Hypertherm HyPro2000 Field Service Bulletin
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Hypertherm HyPro2000 Field Service Bulletin

Hypertherm HyPro2000 Field Service Bulletin

Quick disconnect, torch upgrade
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HyPro2000
Quick Disconnect
™
HT2000 Torch Upgrade
Field Service Bulletin
806550 – Revision 4 – September 2013

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Summary of Contents for Hypertherm HyPro2000

  • Page 1 HyPro2000 Quick Disconnect ™ HT2000 Torch Upgrade Field Service Bulletin 806550 – Revision 4 – September 2013...
  • Page 2 82 51 701 0358 Fax © 2013 Hypertherm, Inc. All rights reserved. HyPro2000 and Hypertherm are trademarks of Hypertherm, Inc. and may be registered in the United States and/or other countries. All other trademarks are the property of their respective holders.

  • Page 3: Required Tools

    See the Safety Section of the system’s Manual for more safety precautions. Introduction Purpose This document describes the steps necessary to upgrade the HT2000 with the HyPro2000 torch. Required tools 5/16 inch, 3/8 inch, 7/16 inch, 1/2 inch, open end wrench, and 2 inch spanner wrench.
  • Page 4 220942 Torch mounting sleeve: 1-3/4 inch outside diameter 220943 Torch mounting sleeve: 2 inch outside diameter 228557 Machine torch with consumables 228567 Gauge: Plasma pressure 228571 Kit: Firmware upgrade 806550 Field service bulletin: HyPro2000, HT2000 Torch Upgrade Field Service Bulletin...

  • Page 5: Pre-Installation

    HyPro2000 — HT2000 TORCH UPGRADE Pre-installation Before starting this upgrade you must determine if the system is a Local High Frequency (LHF) or a Remote High Frequency system (RHF). You need to know this information to choose the correct firmware chip.
  • Page 6 HyPro2000 — HT2000 TORCH UPGRADE Installation of the firmware chip 1. Access the control board (PCB2) by removing the 2 front panels. Inspect the control board. If it is a older model, you will have to replace the board and the fi rmware chip.
  • Page 7 HyPro2000 — HT2000 TORCH UPGRADE If you are installing a new control board skip to step 4. 3. Remove and discard the old chip by using the tool included in this kit. See pictures below. Place the straight end of the chip removal tool under one corner of the chip. Only 2 opposite corners will accept the tool.
  • Page 8 HyPro2000 — HT2000 TORCH UPGRADE Installation of the new control board 1. Install the appropriate fi rmware chip on the new control board by following step 4 on the previous page. Control board location 2. Locate plug PL 2.4 in receptacle 4 on the control board. If no wires are present in sockets 1 and 2 use the jumper wire provided in this kit to jump the 2 sockets.
  • Page 9 HyPro2000 — HT2000 TORCH UPGRADE 3. Label each connector before removing any connections to the old board. After labeling the connectors, remove all connections to the control board. Any wires that are present but not connected to the board will remain disconnected.
  • Page 10 Loosen the off-valve assembly to remove the existing blue plasma hose. Hold the black plasma hose provided in this kit with the bundled cables and hoses and slide the HyPro2000 torch mounting sleeve over the leads (with the threaded end closest to the torch) and install the pilot arc lead insulator onto the pilot arc lead (dark blue hose).
  • Page 11 HyPro2000 — HT2000 TORCH UPGRADE b. Connect the green and red coolant hoses to the fi tting on the torch quick-disconnect receptacle with the corresponding color. Coolant hoses Connect the cap senor lead, the plasma gas hose, and the shield gas/pilot arc lead to the torch quick-disconnect assembly.
  • Page 12 HyPro2000 — HT2000 TORCH UPGRADE 9. Slide the coolant hose insulator over the fi ttings. 10. Secure the coolant hose insulator in place by wrapping electrical tape around the lead set. 11. Slide the torch mounting sleeve over the fi ttings and screw it onto the torch quick-disconnect receptacle.
  • Page 13 HyPro2000 — HT2000 TORCH UPGRADE 12. Install the pressure gauge included in this kit between the plasma gas line and the off-valve assembly. Off-valve connection Plasma gas hose connection 13. Install the torch onto the quick-disconnect receptacle. Align any of the matching dots on the torch and quick-disconnect receptacle, and slide the torch into the receptacle.
  • Page 14 HyPro2000 — HT2000 TORCH UPGRADE 14. Verify gas pressures. Turn on the power to the system and turn on the gas supplies. b. Adjust the gas console settings for the chosen process using the cut charts in this document. Verify the gas pressure reading on the gauge between the plasma gas line and the off-valve assembly with the table below.

  • Page 15: Daily Startup

    HyPro2000 — HT2000 TORCH UPGRADE Daily start-up Prior to start-up, ensure that your cutting environment and that your clothing meet the safety requirements outlined in the Safety section of the system’s instruction manual. Check torch WARNING Before operating this system, you must read the Safety section thoroughly! Turn OFF the power supply’s main disconnect switch before proceeding with the following steps.

  • Page 16: Install Consumables

    HyPro2000 — HT2000 TORCH UPGRADE Install consumables WARNING Always disconnect power to the power supply before inspecting or changing torch consumable parts. Use gloves when removing consumables. The torch might be hot. Install consumables Check the consumable parts daily for wear before cutting. Before removing consumables, bring the torch to the edge of the cutting table, with the torch lifter raised to its highest point to prevent the consumables from dropping into the water of the water table.

  • Page 17: Arc Voltage

    Digital remote Hypertherm has produced a few versions of the digital remote. Some versions increase and decrease in 10 amp increments, and some increase and decrease in 20 amp increments. If you have a digital remote that increases/ decreases by 20 amps, set the digital remote to 120 amps or 140 amps for a 130 amp process.

  • Page 18: Estimated Kerf Width Compensation

    HyPro2000 — HT2000 TORCH UPGRADE Estimated kerf width compensation The widths in the chart below are for reference. Differences between installations and material composition may cause actual results to vary from those shown in the tables. Metric Process Thickness (mm)

  • Page 19: Mild Steel

    HyPro2000 — HT2000 TORCH UPGRADE Mild steel Flow rates – lpm/scfh Air Plasma / Air Shield Preflow 123 / 259 50 A Cutting Cutflow 114 / 241 220532 220936 220890 220529 220528 220935 (No IHS tab) Metric Test Prefl ow Test Cutfl...
  • Page 20 HyPro2000 — HT2000 TORCH UPGRADE Mild steel Flow rates – lpm/scfh O 2 Plasma / Air Shield Preflow 2 / 4 19 / 40 73 / 155 50 A Cutting Cutflow 12 / 25 73 / 155 220532 220936 220891...
  • Page 21 HyPro2000 — HT2000 TORCH UPGRADE Mild steel Flow rates – lpm/scfh O 2 Plasma / Air Shield Preflow 16 / 33 21 / 44 86 / 183 130 A Cutting Cutflow 20 / 42 86 / 183 220491 220936 220893...
  • Page 22 HyPro2000 — HT2000 TORCH UPGRADE Mild steel Flow rates – lpm/scfh Air Plasma / Air Shield Preflow 26 / 56 68 / 145 130 A Cutting Cutflow 44 / 93 68 / 145 220536 220936 220892 220488 220487 220935 (No IHS tab) Metric Test Prefl...
  • Page 23 HyPro2000 — HT2000 TORCH UPGRADE Mild steel Flow rates – lpm/scfh O 2 Plasma / Air Shield Preflow 7 / 15 27 / 57 123 / 260 200 A Cutting Cutflow 32 / 67 123 / 260 Copper electrode 220832...
  • Page 24 HyPro2000 — HT2000 TORCH UPGRADE Mild steel Flow rates – lpm/scfh O 2 Plasma / Air Shield Preflow 7 / 15 27 / 57 123 / 260 200 A Cutting Cutflow 34 / 72 123 / 260 SilverPlus electrode 220832...
  • Page 25 HyPro2000 — HT2000 TORCH UPGRADE Mild steel Flow rates – lpm/scfh Air Plasma / Air Shield Preflow 26 / 56 123 / 220 200 A Cutting Cutflow 31 / 65 123 / 220 420045 220936 420044 220488 220937 220935 (No IHS tab) Metric Test Prefl...
  • Page 26 HyPro2000 — HT2000 TORCH UPGRADE Mild steel – 3 inch under water Flow rates – lpm/scfh O 2 Plasma / Air Shield Preflow 7 / 15 27 / 57 123 / 260 200 A Cutting Cutflow 32 / 67 123 / 260...
  • Page 27 HyPro2000 — HT2000 TORCH UPGRADE Mild steel – 3 inch under water Flow rates – lpm/scfh O 2 Plasma / Air Shield Preflow 7 / 15 27 / 57 123 / 260 200 A Cutting Cutflow 34 / 72 123 / 260...

  • Page 28: Stainless Steel

    HyPro2000 — HT2000 TORCH UPGRADE Stainless steel Flow rates – lpm/scfh Air Plasma / Air Shield Preflow 123 / 259 50 A Cutting Cutflow 114 / 241 220532 220936 220890 220529 220528 220935 (No IHS tab) Metric Test Prefl ow Test Cutfl...
  • Page 29 HyPro2000 — HT2000 TORCH UPGRADE Stainless steel Flow rates – lpm/scfh Air Plasma / Air Shield Preflow 26 / 56 68 / 145 130 A Cutting Cutflow 44 / 93 68 / 145 220536 220936 220892 220488 220487 220935 (No IHS tab) Metric Test Prefl...
  • Page 30 HyPro2000 — HT2000 TORCH UPGRADE Stainless steel Flow rates – lpm/scfh Air Plasma / Air Shield Preflow 26 / 56 123 / 220 200 A Cutting Cutflow 31 / 65 123 / 220 420045 220936 420044 220488 220937 220935 (No IHS tab) Metric Test Prefl...
  • Page 31 HyPro2000 — HT2000 TORCH UPGRADE Stainless steel Flow rates – lpm/scfh N 2 Plasma / Air Shield Preflow 26 / 56 123 / 220 200 A Cutting Cutflow 31 / 65 123 / 220 420045 220936 420044 220529 020415 220935...
  • Page 32 HyPro2000 — HT2000 TORCH UPGRADE Aluminum Flow rates – lpm/scfh Air Plasma / Air Shield Preflow 123 / 259 50 A Cutting Cutflow 114 / 241 220532 220936 220890 220529 220528 220935 (No IHS tab) Metric Test Prefl ow Test Cutfl ow...
  • Page 33 HyPro2000 — HT2000 TORCH UPGRADE Aluminum Flow rates – lpm/scfh Air Plasma / Air Shield Preflow 26 / 56 68 / 145 130 A Cutting Cutflow 44 / 93 68 / 145 220536 220936 220892 220488 220487 220935 (No IHS tab) Metric Test Prefl...
  • Page 34 HyPro2000 — HT2000 TORCH UPGRADE Aluminum Flow rates – lpm/scfh Air Plasma / Air Shield Preflow 26 / 56 123 / 220 200 A Cutting Cutflow 31 / 65 123 / 220 420045 220936 420044 220488 220937 220935 (No IHS tab) Metric Test Prefl...
  • Page 35 HyPro2000 — HT2000 TORCH UPGRADE Aluminum Flow rates – lpm/scfh N 2 Plasma / Air Shield Preflow 26 / 56 123 / 220 200 A Cutting Cutflow 31 / 65 123 / 220 420045 220936 420044 220529 020415 220935 (No IHS tab) Metric Test Prefl...
  • Page 36 HyPro2000 — HT2000 TORCH UPGRADE Field Service Bulletin...

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