example considered for special applications guarding of industrial equipment. The cutting cables should be kept as short e. Health of the people around, for HT4001 Instruction Manual...

  • Page 230: General

    Power Supply 1. Locate the EMI filter box on the top rear of the power supply (see Figure c-1). EMI Filter Figure c-1 HT4001 Power Supply with EMI Filter Box - Rear View HT4001 Instruction Manual...

  • Page 231: Figure C-2 Ht4001 Power Supply With Emi Filter Cover Off

    2. Unscrew the seven filter cover screws and remove cover to access input voltage connections at TB5 (see Figure c-2). 3. Insert the power cable through the strain relief (see Figure c-2). Filter Strain Relief Figure c-2 HT4001 Power Supply with EMI Filter Cover Off HT4001 Instruction Manual 4-98...

  • Page 232: Figure C-3 Power Cable Connections To Tb5

    ON. This indicator is a warning that there is line voltage at the filter even if the circuit breaker on the HT4001 power supply is OFF. As a common safety practice, ALWAYS verify that the line disconnect switch is in the OFF position before installing, disconnecting or servicing in this area.

  • Page 233: Emi Filter Parts List

    Terminal Block SA:HT4001-CE Dual Filter 129016 Electronic Filter SA:HT4001-CE 129033 Pilot Light SA:HT2000-CE Filter 001546 Upper Cover:HT4001-CE Rear Box 001547 Lower Cover:HT4001-CE Rear Box 002255 Cover, Lifting Eye * Not Shown Figure c-4 HT4001 EMI Filter Parts HT4001 Instruction Manual 4-98...
  • Page 234 Appendix D Appendix D POWER CABLE INSTALLATION FOR 200/220V POWER SUPPLIES In this section: General ....................d-2 Power Cable ..................d-2 Connect Power Cable .................d-2 Power Supply .................d-2 Line Disconnect Switch ..............d-4 HT4001 Instruction Manual...

  • Page 235: General

    Power Supply 1. Locate the terminal box on the top rear of the power supply (see Figure d-1). Terminal Figure d-1 HT4001 Power Supply with Terminal Box - Rear View HT4001 Instruction Manual...

  • Page 236: Figure D-2 Ht4001 Power Supply With Terminal Box Cover Off

    2. Unscrew the seven filter cover screws and remove cover to access input voltage connections at TB5 (see Figure d-2). 3. Insert the power cable through the strain relief (see Figure d-2). Strain Relief Figure d-2 HT4001 Power Supply with Terminal Box Cover Off HT4001 Instruction Manual 4-98...

  • Page 237: Figure D-3 Power Cable Connections To Tb5

    ON. This indicator is a warning that there is line voltage at the terminal block even if the circuit breaker on the HT4001 power supply is OFF. As a common safety practice, ALWAYS verify that the line disconnect switch is in the OFF position before installing, disconnecting or servicing in this area.
  • Page 238 Appendix E PROPYLENE GLYCOL SAFETY DATA BENZOTRIAZOLE SAFETY DATA In this appendix: Propylene Glycol Safety Data Section 1 Chemical Product and Company Identification ..........e-2 Section 2 Information on Ingredients ................e-2 Section 3 Hazards Identification..................e-2 Section 4 First Aid Measures ..................e-3 Section 5 Fire Fighting Measures ...................
  • Page 243 % of Propylene Glycol Figure b-1 Freezing Point of Propylene Glycol Solution...
  • Page 247 e-10...

  • Page 248: Appendix F System Grounding

    The customer must furnish all conductors for equipment grounding. Grounding conductors may be purchased through Hypertherm in any length specified by the customer (Part No. 047058). The conductor may also be purchased locally, using a minimum 8 AWG UL Type MTW cable (USA specification) or the appropriate cable specified by national and local codes.

  • Page 249: Figure F-1 Recommended Ground Connection Configuration

    Ground Gas Console (PE) Supplementary Grounding Rod Other Equipment receiving power from the plasma power supply (PE) Figure f-1 Recommended Ground Connection Configuration Note: Configuration may vary for each installation and may require a different ground scheme. HT4001 Instruction Manual...

  • Page 250: Figure F-2 Alternate Ground Connection Configuration

    The preferred cable routing for this configuration is as shown, but it is acceptable to “daisy- chain” the grounds for the gas console and other equipment to the RHF console. The RHF console should NOT be daisy-chained through the other components to the work table. HT4001 Instruction Manual...

  • Page 251: Standards Index

    CSA Standard W117.2, Code for Safety in Welding and Cutting , obtainable from the Canadian Standards Association Standard Sales, 178 Rexdale Boulevard, Rexdale, Ontario M9W 1R3, Canada. NWSA booklet, Welding Safety Bibliography , obtainable from the National Welding Supply Association, 1900 Arch Street, Philadelphia, PA 19103. HT4001 Instruction Manual...
  • Page 252 ANSI Standard Z88.2, Practices for Respiratory Protection , obtainable from the American National Standards Institute, 1430 Broadway, New York, NY 10018. Canadian Electrical Code Part 1, Safety Standards for Electrical Installations , obtainable from the Canadian Standards Association, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W1R3. HT4001 Instruction Manual...

  • Page 253: Section 8 Wiring Diagrams

    Section 8 WIRING DIAGRAMS In this section: Introduction ..................8-2 Wiring Diagram Symbols ..............8-2 HT4001 System Wiring Diagrams ............8-5 HT4001 Instruction Manual...

  • Page 254: Wiring Diagrams

    WIRING DIAGRAMS INTRODUCTION This section contains the wiring diagrams for the HT4001 system. When tracing a signal path or referencing with the Parts List or Troubleshooting sections, please be aware of the following format to assist you in understanding the wiring diagrams' organization: •...
  • Page 255 Ground Clamp Receptacle Battery Ground, Chassis Relay, Coil Cap, polarized Ground, Earth Relay, Normally Closed Cap, non-polarized Inductor Relay, Normally Open Cap, feed-thru Relay, Solid State, AC Circuit breaker Light Relay, Solid State, DC Coax shield Relay, Solid State, Dry Current sensor Resistor Current sensor...
  • Page 256 Torch Symbols Time Delay Closed, Switch, Pressure, NO/On Normally Closed Electrode Transformer Switch, Pressure, Normally Open Transformer, Air Core Nozzle Switch, 1 Pole, 1 Throw Switch, 1 Pole, 2 Throw Transformer Coil Shield Switch, 1 Pole, 2 Throw, Center Off Triac Switch, Temperature, Normally Closed...

  • Page 265: Power Supply

    UNLESS OTHERWISE SPECIFIED: UNLESS OTHERWISE SPECIFIED: DESCRIPTION DESCRIPTION DIMENSIONS ARE IN INCHES. DIMENSIONS ARE IN INCHES. BLK DIA:HT4001 TOLERANCES ARE: TOLERANCES ARE: THIS DRAWING AND ALL INFORMATION THIS DRAWING AND ALL INFORMATION 2 PL DECIMAL 2 PL DECIMAL Å Å }.01 }.01...
  • Page 266 H401 Shunt 600A/50mv 1 AM H401-600ADC FEEDBACK CIRCUIT (2 PCB) H601 Shunts 1000A/50mv 1000A/50mv 1 VM 500VDC 1 AM H601-1000ADC TRANSFORMER 1T PRIMARY CONNECTIONS TRANSFORMER 2T CONNECTIONS 200V 400V 200V 400V 480V 600V HT4001: H401 POWER & CONTROL...
  • Page 267 SHEET SHEET UNLESS OTHERWISE SPECIFIED: DESCRIPTION DESCRIPTION 6-D1 6-C2 DIMENSIONS ARE IN INCHES. BLK DIA:HT4001 TOLERANCES ARE: THIS DRAWING AND ALL INFORMATION 2 PL DECIMAL Å}.01 CONTAINED THEREON IS CONSIDERED 3 PL DECIMAL Å}.005 ITEM NO. ITEM NO. DRAWING NO.

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