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Summary of Contents for Hypertherm HT4400
- Page 1 ™ HySpeed ® HT4400 Plasma Arc Cutting System Instruction Manual 803580 - Revision 4...
- Page 2 Changed Page Description of Change IM358 Rev 3 to 4 11/14/01 Updated parts to include lo-profile filter, P/Ns 128714 & 027927. Item #'s rearranged to fit new art. Page 1...
- Page 3 Added part #s 128654, 058224 & 044030. Re-numbered items. Updated torch body art. 6.11 Part # 129787 corrected, now 120787. Ap. c Footer changed to HT4400 (was HD4070) Line art of 2-stage Reg changed to photo. Ap.d Updated data in table. Correction of all mild steel cutchart s. O Plasma/O2-N2 shield (was N2 Plasma).
- Page 4 Changed Page Description of Change IM358 Rev 1 to 2 11/16/00 Cover Added system art Title page Changed Rev and date Updated to match Rev change Address page updated format Updated table to include Air 2.4 slip pg'd Added 440V power supply part # & specs Updated torch art 2.5 slip pg'd Updated torch w/ dim art to include 2.5"...
- Page 5 Changed Page Description of Change IM358 Rev 0 to 1 5/1/00 0.04 Added Fume Emissions to TOC 2.02 text edit 2.09 Changed p/n of remote current control to 077020 3.01 Added "Fume Emissions" to TOC 3.02 Referenced appendix C 3.04 Added Fume Emissions reference 3.05 Referenced appendix D...
- Page 6 Revision 4 Novenber, 2001 Hypertherm, Inc. Hanover, NH USA www.hypertherm.com © Copyright 2001 Hypertherm, Inc. All Rights Reserved Hypertherm, HT, HyLife, HySpeed and LongLife are trademarks of Hypertherm, Inc., and may be registered in the United States and/or other countries...
- Page 7 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...
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Page 8: Electromagnetic Compatibility (Emc
The size of the surrounding area to be con- Earthing of Workpiece sidered will depend on the structure of the Hypertherm's CE-marked equipment is built Where the workpiece is not bonded to earth building and other activities that are taking in compliance with standard EN50199. -
Page 9: Warranty
GENERAL and to hold Hypertherm harmless in the event of any cause of action arising from the use of the Products. Hypertherm, Inc. warrants that its Products shall be free from... -
Page 10: Table Of Contents
System Components............................2-2 Power Supply ............................2-2 Machine Torch ............................2-2 Valve Cluster ............................2-2 Gas Console............................2-2 Ignition Console............................2-2 Water Cooler ............................2-2 Remote Current Control Console - Optional...................2-2 Command THC - Optional ........................2-2 Specifications ..............................2-3 System Requirements ..........................2-3 Power Supply ............................2-4 HT4400 Instruction Manual... - Page 11 Power Requirements............................3-5 Connecting the Power.............................3-6 Torch Lifter Requirement..........................3-8 System Units Placement ..........................3-8 HT4400 System Interconnections ........................3-11 Ignition Console Connections - 1 of 3 ......................3-12 Ignition Console Connections - 2 of 3 ......................3-13 Ignition Console Connections - 3 of 3 ......................3-14 Gas Console Connections - 1 of 3 ........................3-15...
- Page 12 Torch Coolant Draining............................5-4 Water Cooler Draining.............................5-4 HT4400 Startup Sequence..........................5-5 HT4400 Plasma START Sequence.........................5-6 HT4400 Plasma RUN Sequence ........................5-7 Error Code Troubleshooting - 1 of 3........................5-8 Error Code Troubleshooting - 2 of 3........................5-9 Error Code Troubleshooting - 3 of 3......................5-10 System Troubleshooting - 1 of 4........................5-11 System Troubleshooting - 2 of 4 ........................5-12...
- Page 13 Work Table Grounding..........................a-2 Appendix B Propylene Glycol & Benzotriazole Safety Data ..............b-1 Appendix C Gas Regulators ........................c-1 Appendix D Noise Levels ..........................d-1 Appendix E O2/N2 Cutcharts @ 140 PSI ....................e-1 Appendix F O2/N2 Cutcharts @ 120 PSI ....................f-1 HT4400 Instruction Manual...
- Page 14 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...
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Page 15: 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 16: 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 17: 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 18: 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 19: Warning Label
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 20: Section 1A Sécurité
Le bruit peut provoquer des problè m es auditifs ....................1a-5 Pacemakers et prothè s es auditives ......................1a-5 Un arc plasma peut endommager les tuyaux gelé s ..................1a-5 É t iquette de sé c urité .............................1a-6 Hypertherm Systè m es plasma 1a-1 2/12/01... -
Page 21: Identifier Les Consignes De Sécurité
• Ne pas couper de r é c ipients contenant des mati è r es Se r é f é r er à l’annexe du manuel pour plus de combustibles. renseignements sur les collecteurs d’a é r ation. 1a-2 HYPERTHERM Systè m es plasma 2/12/01... -
Page 22: Les Chocs Électriques Peuvent Être Fatals
é de la source de courant. Ce dispositif permet à • Chaque syst è m e plasma Hypertherm est con ç u pour ê t re l’op é r ateur d’arr ê t er rapidement la source de courant en utilis é... -
Page 23: L'arc Plasma Peut Provoquer Des Blessures Ou Des Brûlures
• S’assurer que toutes les connexions sont bien serr é e s conform é m ent aux codes de s é c urit é locaux ou nationaux pour é v iter la surchauffe. appropri é s . 1a-4 HYPERTHERM Systè m es plasma 2/12/01... -
Page 24: Sécurité Des Bouteilles De Gaz Comprimé
• Se tenir le plus loin possible de la source de courant. Les tuyaux gelé s peuvent ê t re endommagé s ou é c later si l'on essaie de les dé g eler avec une torche plasma. HYPERTHERM Systè m es plasma 1a-5 2/12/01... -
Page 25: Étiquette De Sécurité
é q uipement ou de proc é d er au coupage. 7. Ne pas retirer ou peindre (recouvrir) les é t iquettes de s é c urit é . 1a-6 HYPERTHERM Systè m es plasma 2/12/01... -
Page 26: Specifications
Command THC - Optional ........................2-2 Specifications ..............................2-3 System Requirements ..........................2-3 Power Supply ............................2-4 Machine Torch ............................2-5 Valve Cluster ............................2-5 Gas Console............................2-6 Ignition Console............................2-7 Water Cooler ............................2-8 Remote Current Control Console - Optional...................2-9 Command THC - Optional ........................2-9 HT4400 Instruction Manual... -
Page 27: System Components
The Command THC is an external torch height control and initial height sensing system designed for plasma cutting applications on an x-y cutting table. Refer to the Command THC instruction manual 802780 for more detailed information. HT4400 Instruction Manual 3-00... -
Page 28: Specifications
250 scfh (7080 sclh) @ 120 psi +/- 10 psi (8.3 bar +/- 0.7 bar) 250 scfh (5664 sclh) @ 120 psi +/- 10 psi (8.3 bar +/- 0.7 bar) Cables Gas Hoses Coolant Hoses System components not drawn to scale HT4400 Instruction Manual... -
Page 29: Power Supply
In accordance with IEC 61000-3-12, the R sce (short Circuit Ratio) for the 400 VAC power supply is 100. Dimensions and Weight Width 34" (863 mm) Maximum Height 51" (1295 mm) Maximum Depth 48-11/16" (1236 mm) Weight 1800 lbs (817 kg) HT4400 Instruction Manual... -
Page 30: Machine Torch
Weight 6.6" (168 mm) Height 2.5" (64 mm) Depth 1.2" (30 mm) Weight 2.5 lbs (1,1 kg) 0.88" (22 mm) 0.16" (4 mm) 0.19" (4.8 mm) 0.16" diameter. (4 mm) 6.25" (159 mm) Valve Cluster Mounting Dimensions HT4400 Instruction Manual... -
Page 31: Gas Console
Depth 5.0" (127 mm) Weight 28.7 lbs (13 kg) 5.0" (127 mm) 4.0" (102 mm) 1.0" (25 mm) PEM #S-0420-1 (6 places) 2.0" 5.75" 9.5" (51 mm) (146 mm) (241 mm) Gas Console Mounting Dimensions (bottom view) HT4400 Instruction Manual... -
Page 32: Ignition Console
11.0" (279 mm) Ignition Console Mounting Dimensions (bottom view) Hypertherm recommends mounting the ignition console either horizontally or in the vertical position with the power supply and water cooler connections facing out as shown. Power supply and water cooler connections... -
Page 33: Water Cooler
36" (914 mm) Depth 15.8" (401 mm) Weight 148 lbs (67,2 kg) Coolant capacity 2.5 gal (9.5 l) Maximum coolant flow 0.85 gpm (3.2 l/min) 36" (914 mm) 15.8" 23" (401 mm) (584 mm) Water Cooler with Dimensions HT4400 Instruction Manual 3-00... -
Page 34: Remote Current Control Console - Optional
3.38" (86 mm) (165 mm) 0.50" (13 mm) 6.25" (159 mm) 1.17" 8.5" (216 mm) (30 mm) Remote Current Control Mounting Dimensions (bottom view) Command THC - Optional Refer to the Command THC Instruction Manual 802780. HT4400 Instruction Manual 3-00... -
Page 35: Installation
Power Requirements............................3-5 Connecting the Power.............................3-6 Torch Lifter Requirement..........................3-8 System Units Placement ..........................3-8 HT4400 System Interconnections ........................3-11 Ignition Console Connections - 1 of 3 ......................3-12 Ignition Console Connections - 2 of 3 ......................3-13 Ignition Console Connections - 3 of 3 ......................3-14 Gas Console Connections - 1 of 3 ........................3-15... -
Page 36: Installation Requirements
All installation and service of the electrical and plumbing systems must conform to national or local codes. This work should be performed only by qualified, licensed personnel. Direct any technical questions to the nearest Hypertherm Technical Service Department listed in the front of this manual, or your nearest authorized Hypertherm distributor. -
Page 37: Torch Coolant Requirements
INSTALLATION Torch Coolant Requirements The water cooler is shipped to the customer without any coolant in the tank. Hypertherm recommends a mixture of 30% propylene glycol, 69.9% deionized water, and .1% benzotriazole. This mixture resists freezing to +10° F (-12°... -
Page 38: Water Purity Requirements
Caution: All accessory modules in the HT4400 system must be grounded to earth. Use a minimum of 8 AWG (10 mm2) wire connected from the stud on the side of each module enclosure to the worktable ground. -
Page 39: Noise Levels
Acceptable noise levels as defined by national or local codes may be exceeded by this plasma system. Always wear proper ear protection when cutting with the plasma system. See also Noise Protection in the Safety section of this manual. See also Appendix D for noise levels measured on the HT4400 system. Power Requirements All switches, slow-blow fuses and power cables are customer supplied and must be chosen as outlined by applicable national or local codes. -
Page 40: Connecting The Power
The line disconnect switch must be in the OFF position before making the power cable connections! In the U.S., use a "lock-out/tag-out" procedure until installation is complete. In other countries, follow appropriate local or national safety procedures. HT4400 Instruction Manual... - Page 41 1. Be certain that the line disconnect switch is in the OFF position and remains in the OFF position for the remainder of the installation of the HT4400 system. 2. Insert the power cable through the strain relief located in the rear of the power supply.
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Page 42: Torch Lifter Requirement
Use the HT4400 System Connections diagram later in this section to help make the system cable, torch and hose connections. Follow the number guide on the diagram to find out specific information on each cable, hose or con- nection. - Page 43 INSTALLATION Notes HT4400 Instruction Manual...
- Page 44 Center Bail Front Center Bail Rear Gas Console Ignition Console Command THC Machine Machine Gas Console Water Cooler Interface V/C Interface I/O Power Supply Rear Panel (Logic + 12VDC, close to start) Power Supply Rear Wall Inside 3-10 HT4400 Instruction Manual...
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Page 45: Ht4400 System Interconnections
Machine Interface connections - pgs. 3-20, -21 Work Table connection - pg. 3-22 Command THC connection - see instruction manual 802780 Torch Connections, Mounting and Power supply #2 connection – pg. 3-22 Alignment - pg. 3-23 HT4400 System Interconnections HT4400 Instruction Manual 3-11... -
Page 46: Ignition Console Connections - 1 Of 3
Ignition Console Connections – 1 of 3 See Water Cooler Connections - pg. 3-18, 3-19 Green Green See Water Cooler Connections - pg. 3-18, 3-19 See also Torch Connections, Mounting and Alignment later in this section. 3-12 HT4400 Instruction Manual... -
Page 47: Ignition Console Connections - 2 Of 3
30 ft (9.2 m) 123516 150 ft (45.8 m) SV11 123450 40 ft (12.2 m) 123560 175 ft (53.4 m) SV11 Blue 123512 50 ft (15.3 m) 123561 200 ft (61 m) SV12 SV12 Yellow Black Brown Brown HT4400 Instruction Manual 3-13... -
Page 48: Ignition Console Connections - 3 Of 3
PE (Gnd) White PE (Gnd) Green Torch Leads See also Torch Connections, Mounting and Alignment later in this section. Part No. Length 128462 6 ft (1.8 m) 128463 10 ft (3 m) 128341 15 ft (4.6 m) 3-14 HT4400 Instruction Manual... -
Page 49: Gas Console Connections - 1 Of 3
150 ft (45.8 m) Black 123450 40 ft (12.2 m) 123560 175 ft (53.4 m) Orange 123512 50 ft (15.3 m) 123561 200 ft (61 m) SOD+ Green SOD– Blue Str2+ Yellow Str2– Brown Clk2+ Orange Clk2– White HT4400 Instruction Manual 3-15... -
Page 50: Gas Console Connections - 2 Of 3
024586 024594 128488 40 ft (12.2 m) 024626 024626 024634 024634 024585 024593 128489 50 ft (15.3 m) 024627 024627 024635 024635 024584 024592 128518 60 ft (18.3 m) 024653 024653 024652 024652 024650 024651 3-16 HT4400 Instruction Manual 4-00... -
Page 51: Gas Console Connections - 3 Of 3
25 ft (7.6 m) 024677 125 ft (38.1 m) 024673 30 ft (9.2 m) 024678 150 ft (45.8 m) 024674 40 ft (12.2 m) 024679 175 ft (53.4 m) 024660 50 ft (15.3 m) 024680 200 ft (61 m) HT4400 Instruction Manual 3-17... -
Page 52: Water Cooler Connections - 1 Of 2
Water Pump (240 VAC) Black 123519 15 ft (4.6 m) Water Pump (240 VAC) Brown Shield Shield Fan (120 VAC) Black Fan (120 VAC) White Shield Shield Solenoid V1 (120 VAC) Black Solenoid V1 (120 VAC) Shield Shield 3-18 HT4400 Instruction Manual... -
Page 53: Water Cooler Connections - 2 Of 2
3. Add coolant until level is full on the level gauge. 4. Turn the water cooler on for 1 minute and add more coolant, if necessary. Level gauge See Post Installation later in this section. See also Torch Coolant Requirements earlier in this section. HT4400 Instruction Manual 3-19 3-00... -
Page 54: Remote Current Control Connection
125 ft (38.1 m) I Common Blue/Black 123582 30 ft (9.2 m) 023857 150 ft (45.8 m) Shield Shield 123583 40 ft (12.2 m) 123585 175 ft (53.4 m) 023854 50 ft (15.3 m) 023858 200 ft (61 m) 3-20 HT4400 Instruction Manual... -
Page 55: Machine Interface Connections - 2 Of 2
WARNING hen installing or servicing the HT4400, AC or DC line voltages may be present on the TRANSFER signals even if the power supply line disconnect switch is OFF. Make certain that all line disconnect switches relating to the HT4400 system are OFF during installation and when servicing. -
Page 56: Work Table Connection
Hold Shield Shield 123592 20 ft (6.1 m) 023343 100 ft (30.5 m) 023341 25 ft (7.5 m) 023344 150 ft (45.8 m) 123593 30 ft (9.2 m) Hold cable connections (Logic + 12VDC, close to start) 3-22 HT4400 Instruction Manual... -
Page 57: Torch Connections
Be certain that there is no space between the torch body and the o-ring on the torch leads. See also Ignition Console Connections earlier in this section for torch lead connections to ignition console. HT4400 Instruction Manual 3-23... -
Page 58: Torch Mounting And Alignment
Torch Alignment To align the torch at right angles to the workpiece, use a square at 0° and 90° . See figure above. See also Changing Consumables in Section 4 to install consumables in the torch. 3-24 HT4400 Instruction Manual 4-00... -
Page 59: Post-Installation
After installation is complete, perform the following procedure to ensure the proper performance of the HT4400 system before moving on to the Operation section of this manual. The gas console will display error code FS (flow switch error) on initial startup until: all air is out of the torch coolant loop; the reservoir in the water cooler has an adequate supply of fluid. -
Page 60: Operation
Inspect Electrode Pit Depth ........................4-26 Install Consumables ..........................4-27 Replace Torch Water Tube..........................4-28 Cutting Techniques............................4-29 How to Get Better Cut Quality ......................4-29 How to Get Longer Consumable Life ....................4-30 How to Get Better Pierces ........................4-32 How to Increase Cutting Speed......................4-32 HT4400 Instruction Manual... -
Page 61: Controls And Indicators
OPERATION Controls and Indicators Gas Console Status Display Valve Select Gas Select 1 Gas Select 2 (under lever) HT4400 Instruction Manual... -
Page 62: Gas Console Controls And Indicators
Selects the use of either nitrogen or oxygen as the plasma cutting gas. Status Displays a 2 character code to report the condition of the HT4400 system. See Status Display Display Messages on the Gas Console later in this section. See also Error Code Troubleshooting in Section 5. -
Page 63: Status Display Messages On The Gas Console
RU – Ramp up error XF – No arc transfer Power Supply Front Panel DC Indicator AC Indicator Illuminates when main Indicator illuminates when contactor closes, indicating power up is complete. DC power is being supplied to the torch. HT4400 Instruction Manual... -
Page 64: Remote Current Control Console
DOWN position Remote Current Control Console AMPS Thumb-wheel Adjusts the cutting arc current to 400 amps. Values are chosen from the Cut Charts and depend on the thickness and type of metal to cut. HT4400 Instruction Manual... -
Page 65: Leak Tests
CUTTING WITH OXYGEN CAN CAUSE FIRE OR EXPLOSION Cutting with oxygen as the plasma gas can cause a potential fire hazard due to the oxygen-enriched atmosphere that it creates. As a precaution, Hypertherm recommends that an exhaust ventilation system be installed when cutting with oxygen. - Page 66 In Leak Test 1, valves 1-7 are ON (open), and valves 8-12 are OFF (closed). In Leak Test 2, valves 8-12 are ON (open), and valves 1-7 are OFF (closed). Gas Schematic Valve Select Gas Select 1 Gas Select 2 (under lever) Gas Console HT4400 Instruction Manual...
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Page 67: Daily Startup
• Check the pit depth of the electrode. The electrode should be replaced when the depth exceeds .040 inch (1 mm). A gauge for measuring electrode pit depth can be purchased through Hypertherm. See Section 6 Parts List in this manual. See also Inspect Electrode Pit Depth later in this section. - Page 68 Set the voltage from the machine computer interface or torch-height control system. Select the arc current and arc voltage numbers from the Cut Charts for the type and thickness of metal to cut. HT4400 Instruction Manual...
- Page 69 5. Repeat this procedure to set metering valves M3-M7. Note that the readings for shield gas adjustments appear in gas console PG2 Shield window. (Plasma cutflow) (Plasma preflow) (Shield cutflow) (Shield preflow) (Plasma preflow) (Shield preflow) (Shield cutflow) (under lever) Valve Select 4-10 HT4400 Instruction Manual...
- Page 70 2. Set Valve Select switch to Run after the test preflow and test cutflow rates have been verified. 3. The system is now ready to operate. Press the START command from the machine interface to begin the cutting sequence. HT4400 Instruction Manual 4-11...
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Page 71: Common Cutting Faults
• Torch pilot arc will initiate, but will not transfer. Causes can be: 1. Work cable connection on the cutting table is not making good contact. 2. Malfunction in the HT4400 system. See Section 5. • The workpiece is not totally penetrated, and there is excessive sparking on top of the workpiece. -
Page 72: Performance And Process Data
100A O /Air 3/16" .055 200A O /Air 1/4" .065 .095 300A O /Air 3/8" .072 .110 .105 .130 400A O /Air 1/2" .120 .120 .135 200A N 3/4" .125 .130 .150 400A N 1" .140 .165 HT4400 Instruction Manual 4-13... -
Page 73: Cut Chart And Consumable Parts Index
3–Underwater cutting can only be accomplished by using underwater retaining cap #120984. Using retaining cap #120796 will cause misfires. See appendix D for 120psi inlet and O cutcharts. See appendix E for 140psi inlet and O cutcharts. 4-14 HT4400 Instruction Manual... - Page 74 Cuts on these thicknesses may result in increased cut angle variation and surface roughness. Reduce cut speed by 5%-10% for improvement with some materials. Minimum inlet pressures remain at one setting of 120 psi (8.3 bar) for all material thicknesses. Approximate pressures while cutting in RUN mode: HT4400 Instruction Manual 4-15...
- Page 75 Cuts on these thicknesses may result in increased cut angle variation and surface roughness. Reduce cut speed by 5%-10% for improvement with some materials. Minimum inlet pressures remain at one setting of 120 psi (8.3 bar) for all material thicknesses. Approximate pressures while cutting in RUN mode: 4-16 HT4400 Instruction Manual...
- Page 76 .250 .157 2151 .314 .157 1851 .314 .188 1331 .375 1155 .500 .500 Minimum inlet pressures remain at one setting of 120 psi (8.3 bar) for all material thicknesses. Approximate pressures while cutting in RUN mode: HT4400 Instruction Manual 4-17...
- Page 77 .188 .125 4355 .250 .125 3226 .250 .157 2056 .314 .157 1613 .314 Minimum inlet pressures remain at one setting of 120 psi (8.3 bar) for all material thicknesses. Approximate pressures while cutting in RUN mode: 4-18 HT4400 Instruction Manual...
- Page 78 .375 .188 1411 .375 .188 1032 .375 .250 .250 .250 Piercing not recommended Minimum inlet pressures remain at one setting of 120 psi (8.3 bar) for all material thicknesses. Approximate pressures while cutting in RUN mode: HT4400 Instruction Manual 4-19...
- Page 79 .157 1628 .314 .188 1089 .375 .250 .500 .250 .250 Piercing not recommended Minimum inlet pressures remain at one setting of 120 psi (8.3 bar) for all material thickness. Approximate pressures while cutting in RUN mode: 4-20 HT4400 Instruction Manual...
- Page 80 .188 1668 .375 .188 1290 .375 .250 1085 .250 .250 Piercing not recommended Minimum inlet pressures remain at one setting of 120 psi (8.3 bar) for all material thicknesses. Approximate pressures while cutting in RUN mode: HT4400 Instruction Manual 4-21...
- Page 81 .157 1851 .314 .188 1210 .500 .250 .500 .250 .250 Piercing not recommended Minimum inlet pressures remain at one setting of 120 psi (8.3 bar) for all material thicknesses. Approximate pressures while cutting in RUN mode: 4-22 HT4400 Instruction Manual...
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Page 82: Changing Consumable Parts
Changing Consumable Parts WARNING The HT4400 power supply is designed to go into an idle mode if the retaining cap is removed. However, DO NOT CHANGE CONSUMABLE PARTS WHILE IN THE IDLE MODE! Always disconnect power to the power supply before inspecting or changing torch consumable parts. -
Page 83: Inspect Consumables
See Inspect Electrode Pit Depth later Center surface Wear in this section O-rings 1. Damage None Replace electrode* 2. Lubricant Not dry Apply a thin coat of silicon lubricant *NOTE: Always replace the nozzle and electrode as a set. 4-24 HT4400 Instruction Manual... -
Page 84: Inspect Torch
Not dry Apply a thin coat of silicon lubricant Water Tube* 1. Tightness Not loose Tighten or replace tube* 2. Pitted or missing material None Replace tube* *NOTE: See Replace Torch Water Tube later in this section. HT4400 Instruction Manual 4-25... -
Page 85: Inspect Electrode Pit Depth
Electrode Pit Depth Gauge (004147) 358-04-electrdpit Part Check For Limit Action Electrode Center surface Wear Pit not more than Replace Electrode* 0.040 inch (1 mm) deep *NOTE: Always replace the nozzle and electrode as a set. 4-26 HT4400 Instruction Manual... -
Page 86: Install Consumables
3% hydrogen Silicone peroxide. Grease Do not over-tighten parts! Only tighten until mating parts are seated. Install electrode Insert swirl ring Install retaining cap Install nozzle Tool Part No. 027102 Tool Part No. 004663 HT4400 Instruction Manual 4-27... -
Page 87: Replace Torch Water Tube
WARNING The HT4400 power supply is designed to go into an idle mode if the retaining cap is removed. However, DO NOT REMOVE CONSUMABLE PARTS WHILE IN THE IDLE MODE! Always disconnect power to the power supply before removing torch consumable parts. -
Page 88: Cutting Techniques
How to Get Better Cut Quality In order to get the best cut quality, ensure the HT4400 plasma system is set up according to the Daily Start-Up procedure in this section. The 3 major components of cut quality are: cut angle, dross, and shape (flatness) and smoothness of the cut surface. -
Page 89: How To Get Longer Consumable Life
2. A regular wavy surface is due to machine motion. Tuning the drives and cleaning the rails will help. How to Get Longer Consumable Life The HT4400 plasma system incorporates Hypertherm's patented LongLife ® process to extend the life of consum- able parts. - Page 90 1. Do not lead out to the drop part, which will cause the arc to stretch. 2. Purge the gas lines to clean the plasma chamber before cutting. 3. Make sure the torch does not dive to the plate during cutting. HT4400 Instruction Manual 4-31...
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Page 91: How To Get Better Pierces
4. Use a higher shield pre-flow to help pierce through and blow the molten metal away. This may affect starting reliability. How to Increase Cutting Speed 1. Lower the torch-to-work distance. However, the shield can not touch the plate. The cutting surface will bevel inside when the torch-to-work distance is too low. 4-32 HT4400 Instruction Manual... -
Page 92: Maintenance
Pump Strainer Cleaning............................5-3 Torch Coolant Draining ............................5-4 Water Cooler Draining ............................5-4 HT4400 Startup Sequence .............................5-5 HT4400 Plasma START Sequence ........................5-6 HT4400 Plasma RUN Sequence ..........................5-7 Error Code Troubleshooting - 1 of 3 ........................5-8 Error Code Troubleshooting - 2 of 3 ........................5-9 Error Code Troubleshooting - 3 of 3 ........................5-10... -
Page 93: Introduction
MAINTENANCE Introduction Hypertherm assumes that the service personnel performing the troubleshooting testing are high-level electronic service technicians who have worked with high voltage electro-mechanical systems. Knowledge of final isolation troubleshooting techniques is also assumed. In addition to being technically qualified, maintenance personnel must perform all testing with safety in mind. -
Page 94: Replacing The Water Cooler Filter
027664 discard filter element Pump Strainer Cleaning 1. Disconnect all power to the HT4400 system. 2. Drain coolant. See water Cooler Draining, next page. 3. Remove nut. 4. Remove and clean strainer with a mild soap and water solution. 5. Re-insert strainer. -
Page 95: Torch Coolant Draining
Coolant should be drained from the system every 6 months. See Preventative Maintenance Schedule at the back of this section. 1. Disconnect all power to the HT4400 system. 2. Disconnect the torch leads from the ignition console and valve cluster. -
Page 96: Ht4400 Startup Sequence
MAINTENANCE HT4400 Startup Sequence The following flowchart shows the startup sequence from when the control power circuit breaker is placed in the ON position to the power supply idle state before the plasma START command is given. Shaded boxes indicate action taken by the operator. -
Page 97: Ht4400 Plasma Start Sequence
MAINTENANCE HT4400 Plasma START Sequence The following flowchart shows the sequence from when the plasma START signal is given up to the RUN state. Shaded boxes indicate action taken by the operator Plasma START Signal Given • Gas console displays Hd •... -
Page 98: Ht4400 Plasma Run Sequence
MAINTENANCE HT4400 Plasma RUN Sequence The following flowchart shows the sequence from RUN state through the end of a cut. Shaded boxes indicate action taken by the operator System in RUN state • Analog board compares output current of each chopper to the set current... -
Page 99: Error Code Troubleshooting - 1 Of 3
All error code displays are cleared after error condition has been corrected and the valve select switch is set to MV1 and back to Run. The system is now ready for the plasma START signal. “ FS” error is cleared by cycling the HT4400 power. HT4400 Instruction Manual... -
Page 100: Error Code Troubleshooting - 2 Of 3
MAINTENANCE Error Code Troubleshooting - 2 of 3 HT4400 Instruction Manual... -
Page 101: Error Code Troubleshooting - 3 Of 3
MAINTENANCE Error Code Troubleshooting - 3 of 3 5-10 HT4400 Instruction Manual... -
Page 102: System Troubleshooting - 1 Of 4
MAINTENANCE System Troubleshooting - 1 of 4 HT4400 Instruction Manual 5-11... -
Page 103: System Troubleshooting - 2 Of 4
MAINTENANCE System Troubleshooting - 2 of 4 5-12 HT4400 Instruction Manual... -
Page 104: System Troubleshooting - 3 Of 4
MAINTENANCE System Troubleshooting - 3 of 4 HT4400 Instruction Manual 5-13... -
Page 105: System Troubleshooting - 4 Of 4
MAINTENANCE System Troubleshooting - 4 of 4 5-14 HT4400 Instruction Manual... -
Page 106: Initial Checks
Refer to the Parts List section to identify parts and part numbers. 4. If no damage is apparent, plug in the power supply unit, and apply power by turning on the main disconnect switch. HT4400 Instruction Manual 5-15... -
Page 107: Power Measurement Location - All Voltages
ON. These indicators are a warning that there is line voltage at the contactors even if the circuit breaker on the power supply is OFF. Use extreme care when measuring primary power in these areas. Voltages present at the terminal block and contactors can cause injury or death! 5-16 HT4400 Instruction Manual... -
Page 108: Power Distribution Pcb1 - Status Indicators
If voltages are not present, or incorrect at one or more of these points, disconnect power and troubleshoot fuses and associated pins, connectors and wiring between power distribution board connector J10 and control transformer secondary T1. Also, check wiring and connections between T1, CB1, and CON1. HT4400 Instruction Manual 5-17... -
Page 109: Microprocessor Control Board Pcb2 - Status Indicators
MAINTENANCE Microprocessor Control Board PCB2 - Status Indicators See page 6-2 for location of Microprocessor Control Board. Arc Transfer +12 VDC Plasma Start +5 VDC D14 & D19 Not Used 5-18 HT4400 Instruction Manual... -
Page 110: Analog Board Pcb3 - Status Indicators
7 amps. • D5 Current Detect from CH1&CH2 - illuminates when both CH1&CH2 output more than 7 amps. • D4 Current Detect from CH3&CH4 - illuminates when both CH3&CH4 output more than 7 amps. HT4400 Instruction Manual 5-19... -
Page 111: Current Sense Test
REC6 pins 3 & 4 4 V = 100 amps REC7 pins 3 & 4 4 V = 100 amps Total Current REC10 pins 3 & 4 3.2 V = 400 amps REC9 REC5 REC6 REC7 REC10 REC4 REC3 5-20 HT4400 Instruction Manual... -
Page 112: Relay Board Pcb4 - Status Indicators
Water Cooler +12 VDC pump via the Power Supply Power Distribu- SV-8 Shield tion Board) preflow Error Counter Start Counter P.A. Relay CON1 DC ON (Valve Cluster) Output Enable Relay Board PCB4 Status Indicators HT4400 Instruction Manual 5-21... - Page 113 Test Cutflow Mode SV-9 Shield SV-11 Plasma SV-12 Plasma Power to cut-flow cut-flow off valve Choppers (Valve Cluster) (Valve Cluster)) (Valve Cluster) Analog PCB power Start Circuit Assy power (Power Supply) Pump motor enable +12 VDC Output Enable 5-22 HT4400 Instruction Manual...
- Page 114 Power to off valve cut-flow cut-flow Choppers (Valve Cluster) (Valve Cluster) (Valve Cluster) Analog PCB power Start Circuit Assy power (Power Supply) Pump motor enable Arc on +12 VDC Output Start Counter CON1 DC ON Enable HT4400 Instruction Manual 5-23...
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Page 115: Serial I/O Board Pcb5 - Status Indicators
Plasma preflow pressure switch (PP) LEDN2-5 LEDN1-5 Primary gas shield preflow (SV4) LEDN2-4 LEDN1-4 BCD1 Primary gas shield cut-flow LEDN2-3 LEDN1-3 BCD2 Primary gas preflow (SV2) LEDN2-2 LEDN1-2 BCD4 Plasma cut-flow (SV1) LEDN2-1 LEDN1-1 BCD8 LEDN1 LEDN2 5-24 HT4400 Instruction Manual... - Page 116 LEDN1-6 = SP LEDN2-5 = SV5 LEDN1-5 = PP LEDN2-4 = SV4 LEDN1-3 = BCD2 LEDN2-2 = SV2 LEDN1-1 = BCD8 LEDN1 LEDN2 * These cutflow LEDs may or may not be illuminated in Test Preflow Mode HT4400 Instruction Manual 5-25...
- Page 117 Serial Board LED Status Test Cutflow Mode LEDN1-8 = SC LEDN1-7 = PC LEDN2-6 = SV6 LEDN1-6 = SP LEDN1-5 = PP LEDN1-4 = BCD1 LEDN1-3 = BCD2 LEDN2-3 = SV3 LEDN1-1 = BCD8 LEDN2-1 = SV1 LEDN1 LEDN2 5-26 HT4400 Instruction Manual...
- Page 118 MAINTENANCE Serial Board LED Status RUN Mode - Idle LEDN1-7 = PC LEDN1-5 = PP LEDN1 LEDN2 HT4400 Instruction Manual 5-27...
- Page 119 MAINTENANCE Serial Board LED Status RUN Mode - Cutting LEDN1-8 = SC LEDN1-7 = PC LEDN2-6 = SV6 LEDN1-6 = SP LEDN1-5 = PP LEDN2-3 = SV3 LEDN2-1 = SV1 LEDN1 LEDN2 5-28 HT4400 Instruction Manual...
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Page 120: Start Circuit Board Pcb14 - Status Indicators And Operation
Pilot Arc Current 100-amp current setting 30 amps 200-amp current setting 44 amps 300-amp and 400-amp current setting 60 amps N2 as the Plasma Gas Pilot Arc Current 200-amp current setting 44 amps 400-amp current setting 60 amps HT4400 Instruction Manual 5-29... -
Page 121: Start Circuit Functional Schematic
• Work cable connection on the cutting table is not making good contact. • Check D2. It should be illuminated. • Fire the torch in the air and check to be sure that D1 illuminates. • Check the resistance across the R3 resistor. It should be 10 kΩ. 5-30 HT4400 Instruction Manual... -
Page 122: Phase Loss Detection Board Pcb21 - Status Indicators And Operation
• Check jumper on P2 and verify that the jumper is set for 265V. Phase Loss Board PCB21 location on chopper CH4 - See page 6-3 for location of CH4 P2 Jumper for 265 V LED1 HT4400 Instruction Manual 5-31... -
Page 123: Chopper Module Test Procedure
4. Turn power to the HT4400 ON, and start up system. 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 124 • If the voltmeter reads 0 volts, then replace the chopper module. 3ø Input Bridge (+) Bridge (-) PL3.9 PL3.5 PL3.6 PL3.7 REC9 REC5 REC6 REC7 LED1 LED3 Torch (-) Analog PCB3 (+) Work Chopper Module - Front View HT4400 Instruction Manual 5-33...
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Page 125: Coolant Flow Test
MAINTENANCE Coolant Flow Test 1. Turn power off to the HT4400. 2. Remove the return coolant hose from the Water Cooler (hose with red tape). 3. Set the thumbwheel switch (S2) on the Gas Console to "Leak Test 1" or "Leak Test 2."... - Page 126 MAINTENANCE Blank HT4400 Instruction Manual 5-35...
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Page 127: Pressure Switch Settings
P2 = 140 psi P2 = 140 psi Output 2 - Plasma Preflow (Red LED) Output 2 - Shield Preflow (Red LED) P3 = 10 psi P3 = 15 psi P4 = 140 psi P4 = 140 psi 5-36 HT4400 Instruction Manual... -
Page 128: Gas Console Valve Select Switch Detail
SV3, SV9 SV4, SV8 SV5, SV10, SV12 SV6, SV9 SV7, SV8 Leak Test 1 SV1–SV7 Leak Test 2 SV8–SV12 Test Preflow SV2, SV4, SV5, SV7, SV8, SV10, SV12 Test Cutflow SV1, SV3, SV6, SV9, SV11, SV12 HT4400 Instruction Manual 5-37... -
Page 129: Preventative Maintenance Schedule
Date Completed: Service 1________ Service 2________ Drain coolant system -- See Instruction Manual, Maintenance section Replace coolant filter element - See Instruction Manual, Maintenance section Replace coolant with genuine Hypertherm coolant Annually: Date Completed:________ Replace pilot arc relay Replace main contactor Hypertherm, Inc. -
Page 130: Parts List
Rear Bail (Wall) ..............................6-5 Power Supply................................6-6 Rear Panel Inside and Outside ........................6-6 Ignition Console ..............................6-7 Gas Console ................................6-8 Water Cooler................................6-9 HT4400 Torch ...............................6-10 Consumable Configurations..........................6-11 Consumable Parts Kit ............................6-12 Counterclockwise Consumables...........................6-12 Valve Cluster Assembly - 077035 .........................6-13 Recommended Spare Parts ..........................6-13 Electrode Pit Depth Gauge Assembly - 004147 ....................6-14... -
Page 131: Power Supply
PCB Assy: Relay PCB4 041282 PCB Assy: Analog PCB3 041635 PCB Assy:Serial PCB5 041690 PCB Assy: µP Control PCB2 027080 Fan 225 cfm, 120 VAC, 50-60 Hz M1-4,M6 027079 Fan: 450-550 cfm, 120 VAC, 50-60 Hz M5, M7 HT4400 Instruction Manual... -
Page 132: Power Supply
PARTS LIST Power Supply Front Panel Inside Part Item Number Description Designator Qty. 129160 CH100-CE/LVD Chopper Assembly 129160 CH100-CE/LVD Chopper Assembly 129160 CH100-CE/LVD Chopper Assembly 129160 CH100-CE/LVD Chopper Assembly 041564 PCB: Phase Loss Detection PCB21 HT4400 Instruction Manual... -
Page 133: Power Supply
Power Supply Front Bail (Wall) Part Item Number Description Designator Qty. 129349 Start Circuit Assembly II PCB14 008317 Fuse: 125A 250V 008317 Fuse: 125A 250V 008317 Fuse: 125A 250V 008317 Fuse: 125A 250V 003021 Relay: 120 VAC HT4400 Instruction Manual... -
Page 134: Power Supply
Current Sensor: Hall, 100A=4V 109004 Current Sensor: Hall, 100A=4V 109004 Current Sensor: Hall, 100A=4V 129596 I/O Panel Assembly PCB10 * Installed by customer when ordering the Command THC option. See Command THC instruction manual 802780 for more detailed information. HT4400 Instruction Manual... -
Page 135: Power Supply
129228 *** Kit: 003172 Contactor Contacts Repl 129613 * Filter: 140A 480V FL1A Only used on 400 VAC CE power supplies ** Contactor element replacement kit *** Contactor element replacement kit for 400 VAC CE power supplies HT4400 Instruction Manual... -
Page 136: Ignition Console
PARTS LIST Ignition Console Part Item Number Description Designator Qty. 078088 HT4400 Ignition Console 009040 FIlter: 3A, 3W 128510 Kit: Filter Capacitor Replacement 129616 Inductor: Ignition Console 027648 Ignition Module SSI1 041619 PCB Assy: Ignition Console Interface HT4400 Instruction Manual... -
Page 137: Gas Console
PARTS LIST Gas Console Part Item Number Description Designator Qty. 077032 HT4400 Gas Console 005156 Toggle switch: SP 10A On/Off/On 008106 Nut: Toggle Switch, Dress 128512 Kit: Pressure Switch Replacement 128511 Kit: Pressure Switch Replacement 015330 Filter: 10 Micron 041638... -
Page 138: Water Cooler
Check Valve: 3/8 FPT CHV3 004598 Cap: Reservoir 027634 Filter Assembly: 25 Micron Filter 027664 Filter Element 109207 Capacitor: 6µF 370 VAC 129489 Flowswitch Assembly 011084 Sight Glass: 1/4 NPT 128713 Kit: Lo Profile Filter 027927 Filter Element HT4400 Instruction Manual... -
Page 139: Ht4400 Torch
PARTS LIST HT4400 Torch Entire Torch Assemblies including Leads, Torch and Consumables Part Number Description 128342 HT4400 Torch with 15' leads 128431 HT4400 Torch with 10' leads 128430 HT4400 Torch with 6' leads Lead Assemblies, Torch and Consumables Part Item... -
Page 140: Consumable Configurations
Mild Steel – 100 A 120786 120777 120783 120785 Nitrogen Stainless Steel – 400 A 120786 120856 120853 120855 Nitrogen Stainless Steel – 200 A 120786 120794 120853 120855 Nitrogen Aluminum – 200 A 120786 120794 120853 120855 HT4400 Instruction Manual 6-11... -
Page 141: Consumable Parts Kit
400 amp 300 amp 200 amp 100 amp Swirl Ring 120940 120914 120792 120784 Nozzle 120935 120795 120788 120788 Nitrogen 400 amp 300 amp 200 amp 100 amp Swirl Ring 120854 120854 Nozzle 120857 120795 6-12 HT4400 Instruction Manual 4-00... -
Page 142: Valve Cluster Assembly
Circuit Breaker: 3-Phase * Used on 200V, 480V and 600V power supplies ** Used on 400V power supplies Ignition Console Page (Ref.) Part Showing Number Description Designator Qty. Item 128510 Kit: Filter Capacitor Replacement 027648 Ignition Module SSI1 HT4400 Instruction Manual 6-13... -
Page 143: Electrode Pit Depth Gauge Assembly
Flowswitch Assembly Electrode Pit Depth Gauge Assembly - 004147 To accurately measure the electrode pit depth, order the electrode pit depth gauge assembly. See Inspect Elec- trode Pit Depth in Section 4 for graphic and procedure. 6-14 HT4400 Instruction Manual... -
Page 144: Wiring Diagrams
WIRING DIAGRAMS Introduction This section contains the wiring diagrams for the HT4400 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 145 Push Button, Battery Fuse Normally Open Receptacle Ground Clamp Cap, polarized Relay, Coil Ground, Chassis Cap, non-polarized Relay, Normally Closed Ground, Earth Cap, feed-thru Relay, Normally Open IGBT Circuit breaker Relay, Solid State, AC Inductor Coax shield Relay, Solid State, DC Current Sensor Relay, Solid State, Dry Light...
- Page 146 Time Delay Closed, Switch, Level, Torch Sybols NO/Off Normally Closed Switch, Pressure, Transformer Normally Closed Electrode Switch, Pressure, Transformer, Air Core Normally Open Switch, 1 Pole, 1 Throw Nozzle Transformer Coil Switch, 1 Pole, 2 Throw Triac Switch, 1 Pole, 1 Throw, Shield Center Off VAC Source...
- Page 147 013338BA FOR MANUFACTURING OR FABRICATION ANGULAR Å } .5fl PART MUST BE FREE OF BURRS AND PURPOSES WITHOUT PERMISSION SCALE MODEL SHEET SHARP EDGES. BREAK SHARP EDGES IF FROM HYPERTHERM, INC. 1 OF 13 NECESSARY WITH CHAMFER OR RADIUS .015.
- Page 151 041690 041688 041690...
- Page 153 SHEET 9-A3 APP. BY DATE VOUT+ Box-5010 Hanover, NH 03755-5010 603/643-3441 UNLESS OTHERWISE SPECIFIED: DESCRIPTION DIMENSIONS ARE IN INCHES. BLK DIA:HT4400 SHEET SHEET TOLERANCES ARE: THIS DRAWING AND ALL INFORMATION 2 PL DECIMAL Å }.01 Cable: 123446 9-D1 ITEM NO.
- Page 159 APP. BY DATE Box-5010 Hanover, NH 03755-5010 603/643-3441 UNLESS OTHERWISE SPECIFIED: DESCRIPTION DIMENSIONS ARE IN INCHES. BLK DIA:HT4400 TOLERANCES ARE: THIS DRAWING AND ALL INFORMATION 2 PL DECIMAL Å }.01 CONTAINED THEREON IS CONSIDERED 3 PL DECIMAL Å }.005 ITEM NO.
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Page 160: Appendix A System Grounding
Figures a-1 and a-2. The ignition console should be installed near the work table, and grounded directly to it. Other modules should be installed near the power supply, and grounded directly to it (Figure a-1). HYPERTHERM Plasma Systems... -
Page 161: Work Table 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 162 Work Table Gas Console (PE) Supplementary Grounding Rod Other Equipment receiving power from the plasma power supply (PE) Figure a-1 Recommended Ground Connection Configuration Note: Configuration may vary for each installation and may require a different ground scheme. HYPERTHERM Plasma Systems...
- Page 163 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 ignition console. The ignition console should NOT be daisy-chained through the other components to the work table. HYPERTHERM Plasma Systems...
- Page 164 Section IV Fire and Explosion Hazard Data ......................b-8 Section V Health Hazard Data..........................b-8 Section VI Reactivity Data ............................b-9 Section VII Spill or Leak Procedures ........................b-9 Section VIII Special Protective Information......................b-9 Section IX Special Precautions..........................b-10 Section X Regulatory Status..........................b-10 HYPERTHERM Plasma Systems...
- Page 165 HYPERTHERM Plasma Systems...
- Page 166 HYPERTHERM Plasma Systems...
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- Page 168 HYPERTHERM Plasma Systems...
- Page 169 % of Propylene Glycol Figure b-1 Freezing Point of Propylene Glycol Solution HYPERTHERM Plasma Systems...
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Page 174: Appendix C Gas Regulators
Appendix C GAS REGULATORS In this section: Gas Regulators ...............................c-2 HYPERTHERM Plasma Systems... - Page 175 Use a high-quality, 2-stage, gas regulator to maintain consistent gas supply pressure from high pressure gas cylinders. The high-quality gas regulators listed below are available from Hypertherm and meet U.S. Compressed Gas Association (CGA) specifications.
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Page 176: Appendix D Noise Levels
Appendix D NOISE LEVELS In this section: Noise Levels ................................d-2 HT4400 Instruction Manual... - Page 177 Noise Levels Noise level measurements listed below for the HT4400 plasma system were taken from a distance of 39" (1 m), at a height of 46" (1.2 m) from the torch. Sound levels may vary due to room acoustics, room size, material being cut, cutting amps being used and other factors.
- Page 178 In this section: Mild Steel 400 Amps ...............................e-2 Mild Steel 300 Amps ...............................e-3 Mild Steel 200 Amps ...............................e-4 Mild Steel 100 Amps ...............................e-5 Stainless Steel 400 Amps ............................e-6 Stainless Steel 200 Amps ............................e-7 Aluminum 400 Amps...............................e-8 Aluminum 200 Amps...............................e-9 HT4400 Instruction Manual...
- Page 179 Cuts on these thicknesses may result in increased cut angle variation and surface roughness. Reduce cut speed by 5%-10% for improvement with some materials. Minimum inlet pressures remain at one setting of 140 psi (9.6 bar) for all material thicknesses. Approximate pressures while cutting in RUN mode: HT4400 Instruction Manual...
- Page 180 Cuts on these thicknesses may result in increased cut angle variation and surface roughness. Reduce cut speed by 5%-10% for improvement with some materials. Minimum inlet pressures remain at one setting of 140 psi (9.6 bar) for all material thicknesses. Approximate pressures while cutting in RUN mode: HT4400 Instruction Manual...
- Page 181 2419 .250 .157 2151 .314 .157 1851 .314 .188 1331 .375 1155 .500 .500 Minimum inlet pressures remain at one setting of 140 psi (9.6 bar) for all material thicknesses. Approximate pressures while cutting in RUN mode: HT4400 Instruction Manual...
- Page 182 6462 .188 .125 4355 .250 .125 3226 .250 .157 2056 .314 .157 1613 .314 Minimum inlet pressures remain at one setting of 140 psi (9.6 bar) for all material thicknesses. Approximate pressures while cutting in RUN mode: HT4400 Instruction Manual...
- Page 183 1694 .375 .188 1411 .375 .188 1032 .375 .250 .250 .250 Piercing not recommended Minimum inlet pressures remain at one setting of 140 psi (9.6 bar) for all material thicknesses. Approximate pressures while cutting in RUN mode: HT4400 Instruction Manual...
- Page 184 .314 .157 1628 .314 .188 1089 .375 .250 .500 .250 .250 Piercing not recommended Minimum inlet pressures remain at one setting of 140 psi (9.6 bar) for all material thickness. Approximate pressures while cutting in RUN mode: HT4400 Instruction Manual...
- Page 185 .375 .188 1668 .375 .188 1290 .375 .250 1085 .250 .250 Piercing not recommended Minimum inlet pressures remain at one setting of 140 psi (9.6 bar) for all material thicknesses. Approximate pressures while cutting in RUN mode: HT4400 Instruction Manual...
- Page 186 .250 .157 1851 .314 .188 1210 .500 .250 .500 .250 .250 Piercing not recommended Minimum inlet pressures remain at one setting of 140 psi (9.6 bar) for all material thicknesses. Approximate pressures while cutting in RUN mode: HT4400 Instruction Manual...
- Page 187 In this section: Mild Steel 400 Amps ..............................f-2 Mild Steel 300 Amps ..............................f-3 Mild Steel 200 Amps ..............................f-4 Mild Steel 100 Amps ..............................f-5 Stainless Steel 400 Amps ............................f-6 Stainless Steel 200 Amps ............................f-7 Aluminum 400 Amps..............................f-8 Aluminum 200 Amps..............................f-9 HT4400 Instruction Manual...
- Page 188 Cuts on these thicknesses may result in increased cut angle variation and surface roughness. Reduce cut speed by 5%-10% for improvement with some materials. Minimum inlet pressures remain at one setting of 120 psi (8.3 bar) for all material thicknesses. Approximate pressures while cutting in RUN mode: HT4400 Instruction Manual...
- Page 189 Cuts on these thicknesses may result in increased cut angle variation and surface roughness. Reduce cut speed by 5%-10% for improvement with some materials. Minimum inlet pressures remain at one setting of 120 psi (8.3 bar) for all material thicknesses. Approximate pressures while cutting in RUN mode: HT4400 Instruction Manual...
- Page 190 2419 .250 .157 2151 .314 .157 1851 .314 .188 1331 .375 1155 .500 .500 Minimum inlet pressures remain at one setting of 120 psi (8.3 bar) for all material thicknesses. Approximate pressures while cutting in RUN mode: HT4400 Instruction Manual...
- Page 191 6462 .188 .125 4355 .250 .125 3226 .250 .157 2056 .314 .157 1613 .314 Minimum inlet pressures remain at one setting of 120 psi (8.3 bar) for all material thicknesses. Approximate pressures while cutting in RUN mode: HT4400 Instruction Manual...
- Page 192 1694 .375 .188 1411 .375 .188 1032 .375 .250 .250 .250 Piercing not recommended Minimum inlet pressures remain at one setting of 120 psi (8.3 bar) for all material thicknesses. Approximate pressures while cutting in RUN mode: HT4400 Instruction Manual...
- Page 193 .314 .157 1628 .314 .188 1089 .375 .250 .500 .250 .250 Piercing not recommended Minimum inlet pressures remain at one setting of 120 psi (8.3 bar) for all material thickness. Approximate pressures while cutting in RUN mode: HT4400 Instruction Manual...
- Page 194 .375 .188 1668 .375 .188 1290 .375 .250 1085 .250 .250 Piercing not recommended Minimum inlet pressures remain at one setting of 120 psi (8.3 bar) for all material thicknesses. Approximate pressures while cutting in RUN mode: HT4400 Instruction Manual...
- Page 195 .250 .157 1851 .314 .188 1210 .500 .250 .500 .250 .250 Piercing not recommended Minimum inlet pressures remain at one setting of 120 psi (8.3 bar) for all material thicknesses. Approximate pressures while cutting in RUN mode: HT4400 Instruction Manual...
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