Hypertherm HySpeed HT2000 Instruction Manual
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Hypertherm HySpeed HT2000 Instruction Manual

Hypertherm HySpeed HT2000 Instruction Manual

200 volt plasma arc cutting system
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HySpeed
HT2000
200 Volt
Plasma Arc
Cutting System
Instruction Manual
802460 – Revision 14
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Summary of Contents for Hypertherm HySpeed HT2000

  • Page 1 HySpeed ® HT2000 ® 200 Volt Plasma Arc Cutting System Instruction Manual 802460 – Revision 14...
  • Page 2 IM246 Rev 11 to 12 4/10/00 Changed Page Description 0.02 Replaced text from "to Hypertherm's place of business..." to "to an authorized Hypertherm repair facility..." 4.14 Added remote power on/off signals to machine interface cable 6.13 Added p/ns for retaining cap with IHS tab 8.20...
  • Page 3 IM246 Rev 9 to 10 1/18/99 Changed Page Description 0.01 Uprevved because of ECNs 10078, 10079, 10070, 9753, 10012, 9864, 9742, 10020, 9926 0.05-0.08 Changed TOC for new figure descriptions, headings for parts list 2.04 Added The water muffler cannot be used with the stainless steel torch 2.06 Added new part numbers for torches, call out 2 dimensions for diameter 2.10...
  • Page 4 IM246 Rev 8 to 9 8/21/98 Changed Page Description 0.01 Uprevved because of ECNs 9763, 9758, 9803 8.25 New graphic of coolant flow 8.26 Updated graphic of coolant tank 9/18 New graphic of rear wall outside 9.19 New part numbers for solenoid valve assembly, water pump assembly 10.01 Added coolant flow diagram to wiring diagrams TOC 10.19...
  • Page 5 Changed Page Description IM246 Rev 5 to 6 1/15/98 0.01 Uprevved because of IOP, ECNs 8912, 8910, 9035, 8746 0.04 Updated TOC 0.06 Updated TOC 4.04 Added torque spec. 4.16 Removed current 400 signal from cable description 6.01 Changed TOC 6.03 Added note to hold down on button for up to 1 minute 6.10...
  • Page 6 IM246 Rev 4 to 5 7/11/97 Changed Page Description 0.01 Uprevved to 5 because of new valve in RHF console 4.07 New graphic of RHF console 6.13 Eliminated 40A cutting chart for mild steel 6.16 Eliminated 40A cutting chart for mild steel 6.17 Added to note on 020679 swirl ring use 7.05...
  • Page 7 IM246 Rev 2 to 3 2/14/97 Changed Page Description 0.01 Uprevved to 3, added email and web address 0.05 Changed Appendices page #s 2.05 Added 440/460 power supply part # 2.06 Changed part # of machine torch 2.07 Changed part #s of Gas Console and Motor Valve Console 3.05 Added current draw and fuse size for 440V power supply 3.06...
  • Page 8 IM246 Rev 1 to 2 12/20/96 Changed Page Description 0.01 Uprevved manual due to LVD compliance 0.03-0.08 Updated table of contents 1.01-1.04 New Safety section 1a.01-1a.04 New French Safety section 2.02 Changed reference from 380-415V CE to 400V CE 2.05 Changed reference from 380-415V CE to 400V CE 3.04 Changed warning on propylene glycol to not induce vomiting...
  • Page 10 Revision 14 – November, 2013 Hypertherm, Inc. Hanover, NH USA www.hypertherm.com © Copyright 2013 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 11 Hypertherm, Inc. Etna Road, P.O. Box 5010 Hanover, NH 03755 USA 603-643-3441 Tel (Main Office) 603-643-5352 Fax (All Departments) info@hypertherm.com (Main Office Email) 800-643-9878 Tel (Technical Service) service@hypertherm.com (Technical Service Email) 800-737-2978 Tel (Customer Service) customer.service@hypertherm.com (Customer Service Email) Hypertherm Automation, LLC...
  • Page 12 The size of the surrounding area to be EMC INTRODUCTION Earthing of Workpiece considered will depend on the structure of Hypertherm's CE-marked equipment is built Where the workpiece is not bonded to earth the building and other activities that are tak- in compliance with standard EN50199. The for electrical safety , nor connected to earth ing place.
  • Page 13 WARRANTY Hypertherm, infringes any patent of any third party . You shall WARNING notify Hypertherm promptly upon learning of any action or Genuine Hypertherm parts are the factory-recommended threatened action in connection with any such alleged replacement parts for your Hypertherm system. Any damage infringement, and Hypertherm’...

  • Page 14: Table Of Contents

    Remote High Frequency (RHF) Console ......................2-2 Gas Console ..............................2-3 Motor Valve Console............................2-3 Argon-Hydrogen Console..........................2-3 Remote Voltage/Current (V/C) Control ......................2-3 Initial Height Sensing (IHS) ..........................2-4 Timer/Counter ..............................2-4 Water Muffler..............................2-4 Specifications................................2-5 System Requirements............................2-5 Power Supply ..............................2-5 HySpeed HT2000 Machine Torches ........................2-6 HySpeed HT2000 Instruction Manual...
  • Page 15 Connecting the HF Torch Leads to the RHF Console..................4-28 Connecting the HF Torch Leads to the Torch ....................4-30 Connecting the Off-Valve Cable and Plasma Hose from the Torch to the Motor Valve Console ....4-30 Optional Power Supply Connections ........................4-32 HySpeed HT2000 Instruction Manual...
  • Page 16 Removal and Inspection..........................6-37 Replacement ..............................6-38 Changing the Water Tube ..........................6-39 How to Optimize Cut Quality...........................6-40 Tips for Table and Torch ..........................6-40 Plasma Set-up Tips............................6-40 Maximize the Life of Consumable Parts......................6-40 Additional Factors of Cut Quality........................6-41 Additional Improvements..........................6-42 HySpeed HT2000 Instruction Manual...
  • Page 17 Introduction ................................9-2 System Parts Diagram ..............................9-2 Power Supply Front Panel...............................9-5 THC Assembly ..............................9-5 Control Panel ..............................9-6 Base Plate and Components ...........................9-7 Center Wall Right Side.............................9-9 Center Wall Left Side .............................9-11 Front Wall Inside ............................9-13 Rear Wall Inside.............................9-15 HySpeed HT2000 Instruction Manual...
  • Page 18 Remote V/C – Programmable (PR) Control Station ....................9-31 IHS Console................................9-33 Argon-Hydrogen Console ............................9-34 Timer/Counter .................................9-35 Hyspeed HT2000 Machine Torch ...........................9-37 Hyspeed HT2000 Stainless Steel Machine Torch ....................9-37 Torch Mounting Bracket............................9-37 Hyspeed HT2000 Optional Machine Torch......................9-39 Torch Mounting Bracket............................9-39 Torch Leads, Leads, Cables, and Hoses........................9-40 Consumable Parts Kits ............................9-50...
  • Page 19 Connect Power Cable ...............................e-2 Power Supply ..............................e-2 Line Disconnect Switch ............................e-4 EMI Filter Parts List ..............................e-5 Appendix F SYSTEM GROUNDING ........................g-1 System Grounding Requirements..........................g-1 Suggested Ground Cable Routing..........................g-1 Power Supply ..............................g-1 Equipment Grounding ............................g-1 Work Table Grounding .............................g-2 HySpeed HT2000 Instruction Manual viii...
  • Page 20 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 21: Follow Safety Instructions

    • 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 22: 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 23: 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 5/6/02...

  • Page 24: 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 25: 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) warning labels. Hypertherm Plasma Systems 8-99...

  • Page 26: Section 1A

    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 27: 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. Hypertherm Systèmes plasma 1a-2 2/12/01...

  • Page 28: Les Chocs Électriques Peuvent Être Fatals

    • Installer un sectionneur avec fusibles appropriés, à la prise de terre appropriée. proximité de la source de courant. Ce dispositif permet à • Chaque système plasma Hypertherm est conçu pour être l’opérateur d’arrêter rapidement la source de courant en utilisé uniquement avec des torches Hypertherm cas d’urgence.

  • Page 29: 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. Hypertherm Systèmes plasma 1a-4 5/6/02...

  • Page 30: Sécurité Des Bouteilles De Gaz Comprimé

    LES TUYAUX GELÉS • Se tenir le plus loin possible de la source de courant. Les tuyaux gelés peuvent être endommagés ou éclater si l'on essaie de les dégeler avec une torche plasma. Hypertherm Systèmes plasma 1a-5 2/12/01...

  • Page 31: 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. Hypertherm Systèmes plasma 1a-6 2/12/01...

  • Page 32: Specifications

    Initial Height Sensing (IHS) ..........................2-4 Timer/Counter ..............................2-4 Water Muffler..............................2-4 Specifications................................2-5 System Requirements............................2-5 Power Supply ..............................2-5 HYSpeed HT2000 Machine Torches .......................2-6 Remote High Frequency Console ........................2-6 Gas Console ..............................2-7 Motor Valve Console............................2-7 Argon/Hydrogen Console..........................2-8 Digital Remote (DR) V/C Control ........................2-8 Programmable Remote (PR) V/C Control ......................2-9 Initial Height Sensing .............................2-10...

  • Page 33: Introduction

    SPECIFICATIONS Introduction Hypertherm’s HT2000 is designed as a machine-mounted plasma cutting system for cutting most metals from gauge to two-inch (50mm) thick. A micro-controller on the power supply control board helps to provide extended life for the torch consumable parts. To achieve consumable long life, all cuts must begin and end on the plate surface;...

  • Page 34: Gas Console

    It is used with guidance machinery that already includes plasma control switches. Programmable Remote - Includes the voltage and current displays. No switches or potentiometers are included. All functions are controlled by the guidance machinery computer. This unit also interconnects with the computer interface. HySpeed HT2000 Instruction Manual...

  • Page 35: Initial Height Sensing (Ihs)

    The water muffler can be used to cut both above and below water. The water muffler can not be used with the stainless steel machine torch. Refer to the Water Muffler Instruction Manual (#802050) for more detailed information. HySpeed HT2000 Instruction Manual...

  • Page 36: System Requirements

    #073196 with THC ........440/460 VAC, 3PH, 50-60 Hz, 49/47 amps #073063 with THC/ #073104 without THC ..200 VAC, 3PH, 50 Hz, 108 amps #073066 with THC/ #073108 without THC ..600 VAC, 3PH, 60 Hz, 36 amps HySpeed HT2000 Instruction Manual...

  • Page 37: Power Supply

    Depth ................41-1/4" (104 cm) Weight................780 pounds (351 kg); 800 pounds (363 kg) on CE units Cooling ..............Forced Air (Class F) Torch Coolant Tank Capacity ........2.9 gallons (11 liters) HySpeed HT2000 Machine Torches (#128381,128367 or 128141) 17.75 (450.85) 2.38 11.75 (298.45) 3.62 (91.92) (60.48)
  • Page 38 Motor Valve Console (#073219) 11-1/2" 10-3/4" 8" 6" 5/16" dia. (4) Figure 2-3 Mounting Dimensions - Motor Valve Console Dimensions and Weight: Width................11.5" (29 cm) Height ................4" (10 cm) Depth ................8" (20 cm) Weight................18 pounds (8.2 kg) HySpeed HT2000 Instruction Manual...
  • Page 39 Control Range............Current: 40 to 200 Amps Voltage: 100 to 200 Volts Control Resolution ............Current: 10 Amps Voltage: 5 Volts Dimensions and Weight: Width................11-1/2" (29 cm) Height ................3" (7.6 cm) Depth ................13-3/8" (34 cm) Weight................5 pounds-5 oz. (2.4 kg) HySpeed HT2000 Instruction Manual...
  • Page 40 Control Range ..............Current: 40 to 200 Amps Voltage: 100 to 200 Volts Control Resolution ..............Current: 10 Amps Voltage: 5 Volts Dimensions and Weight: Width ..................11-1/2" (29 cm) Height..................3" (7.6 cm) Depth ..................12-1/2" (31.8 cm) Weight ................5 pounds-5 oz. (2.4 kg) HySpeed HT2000 Instruction Manual...
  • Page 41 Height ................2-1/2" (6.4 cm) Depth ................8-5/8" (21.9 cm) Weight................3 pounds (1 kg) Water Muffler – Optional The water muffler can not be used with the stainless steel machine torch. Refer to Water Muffler Instruction Manual (#802050). HySpeed HT2000 Instruction Manual 2-10...

  • Page 42: Pre-Installation

    Power Cable..............................3-5 Positioning the Power Supply ..........................3-6 Electrical Configurations ............................3-7 240/480V Linkboard Configurations.........................3-7 220/380/400/415V Transformer T1 and T2 Configurations ................3-8 Connecting the Power ............................3-10 Torch Lifter Requirement............................3-11 Optional Equipment..............................3-11 Water Muffler ..............................3-11 Initial Height Sensing (IHS) ..........................3-12 HySpeed HT2000 Instruction Manual...

  • Page 43: Introduction

    Use an inert gas hose to connect the air supply to the input connection on the gas console. Hosing can be purchased through Hypertherm. When using air as the plasma or shield gas, Hypertherm recommends a three-stage filtration system. See Appendix section for suggested filtration.

  • Page 44: Oxygen, Nitrogen, Or Argon/Hydrogen As Plasma Gas

    From Gas Console to Motor Valve Console Hose from the gas console to the motor valve console is provided by Hypertherm. WARNING Cutting with oxygen as the plasma gas can cause a potential fire hazard due to the oxygen- enriched atmosphere that it creates.

  • Page 45: Torch Coolant Requirements

    PRE-INSTALLATION Torch Coolant Requirements The power supply 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° C) and contains a corrosion inhibitor (benzotriazole) to protect copper surfaces in the coolant loop.

  • Page 46: Power Requirements

    Wire sizes vary based on the distance of the receptacle from the main box. The wire sizes listed on the following page were taken from the National Electric Code 1990 handbook, table 310.16. Use a 4-conductor HySpeed HT2000 Instruction Manual...

  • Page 47: Positioning The Power Supply

    3. Do not place any filter device over the air intake locations. This reduces cooling efficiency and VOIDS THE WARRANTY. 4. After placement of the power supply, the line disconnect switch box can be placed close to the power supply for safety purposes. HySpeed HT2000 Instruction Manual...

  • Page 48: Electrical Configurations

    • The 240/480-volt units are shipped from the factory linked for 480-volt operation. The links must be moved for 240-volt operation. Ensure that the linkboard is configured properly to the appropriate voltage line (see Figure 3-1). Figure 3-1 Dual Voltage 240/480-Volt Linkboard Configurations HySpeed HT2000 Instruction Manual...

  • Page 49: 220/380/415V Transformer T1 And T2 Configurations

    T1 and 30 kw transformer T2 must be re-configured (see Figure 3-2). * A long #6 AWG 600V wire is shipped with every unit. Figure 3-2 220/380/400/415V Transformer T1 and T2 Configurations – 1 of 2 HySpeed HT2000 Instruction Manual...
  • Page 50 PRE-INSTALLATION Figure 3-2 220/380/400/415V Transformer T1 and T2 Configurations – 2 of 2 HySpeed HT2000 Instruction Manual...

  • Page 51: Connecting The Power

    ON (1) pushbutton on the power supply has not been pressed. 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. HySpeed HT2000 Instruction Manual 3-10...

  • Page 52: Torch Lifter Requirement

    This results in excessive noise and smoke during the initial starting. Water pump and water hosing can be purchased by the customer, or supplied by Hypertherm when ordering a Water Muffler system. Please refer to Water Muffler System part numbers listed below, and Water Muffler instruction manual 802050 for further information.

  • Page 53: Initial Height Sensing (Ihs)

    A power cable for the Water Muffler pump must be provided by the customer. 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 and cable sizes should be selected accordingly.

  • Page 54: Installation

    Connecting the Off-Valve Cable and Plasma Hose from the Torch to the Motor Valve Console ....4-30 Optional Power Supply Connections ........................4-32 Timer/Counter to Power Supply ........................4-32 Hold Cable Connections (When using Multi-Torch Systems).................4-32 Argon-Hydrogen Connections........................4-34 Mounting the Machine Torch...........................4-34 Torch Alignment..............................4-34 HySpeed HT2000 Instruction Manual...

  • Page 55: Upon Receipt

    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 department at 1-800-643-0030 or Field Service at 1-800-643-9878.

  • Page 56: Module Grounding And Grounding Checks

    Water at bottom of plate without Water Muffler 100 dbs Water at bottom of plate with Water Muffler 95 dbs Water 3" over plate without Water Muffler 75 dbs Water 3" over plate with Water Muffler 72 dbs Figure 4-1 Noise Levels (Decibels) HySpeed HT2000 Instruction Manual...

  • Page 57: System Units Placement

    Water Filter RHF Console IHS Console Air In Shield Gas In Plasma Gas In Gas Console Water Muffler Remote V/C Pump Power In Machine Control Power Supply Power In Figure 4-2 Typical Unit Placement for Gantry Cutter HySpeed HT2000 Instruction Manual...
  • Page 58 Power Plasma gas hosing Shield gas hosing Air hosing Shielded torch leads Water cooling hosing Cables , etc. Reference to installation steps See Section 7 Figure 4-3 HT2000 Interconnect System Diagram with IHS and Water Muffler HySpeed HT2000 Instruction Manual...

  • Page 59: Power Supply Connections

    Any special instructions for installation are explained on the left-hand page. The cable and hose part numbers on these pages represent the most commonly used lengths. For additional lenghts, see Section 9 or call Hypertherm. WARNING All power must be turned OFF before performing installation!! Negative Lead –...
  • Page 60 INSTALLATION Pilot Arc Shield To work table Power Supply Connections– Rear RHF Console Figure 4-4 Power Supply Connections to RHF Console and Work Table HySpeed HT2000 Instruction Manual...
  • Page 61 75 ft (23 m) 028440 15 ft (4.6 m) 028444 100 ft (30 m) 028653 20 ft (6 m) 028445 150 ft (46 m) 028441 25 ft (7.6 m) 028637 200 ft (61 m) 028442 50 ft (15 m) HySpeed HT2000 Instruction Manual...
  • Page 62 INSTALLATION Power Supply – Rear RHF Console – Rear Figure 4-5 Power Supply Connections to RHF Console HySpeed HT2000 Instruction Manual...
  • Page 63 023605 25 ft (7.5 m) 023757 38 ft (11.5 m) 023606 50 ft (15 m) 023607 75 ft (23 m) 023608 100 ft (30.5 m) 023743 125 ft (38 m) 023609 150 ft (46 m) HySpeed HT2000 Instruction Manual 4-10...
  • Page 64 INSTALLATION Power Supply – Rear 3 X 1 2WRENCHES Gas Console Figure 4-6 Power Supply Connection to Gas Console HySpeed HT2000 Instruction Manual 4-11...
  • Page 65 023590 25 ft (7.6 m) 023776 35 ft (10.5 m) 023591 50 ft (15 m) 023592 75 ft (23 m) 023593 100 ft (30.5 m) 023594 150 ft (46 m) 023658 200 ft (61 m) HySpeed HT2000 Instruction Manual 4-12...
  • Page 66 INSTALLATION Power Supply – Rear Motor Valve Console Figure 4-7 Power Supply Connection to Motor Valve Console HySpeed HT2000 Instruction Manual 4-13...
  • Page 67 Remote Power ON Shield Shield * Signals are AC relays. DC relays available as an option from Hypertherm by ordering kit:128404 †WARNING When installing or servicing the HT2000, 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 HT2000 system are OFF during installation and when servicing.
  • Page 68 100 ft (30.5 m) 123650 115 ft (35 m) 023903 125 ft (38 m) 023857 150 ft (46 m) 023858 200 ft (61 m) Figure 4-9 Machine V/C Interface Cable – PS to Machine Computer Interface HySpeed HT2000 Instruction Manual 4-15...
  • Page 69 023836 50 ft (15 m) 023899 250 ft (76 m) 023837 75 ft (23 m) 023900 275 ft (84 m) 023838 100 ft (30.5 m) 023901 300 ft (92 m) 023898 125 ft (38 m) HySpeed HT2000 Instruction Manual 4-16...
  • Page 70 INSTALLATION Power Supply – Rear Digital Remote – Rear Programmable Remote – Rear Figure 4-10 Power Supply Connections to Remote V/C Modules HySpeed HT2000 Instruction Manual 4-17...
  • Page 71 25 ft (7.6m) Indicates Pairs w/Drain 023860 50 ft (15m) 023861 75 ft (23m) Note: On IHS End, cut Red/Black Shield & 023862 100 ft (30.5m) White/Black Shield Wires 023863 150 ft (46m) 023864 200 ft (61m) HySpeed HT2000 Instruction Manual 4-18...
  • Page 72 INSTALLATION Power Supply – Rear IHS Module Figure 4-11 Power Supply Connections to Water Muffler and IHS Console HySpeed HT2000 Instruction Manual 4-19...

  • Page 73: Initial Height Sensing (Ihs) Connections

    Air Hose Assembly – IHS Module to Inductive Sensor Air Cylinder The 40-foot air hose is a component of the IHS leads packages – see page 9-43. Part No. Length 024144 40 ft (12 m) HySpeed HT2000 Instruction Manual 4-20...

  • Page 74: Initial Height Sensing (Ihs) Connections

    INSTALLATION AIR CYLINDER INDUCTIVE IHS CONTROL PROBES MODULE TORCH MOUNTING SUBASSEMBLY TORCH LIFTER (TYPICAL) SWIVEL FITTING TORCH (TYPICAL) 20 PSI REGULATED SHOP AIR Figure 4-12 Initial Height Sensing Connections HySpeed HT2000 Instruction Manual 4-21...
  • Page 75 Note: If the upper limit switch signal comes from an interface on the cutting machine, the shield must be electrically isolated from other shields in other cables. Using a separate cable will avoid ground-loop problems. HySpeed HT2000 Instruction Manual 4-22...
  • Page 76 INSTALLATION UPPER LIMIT SWITCH AND CABLE IHS CONTROL MODULE TORCH LIFTER Figure 4-13 Intial Height Sensing Upper Limit Switch Connections HySpeed HT2000 Instruction Manual 4-23...

  • Page 77: Gas Console Connections

    024115 100 ft (30 m) 024342 20 ft (6 m) 024119 150 ft (46 m) 024133 25 ft (7.6 m) 024184 180 ft (55 m) 024012 50 ft (15 m) 024123 200 ft (61 m) HySpeed HT2000 Instruction Manual 4-24...
  • Page 78 INSTALLATION 2WRENCHES Gas Console – Rear Figure 4-14 Gas Console Connections – Gas Console to Gas Supplies HySpeed HT2000 Instruction Manual 4-25...
  • Page 79 024323 45 ft (13.8 m) 024308 20 ft (6.2 m) 024311 50 ft (15 m) 024321 25 ft (7.6 m) 024357 75 ft (23 m) 024309 30 ft (9.1 m) 024358 100 ft (30 m) HySpeed HT2000 Instruction Manual 4-26...
  • Page 80 INSTALLATION 2WRENCHES Gas Console – Rear Motor Valve Console – Rear RHF Console – Rear Figure 4-15 Gas Console Connections – Gas Console to RHF and Motor Valve Consoles HySpeed HT2000 Instruction Manual 4-27...

  • Page 81: Rhf And Motor Valve Consoles To Torch Connections

    028658 15 ft (4.5 m) 028662 40 ft (12 m) 028659 20 ft (6 m) 028663 45 ft (13.7 m) 028546 25 ft (7.5 m) 028547 50 ft (15 m) 028660 30 ft (9 m) HySpeed HT2000 Instruction Manual 4-28...
  • Page 82 INSTALLATION Pilot/Shield Gas Hose (Blue) Torch Brass Fitting Cap-On Sensor Hose (Gray) Torch Coolant Hose (w/Red Band) Torch Coolant Hose (w/Green Band) Figure 4-16 HF Torch Lead Connections in RHF Console HySpeed HT2000 Instruction Manual 4-29...

  • Page 83: Connecting The Hf Torch Leads To The Torch

    A. Connect the Plasma hose from Point 1 (left-hand threaded connection) of the Off-valve subassembly to the Plasma Flow connector on the motor valve console. B. Connect the Torch off-valve cable from the Off-valve subassembly to the 4X2 connector on the motor valve console. HySpeed HT2000 Instruction Manual 4-30...
  • Page 84 Point 2 (left-hand threaded) Off-valve subassembly Off-valve connector Torch sleeve 12" Off-valve hose Motor Valve Console Red and Green tubes Point 5 Point 4 (left-hand threaded) Point 3 Torch main body Figure 4-17 Machine Torch Connections HySpeed HT2000 Instruction Manual 4-31...

  • Page 85: Optional Power Supply Connections

    023340 15 ft (4.5 m) 023341 25 ft (7.6 m) – Black Hold Signal 023342 50 ft (15 m) – Hold Common 023343 100 ft (30 m) Shield Hold Shield 023344 150 ft (46 m) HySpeed HT2000 Instruction Manual 4-32...
  • Page 86 INSTALLATION Power Supply – Inside Rear 11X1 Timer/Counter – Rear Figure 4-18 Timer/Counter Cable Connections / Hold Cable Connections HySpeed HT2000 Instruction Manual 4-33...

  • Page 87: Argon-Hydrogen Connections

    Prior to cutting with the machine torch, ensure that the torch is at right angles to the workpiece to get a clean, vertical cut. Use a square to align the torch. The torch should be aligned at 0° and 90° (Figure 4-20). HySpeed HT2000 Instruction Manual 4-34...
  • Page 88 Turn Gases On..............................5-3 Turn Power Supply On and Adjust Voltage/Current ..................5-3 Adjust Preflow Gases............................5-5 Adjust Cut Flow Gases and Check Initial Height Sensing (IHS) ..............5-5 Final Torch Adjustment .............................5-6 Check Torch Height Control (THC) and V/C Module..................5-6 HySpeed HT2000 Instruction Manual...

  • Page 89: Introduction

    • Ensure that your cutting environment and that your clothing meet the safety requirements outlined in the Safety section of this manual. • Be certain that all pre-installation and installation requirements have been met. Refer to Section 3 Pre-Installation and Section 4 Installation in this manual. HySpeed HT2000 Instruction Manual...

  • Page 90: System Checkout

    Ensure the green POWER ON indicator on the power supply lights. 7. Set the VOLTAGE and CURRENT on the DR V/C module. Select the arc current and arc voltage from the Cut Charts in Section 6 for the type and thickness of metal to test cut. HySpeed HT2000 Instruction Manual...
  • Page 91 POST-INSTALLATION UP Indicator DOWN Indicator POWER ON Button Figure 5-1 Controls and Indicators for System Checkout HySpeed HT2000 Instruction Manual...

  • Page 92: Adjust Preflow Gases

    DOWN indicator light on the V/C module will go off and the probes will start to retract. At this point, depress the STOP button and disable the Initial Height Sensing. You are now ready for Final Torch Adjustment. HySpeed HT2000 Instruction Manual...

  • Page 93: Final Torch Adjustment

    As the torch makes a corner cut, the machine motion speed should remain constant and the UP and DOWN indicators do not light. Machine motion and plasma arc will automatically stop when the cut is complete. The system is now operational. HySpeed HT2000 Instruction Manual...
  • Page 94 If the system does not function as outlined in this procedure, recheck the pre-installation requirements and installation directions in this manual. 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.
  • Page 95 POST-INSTALLATION HySpeed HT2000 Instruction Manual...

  • Page 96: Operation

    Removal and Inspection..........................6-37 Replacement ..............................6-38 Changing the Water Tube ..........................6-39 How to Optimize Cut Quality...........................6-40 Tips for Table and Torch ..........................6-40 Plasma Set-up Tips............................6-40 Maximize the Life of Consumable Parts......................6-40 Additional Factors of Cut Quality........................6-41 Additional Improvements..........................6-42 HySpeed HT2000 Instruction Manual...

  • Page 97: Front Panel Controls And Indicators

    When illuminated, indicates that the plasma gas pressure is inadequate. • COOLANT TEMP LED When illuminated, indicates that the torch coolant temperature is too high (above 70°C (160°F)). • COOLANT FLOW LED When illuminated, indicates that the coolant flow from the torch is inadequate. HySpeed HT2000 Instruction Manual...

  • Page 98: Status Indicators Before Startup

    LEDs remain illuminated, shut down the system and correct the problem. See Status LED Troubleshooting in Section 8, if necessary. ON (1) OFF(0) DC ON INTERLOCK TRANSFORMER COOLANT LEVEL SHIELD GAS/CAP PLASMA GAS COOLANT TEMP COOLANT FLOW Figure 6-1 Power Supply Front Panel Controls and Indicators HySpeed HT2000 Instruction Manual...

  • Page 99: Gas Console

    Run – This position enables the contactor and the subsequent firing of the arc after the gas rates have been set in the Test Preflow and Test Cut Flow positions. HySpeed HT2000 Instruction Manual...
  • Page 100 • Shield Gas Metering Valve (MV4) Adjusts shield gas pressure to the torch. • DC Light (LT1) Lights when main contactor closes, indicating DC power is being supplied to the torch. Figure 6-2 Gas Console Front Panel Controls and Indicators HySpeed HT2000 Instruction Manual...

  • Page 101: Digital Remote (Dr) V/C Module

    Displays cutting current. • UP / DOWN LEDs Indicates that torch height is being adjusted up or down. UP LED VOLTAGE Adjust CURRENT Adjust DOWN LED Figure 6-3 Digital Remote (DR) V/C Front Panel Controls and Indicators HySpeed HT2000 Instruction Manual...

  • Page 102: Programmable Remote (Pr) V/C Module

    Indicates the number of times that the arc cut cycle ended before the programmed current ramp-down time had elapsed. This reading provides a direct correlation to the long-life operation of the electrode; the higher the reading, the shorter the electrode life. Reset Reset Figure 6-5 Timer / Counter HySpeed HT2000 Instruction Manual...

  • Page 103: Noise Levels (Decibels)

    • Water at bottom of plate with Water Muffler @ 10 feet- 95 dbs • Water 3" over plate without Water Muffler @ 10 feet- 75 dbs • Water 3" over plate with Water Muffler @ 10 feet- 72 dbs Figure 6-6 Noise Levels (Decibels) HySpeed HT2000 Instruction Manual...

  • Page 104: Daily Start-Up

    5. Set S1 on the gas console to N /Air (for nitrogen or air as plasma /Air gas), or O (for oxygen as plasma gas). 6. Turn the required supply gases On. /Air PLASMA PreFlow Cut Flow PreFlow Test Test Preflow Cutflow HySpeed HT2000 Instruction Manual...

  • Page 105: Turn Power Supply On And Adjust Voltage/Current

    Cut Chart specifications by turning the shield gas adjust knob (MV4). Note: If you have changed consumable parts or if the power supply has been off for more than one hour, purge gas lines by leaving system in Test Preflow for one minute. HySpeed HT2000 Instruction Manual 6-10...

  • Page 106: Adjust Cut Flow Gases And Prepare For Cutting

    3. Torch parts are worn (see Changing Consumable Parts). • Cut angle not square. Causes can be: 1. Wrong direction of machine travel. High quality side is on the right with respect to the forward motion of the torch. HySpeed HT2000 Instruction Manual 6-11...

  • Page 107: Technical Questions

    Also see Cutting Techniques later in this section for methods to improve cutting performance. Technical Questions Claims for defective merchandise – All units shipped from Hypertherm undergo rigorous quality control testing. However, if your system does not function correctly: 1. Recheck all pre-installation and installation requirements and connections.
  • Page 108 020955 counterclockwise can be used for all cutting currents except 50A; 120185 for 50A cutting only. For Hyspeed 200A O cutting only; Use retaining cap part # 220238 (clockwise cutting) & 220241 (counter-clockwise cutting). HySpeed HT2000 Instruction Manual 6-13...
  • Page 109 OPERATION Mild Steel HySpeed 200 amps • O Plasma / Air Shield This gas combination gives superior cut speed, minimum dross, minimum surface nitriding and excellent weldability. 220242 (cw) 220236 (cw) 220243 (ccw) 220244 (ccw) 220239 220237 220235 Retaining cap Shield Nozzle Swirl ring...
  • Page 110 OPERATION Mild Steel 200 amps • O Plasma / Air Shield This gas combination gives superior cut speed, minimum dross, minimum surface nitriding and excellent weldability. 120837 (cw) 120833* (cw) 120667 (standard) 120838 (ccw) 120834 (ccw) 020424 020605 Electrode Retaining cap Swirl ring Shield Nozzle...
  • Page 111 Set plasma gas inlet pressure to 90 psi (6.2 bar) Set shield gas inlet pressure to 90 psi (6.2 bar) Production cutting above 1" (25 mm) not recommended Drop cutting above 1-1/2" (38 mm) not recommended HySpeed HT2000 Instruction Manual 6-16...
  • Page 112 .157 .314 1140 3/16 1-1/4 1-1/2 Notes: Set plasma gas inlet pressure to 120 psi (8.3 bar) Set shield gas inlet pressure to 90 psi (6.2 bar) Production cutting above 1" (25 mm) not recommended HySpeed HT2000 Instruction Manual 6-17...
  • Page 113 Set arc current to 80 amps when cutting .075" (2 mm) thick mild steel Notes: Set plasma gas inlet pressure to 90 psi (6.2 bar) Set shield gas inlet pressure to 90 psi (6.2 bar) Production cutting above 3/8" (10 mm) not recommended HySpeed HT2000 Instruction Manual 6-18...
  • Page 114 OPERATION Mild Steel 100 amps • O Plasma / Air Shield This gas combination gives good cut speed, low dross and is very economical. Some surface nitriding can occur. While this process may be used on thicker materials, optimal recommended range is to 3/8" (10mm). 120837 (cw) 020613 (cw) 120838 (ccw)
  • Page 115 Note that some height control systems may need to be locked out to prevent the torch from diving into the plate if the machine motion delay option is used. HySpeed HT2000 Instruction Manual 6-20...
  • Page 116 .314 1520 3/16 1150 Notes: Set air plasma gas inlet pressure to 90 psi (6.2 bar) Set air shield gas inlet pressure to 90 psi (6.2 bar) Production cutting above 7/8" (22 mm) not recommended HySpeed HT2000 Instruction Manual 6-21...
  • Page 117 .157 .314 1140 3/16 Notes: Set nitrogen plasma gas inlet pressure to 120 psi (8.3 bar) Set air shield gas inlet pressure to 90 psi (6.2 bar) Production cutting above 7/8" (22 mm) not recommended HySpeed HT2000 Instruction Manual 6-22...
  • Page 118 .314 1350 3/16 Notes: Set nitrogen plasma gas inlet pressure to 120 psi (8.3 bar) Set carbon dioxide shield gas inlet pressure to 90 psi (6.2 bar) Production cutting above 7/8" (22 mm) not recommended HySpeed HT2000 Instruction Manual 6-23...
  • Page 119 Shield Argon-Hydrogen Manifold (073109) Required* This gas combination (Hypertherm recommends a mixture of 35% hydrogen and 65% argon for the plasma gas) gives maximum thickness cutting capability, minimum dross levels, minimum amount of surface contamination, excellent weldability and excellent cut quality on thicknesses greater than 1/2". On thicknesses less than 1/2", excessive dross levels may be experienced.
  • Page 120 SCFH) SCFH) 1720 1120 Notes: Set air plasma gas inlet pressure to 90 psi (6.2 bar) Set air shield gas inlet pressure to 90 psi (6.2 bar) Production cutting above 3/8" (10 mm) not recommended HySpeed HT2000 Instruction Manual 6-25...
  • Page 121 Shield Argon-Hydrogen Manifold (073109) Required* This gas combination (Hypertherm recommends a mixture of 35% hydrogen and 65% argon for the plasma gas) gives good cut speed, but may result in excessive dross. Some surface nitriding and surface oxidation of alloying elements can occur.
  • Page 122 SCFH) 3/32 3/16 1900 Notes: Set air plasma gas inlet pressure to 90 psi (6.2 bar) Set air shield gas inlet pressure to 90 psi (6.2 bar) Production cutting above 1/8" (3 mm) not recommended HySpeed HT2000 Instruction Manual 6-27...
  • Page 123 2240 .157 .314 1650 3/16 1150 Notes: Set plasma gas inlet pressure to 90 psi (6.2 bar) Set shield gas inlet pressure to 90 psi (6.2 bar) Production cutting above 7/8" (22 mm) not recommended HySpeed HT2000 Instruction Manual 6-28...
  • Page 124 2600 1620 .157 .314 1350 3/16 Notes: Set plasma gas inlet pressure to 120 psi (8.3 bar) Set shield gas inlet pressure to 90 psi (6.2 bar) Production cutting above 7/8" (22 mm) not recommended HySpeed HT2000 Instruction Manual 6-29...
  • Page 125 2600 1820 .157 .314 1350 3/16 Notes: Set plasma gas inlet pressure to 120 psi (8.3 bar) Set shield gas inlet pressure to 90 psi (6.2 bar) Production cutting above 7/8" (22 mm) not recommended HySpeed HT2000 Instruction Manual 6-30...
  • Page 126 Shield Argon-Hydrogen Manifold (073109) Required* This gas combination (Hypertherm recommends a mixture of 35% hydrogen and 65% argon for the plasma gas) gives maximum thickness cutting capability, excellent cut quality and excellent weldability. Electrode life is extended when this combination is used.
  • Page 127 2050 SCFH) SCFH) SCFH) 1510 1000 Notes: Set plasma gas inlet pressure to 90 psi (6.2 bar) Set shield gas inlet pressure to 90 psi (6.2 bar) Production cutting above 3/8" (10 mm) not recommended HySpeed HT2000 Instruction Manual 6-32...
  • Page 128 100 amps • H35 Plasma / N Shield Argon-Hydrogen Manifold (073109) Required* This gas combination (Hypertherm recommends a mixture of 35% hydrogen and 65% argon for the plasma gas) gives good cut speed, low dross levels and is very economical. WARNING...
  • Page 129 3/32 3/16 2550 SCFH) SCFH) SCFH) Notes: Set plasma gas inlet pressure to 90 psi (6.2 bar) Set shield gas inlet pressure to 90 psi (6.2 bar) Production cutting above 1/8" (3 mm) not recommended HySpeed HT2000 Instruction Manual 6-34...
  • Page 130 Set nitrogen plasma gas inlet pressure to 120 psi (8.3 bar). Set shield gas inlet pressure to 90 psi (6.2 bar). Production cutting above 1" (25 mm) not recommended Beveling cuts should be made between 45° and 90° to the work surface. HySpeed HT2000 Instruction Manual 6-35...
  • Page 131 (psi) (81.8 SCFH) Stainless Steel or Aluminum Gouging 200 amps • H35 Plasma / N Shield Argon-Hydrogen Manifold (073109) Required* Hypertherm recommends a mixture of 35% hydrogen and 65% argon for the plasma gas. 120837 020607 020485 020615 020415 Retaining cap...

  • Page 132: Changing Consumable Parts

    A preferred method to clean the current ring is with a clean paper towel or Q-tip dipped in water or 3% hydrogen peroxide. If the Water tube is damaged at all, it may need to be replaced. See Changing the Water Tube. HySpeed HT2000 Instruction Manual 6-37...

  • Page 133: Replacement

    Make sure that it is tightened snugly; if it is loose, it can affect the shield gas flow. Shield Retaining cap Nozzle Swirl ring Electrode Water tube Current Torch body (shown without off valve SA and sleeve) ring Figure 6-7 Changing Consumable Parts HySpeed HT2000 Instruction Manual 6-38...

  • Page 134: Changing The Water Tube

    3. Look for any damage or bends in the water tube. 4. Remove and replace the water tube by using the water tube wrench (027347) supplied by Hypertherm – Fig. 6-8. When installing water tube, do not over tighten! Snug down by hand only.

  • Page 135: How To Optimize Cut Quality

    Note: It may be difficult to achieve the full benefits of the LongLife process in some conditions. HySpeed HT2000 Instruction Manual 6-40...

  • Page 136: Additional Factors Of Cut Quality

    As the workpiece heats up, more dross may form on subsequent cuts. Dross is more likely to form on mild steel than on stainless steel or aluminum. Worn or damaged consumables may produce intermittent dross. HySpeed HT2000 Instruction Manual 6-41...

  • Page 137: Additional Improvements

    How to Increase Cutting Speed • Decrease the torch-to-work distance. Trade-off: This will increase the negative cut angle Note: The torch must not touch the workpiece while piercing or cutting. HySpeed HT2000 Instruction Manual 6-42...

  • Page 138: Operation: Argon-Hydrogen Manifold

    OPERATION: ARGON-HYDROGEN MANIFOLD In this section: Front Panel Controls and Indicators .........................7-2 Installation.................................7-3 Operation ..................................7-6 Check Torch..............................7-6 Turn Gases On..............................7-6 Turn Power Supply On and Adjust Voltage/Current..................7-7 Adjust H35 Gas Flow ............................7-7 After Cutting with Argon-Hydrogen ........................7-8 HySpeed HT2000 Instruction Manual...

  • Page 139: Front Panel Controls And Indicators

    • Argon-Hydrogen Flowmeter (FM1) Indicates the argon-hydrogen plasma gas flow rate %. Flow rates for argon-hydrogen are specified in Cut Charts. Flowmeter Adjust Valve (MV1) Argon-Hydrogen Flowmeter (FM1) Figure 7-1 Argon-Hydrogen Manifold Front Panel Controls and Indicators HySpeed HT2000 Instruction Manual...

  • Page 140: Installation

    A. Attach one end of the supply hosing to the argon/hydrogen supply tank or regulator, and attach the other end to the Argon-Hydrogen Supply Hose Connection on the manifold. (Fig. 7-2) Cable Connection Point Plasma Gas Torch Lead Connection Argon-Hydrogen Supply Hose Connection Figure 7-2 Argon-Hydrogen Manifold Connection Points HySpeed HT2000 Instruction Manual...
  • Page 141 024368 20 ft (6.2 m) 024369 30 ft (9.1 m) 024370 40 ft (12.4 m) 024443 50 ft (15 m) 024467 75 ft (23 m) Figure 7-4 Plasma Gas Torch Lead – Argon-Hydrogen Manifold to Torch HySpeed HT2000 Instruction Manual...
  • Page 142 Argon-Hydrogen Manifold to Torch Connection Points Nitrogen supply to Gas Console (Fig. 7-6) Connect the nitrogen supply to the shield connection at the rear of the gas console. (Fig. 7-5) 2WRENCHES Figure 7-6 Nitrogen Supply to Gas Console HySpeed HT2000 Instruction Manual...

  • Page 143: Operation

    • Adjust the argon-hydrogen plasma gas supply regulator to read 120 psi +/- 10 psi (8.2 bar +/- 0.7 bar). • Adjust supply regulator for shield gas to read 90 psi +/- 10 psi (6.2 bar +/- 0.7 bar). HySpeed HT2000 Instruction Manual...

  • Page 144: Turn Power Supply On And Adjust Voltage/Current

    3. Look at the shield gas pressure gauge (PG3) on the gas console, and set to the Cut Chart specifications by turning the shield gas adjust knob (MV4). 4. Set S2 to Run after the test preflow rate has been set. The system is now ready to run. HySpeed HT2000 Instruction Manual...

  • Page 145: After Cutting With Argon-Hydrogen

    See Figure 7-7. 7. Connect the shield gas supply hose to the shield supply connection of the gas console. See Gas Console Connections in Section 4. 2WRENCHES Figure 7-7 Nitrogen Supply to N Input of Gas Console HySpeed HT2000 Instruction Manual...

  • Page 146: Maintenance

    Relay Board LED Status Conditions ......................8-23 Coolant Flow Test Procedure ..........................8-25 Check Reservoir Coolant ..........................8-25 Verify Flow Rate Return from Torch.......................8-25 Verify Flow Rate to Torch..........................8-26 Check Pump, Motor and Solenoid Valve .......................8-27 Torch Coolant Draining ............................8-28 Preventive Maintenance Schedule .........................8-29 HySpeed HT2000 Instruction Manual...

  • Page 147: Introduction

    MAINTENANCE Introduction The HT2000, and all Hypertherm plasma systems, undergo rigorous testing prior to shipment and should require little maintenance if proper installation and operation procedures as outlined in this manual are followed. After a routine maintenance section, a system initialization sequence of events flowchart is presented.

  • Page 148: Routine Maintenance

    (027005) every six months. • Every six months, clean pump strainer with a mild soap and water solution. Note: Remove pump from system before removing strainer to avoid any debris from falling into pump housing. See Fig. 8-0. HySpeed HT2000 Instruction Manual...

  • Page 149: Gas Console

    Inspect the motor valve console on a routine basis. • Check the exterior for any damage. • Inspect all interconnecting cables, hoses and leads for wear and damage. Ensure all connections are tight and that there are no leaks. Do not overtighten fittings. HySpeed HT2000 Instruction Manual...

  • Page 150: Rhf Console

    The terminus is used to indicate the beginning or ending Terminus point of a flowchart. The process or task box is used to Box indicate any Task/Process process or task other than an input/output operation or a decision. HySpeed HT2000 Instruction Manual...
  • Page 151 PCB2 (Power Supply-µP PCB4 (Power Supply Relay Board) Control Board) PCB9 (Power Supply THC Board) PCB11 (Power Supply Isolation Board) All STATUS LEDs on PCB5 (Interlock Display Board) are extinguished. Release ON button(PB1) System initialization is complete HySpeed HT2000 Instruction Manual...

  • Page 152: Initial Checks

    (220, 380 or 415 VAC). If there is a problem at this point, disconnect main power and check connections, power cable, and fuses at line disconnect switch. Repair and/or replace defective component(s) if necessary. HySpeed HT2000 Instruction Manual...
  • Page 153 There is line voltage at the contactor after the line disconnect switch is ON, even if the ON (1) pushbutton on the HT2000 power supply has not been pressed. Use extreme care when measuring primary power in this area. Voltages present at the terminal block and contactor can cause injury or death! HySpeed HT2000 Instruction Manual...
  • Page 154 T1. Refer to Figure 9-4 for location of T1. Also, check main power circuit breaker CB1 located in Figure 9-4, and associated wiring and connections between T1 and points L1 and L2 (including linkboard). Repair and/or replace defective component(s) if necessary. HySpeed HT2000 Instruction Manual...

  • Page 155: 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 1-800-643-9878.
  • Page 156 T1 to relay board PCB4. If connections are OK, there may be a problem with either PCB4 or PCB2. See sheet 4 of 13 in Section 10 for location of the relay that controls RHF transformer T1. HySpeed HT2000 Instruction Manual 8-11...
  • Page 157 If there is 120VAC across the relay (see above steps), and CR1 does not close, replace CR1. 5.3. Main contactor (CON1) or PCB4 is defective. • With an AC voltmeter, see if contactor CON1 is getting 120VAC after START command is given. HySpeed HT2000 Instruction Manual 8-12...
  • Page 158 TEST and RUN modes as specified in the Cut Charts. 6.4. Torch is getting insufficient current. Check the arc current setting in the Cut Charts for the type and thickness of metal you are cutting. HySpeed HT2000 Instruction Manual 8-13...
  • Page 159 Shut down system and wait for unit to cool down. If power supply will not restart, see Status LED Troubleshooting guide later in this section. 6.6. Choppers are defective or not functioning. See Chopper Module Test Procedure later in this section. HySpeed HT2000 Instruction Manual 8-14...

  • Page 160: Status Led Troubleshooting

    • Check pins, connectors and associated wiring to temperature switches. • Leave the fans running, and try restarting the unit after one hour. If LED still illuminates, one of the choppers or the main transformer may need to be replaced. HySpeed HT2000 Instruction Manual 8-15...
  • Page 161 Clean or replace, if necessary. See Changing Consumable Parts in the Operation section. 4.3. Pressure switch PS3 in RHF console not functioning. PS3 is normally open, and closes when shield gas pressure is 12 psi (0.83 bar) or greater. HySpeed HT2000 Instruction Manual 8-16...
  • Page 162 • Check to see if water coolant is above 160°F. • Check to see if TS2 (located in the coolant reservoir) is open. TS2 is normally closed, and is opened when a temperature above 160°F (71°C) is reached. HySpeed HT2000 Instruction Manual 8-17...
  • Page 163 Note: Coolant flow LED illuminates when line disconnect switch is turned ON because coolant reservoir pump M2 is not activated until the power supply POWER ON (PB1) is pressed. HySpeed HT2000 Instruction Manual 8-18...

  • Page 164: Chopper Module Test Procedure

    Repair or replace defective component(s), if necessary. Also check to see if LED3 is turning green when enabled (normal condition). If LED1 is on and LED3 is red when enabled (fault condition), then make sure that JP9 is seated properly. HySpeed HT2000 Instruction Manual 8-19...
  • Page 165 • If the voltmeter reads +280 VDC, then replace either control board PCB2 or analog board PCB3. • If the voltmeter reads 0 volts, then replace corresponding chopper module CH1 or CH2. Bridge (–) Bridge (+) LED1 LED3 - TORCH + WORK Figure 8-3 Chopper Module – Front View HySpeed HT2000 Instruction Manual 8-20...

  • Page 166: Error Codes

    D8: ERROR CODE D9: +12 VDC D14: PLASMA START (+12 VDC) Rec 1 Rec 5 Terminals are normally disconnected. Rec 6 Rec 2 Rec 7 Rec 3 Figure 8-4 Control Board (micro-processor) Error Code LED Location HySpeed HT2000 Instruction Manual 8-21...

  • Page 167: Analog Board Led Functions

    Eg: Input voltage for a 480V power supply drops below 408V. Figure 8-5 Error Codes Analog Board LED Functions D3: +12VDC D4: Chopper Current CH2 Rec 2 D6: Chopper Current CH1 Rec 3 Rec 1 HySpeed HT2000 Instruction Manual 8-22...

  • Page 168: Relay Board Led Function List

    Solenoid Valve (SV1A), if in O Mode D10: Plasma Off-Valve Solenoid Valve (SV5) D11: Preflow Solenoid Valve (SV4B) D19: Cap Sense Solenoid Valve (SV7) D20: Output Enable D26: Spare D28: Shield Gas Solenoid Valve (SV6) HySpeed HT2000 Instruction Manual 8-23...
  • Page 169 D14: Main Contactor (CON1) D15: DC ON Lights (LT1/LT2) D16: N Solenoid Valve (SV1B), if in N Mode D19: Cap Sense Solenoid Valve (SV7) D20: Output Enable D24: Arc Transfer D26: Spare D28: Shield Gas Solenoid Valve (SV6) HySpeed HT2000 Instruction Manual 8-24...

  • Page 170: Coolant Flow Test Procedure

    3. Remove the torch coolant return hose (black hose with the red band) from the cathode block. Torch Coolant Supply Hose (Black with Green Band) Cathode Block Torch Coolant Return Hose (Black with Red Band) Remove this hose Figure 8-6 Torch Coolant Supply and Return Hoses HySpeed HT2000 Instruction Manual 8-25...

  • Page 171: Verify Flow Rate To Torch

    1 gallon of fluid per minute, go to Check Pump, Motor, and Solenoid Valve (V1). 8. If replacing the torch does not satisfy the flow switch, then replace torch leads. HySpeed HT2000 Instruction Manual 8-26...

  • Page 172: Check Pump, Motor And Solenoid Valve

    Filter Heat Exchanger Pump with Solenoid Valve Relief Valve Cathode Block (in back of power supply) Remote High Frequency Console Torch Figure 8-7 Plumbing Schematic of Power Supply Reservoir Assembly with RHF Console and Torch HySpeed HT2000 Instruction Manual 8-27...

  • Page 173: Torch Coolant Draining

    After this draining procedure, a small amount of coolant will remain in the system pump and valves. For this reason, Hypertherm also recommends that a suitable ratio of propylene glycol be purged through the system prior to draining if the system will experience extremely cold temperatures. Note that Hypertherm's stock propylene glycol solution 028872 is rated to 10°...

  • Page 174: Preventive 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 175 MAINTENANCE HySpeed HT2000 Instruction Manual 8-30...

  • Page 176: Parts List

    Remote V/C – Programmable (PR) Control Station ....................9-31 IHS Console................................9-33 Argon-Hydrogen Console ............................9-34 Timer/Counter .................................9-35 HySpeed HT2000 Machine Torch with 2" Sleeve....................9-37 HySpeed HT2000 Stainless Steel Machine Torch....................9-37 Torch Mounting Bracket............................9-37 HySpeed HT2000 Machine Torch with 1-3/4" Sleeve.....................9-39 Torch Mounting Bracket............................9-39 Torch Leads, Leads, Cables, and Hoses........................9-40...

  • Page 177: Introduction

    PARTS LIST Introduction The format to list and call out Hypertherm parts is as follows: Part Item Number Description Designator Qty. 129118 Chopper SA, 15KW, HT2000 001232 Bracket, HT2000 Chopper Module 041118 PC BD Assy Snubber PCB1 Refers to item call out on same or opposing page.

  • Page 178: Power Supply

    PARTS LIST Console Console To Second Hyspeed HT2000 Power Supply 11X1 Timer/Cntr Motor Valve Console Console Off Valve Shield Gas Power Plasma N Plasma O 2 Supply 14X1 Ar-H Manifold Argon-Hydrogen 1X10 Work table Workpiece Machine Water Computer Muffler Interface...
  • Page 179 PARTS LIST See Figure 9-2 for detail of control panel See Figure 9-1A for detail of THC Figure 9-1 HT2000 Power Supply – Front Panel HySpeed HT2000 Instruction Manual...

  • Page 180: Front Panel

    Part Item Number Description Designator Qty. 029697 HT2000 THC SA 001297 Cov: HT2000 THC Dust 004338 Hinge - THC Pan, HT2000 041294 PCB Assy: HT2000 THC Mother PCB9 041186 PCB Assy: HT2000 Torch Hght Cntrl PCB10 HySpeed HT2000 Instruction Manual...

  • Page 181: Control Panel

    Spcr, .19 OD .12 ID .50 LG 009063 Diode, Ind LED Amber 041535 PC BD only Intlck Dsply 200/1070 005121 Pushbutton, 2 NO Green Illumin PB1/LT1 005122 Pushbutton, 2 NC Red Extended Figure 9-2 HT2000 Power Supply – Control Panel HySpeed HT2000 Instruction Manual...

  • Page 182: Base Plate And Components

    *** Used on 220/380/415 volt power supplies and 400V CE power supplies **** Used on 200 volt power supply ***** Used on 600 volt power supplies ****** Used on 440/460 volt power supplies Figure 9-3 HT2000 Power Supply – Base Plate and Components HySpeed HT2000 Instruction Manual...
  • Page 183 PARTS LIST Figure 9-4 HT2000 Power Supply – Center Wall Right Side HySpeed HT2000 Instruction Manual...

  • Page 184: Center Wall Right Side

    ****** Used on 440/460V power supplies † See Appendix E for location of 029316 on 400V CE power supplies. †† See Figure 8-2 for front graphic of 041534 power distribution board. ††† Not shown graphically in Figure 9-4. HySpeed HT2000 Instruction Manual...
  • Page 185 PARTS LIST Figure 9-5 HT2000 Power Supply – Center Wall Left Side HySpeed HT2000 Instruction Manual 9-10...

  • Page 186: Center Wall Left Side

    075092 M/S, 10-32 X 1/2, PH, Pan 075241 M/S, 1/4-20 X 1/2, SL, IHW 075136 Hhdcap, 3/8-16 X 3/4, Hex, S/Z 075216 Flwshr, 5/16 075192 Lkwshr, 1/4, Splitlock 008245 Bushing, 7/8" hole X 11/16" ID HySpeed HT2000 Instruction Manual 9-11...
  • Page 187 PARTS LIST See Figure 9-6A for detail of item 2 (CH2), right side. Figure 9-6 HT2000 Power Supply – Front Wall Inside HySpeed HT2000 Instruction Manual 9-12...

  • Page 188: Front Wall Inside

    005199 Temperature Switch 82°C TSW1 129118 CH130 CE/LVD Chopper SA 005199 Temperature Switch 82°C TSW2 008509 Bushing 1.75 MTG X 1.37 ID 041564 PCB Assy:Phase Loss Detection Circuit Figure 9-6A Chopper CH2 – Right Side HySpeed HT2000 Instruction Manual 9-13...
  • Page 189 PARTS LIST See Figure 9-9 for High Frequency and I/O PCB parts Figure 9-8 HT2000 Power Supply – Rear Wall Inside HySpeed HT2000 Instruction Manual 9-14...

  • Page 190: Rear Wall Inside

    008079 Terminal Strip (8) 008073 Terminal Strip (16) 008447 Receptacle, 23-37, Std Sex 1X6, 1X5 008208 Receptacle, 23-37, Rev Sex 1X1,1X2, 1X3 1X7, 1X4 008201 Receptacle, 17-14, Rev Sex 008210 Receptacle, 11-4, Rev Sex 1X10 HySpeed HT2000 Instruction Manual 9-15...
  • Page 191 PARTS LIST Figure 9-9 HT2000 Power Supply – High Frequency & I/O PCB Assembly HySpeed HT2000 Instruction Manual 9-16...

  • Page 192: High Frequency And I/O Pcb

    075361 Flwshr, 3/8, .394, .625, .032, Brs 009356 Coil, A.C.T., 8G THHN 041145 PC BD Assy MAX200 I/O PCB8 029202 Current Sensor SA 015134 Insert, 3/8 OD X .062 Brass 075072 M/S, 8-32 X 1/2 HySpeed HT2000 Instruction Manual 9-17...
  • Page 193 PARTS LIST Figure 9-10 HT2000 Power Supply – Rear Wall Outside HySpeed HT2000 Instruction Manual 9-18...

  • Page 194: Rear Wall Outside

    Heat Exchanger, Water/Air M5,M6 129383 Valve SA:HT2000 Power Supply 006046 Valve, Sol 240V 3/8 NPT NC 129252 Water Pump SA 128385 Kit: Motor, 1/3 HP Carbon 230/50-60 128384 Kit: Pump, 70 GPH Positive Displace 031122 Coupler:Pro Pump-Motor HySpeed HT2000 Instruction Manual 9-19...
  • Page 195 PARTS LIST Figure 9-11 Remote High Frequency Console HySpeed HT2000 Instruction Manual 9-20...

  • Page 196: Remote High Frequency Console

    ** See Fig. 9-12 for detail of Spark Gap Assy † Part number for spark gap assembly before RHF console # 2000-005000 is 009350 †† Part number for HV Transformer SA before RHF console # 2000-005000 is 029317 HySpeed HT2000 Instruction Manual 9-21...
  • Page 197 PARTS LIST Figure 9-12 Remote High Frequency Console – Spark Gap Assembly HySpeed HT2000 Instruction Manual 9-22...

  • Page 198: Spark Gap Assembly

    SktSet:8-32 X 3/8 HexCp SST 075101 SktSet:8-32 X 5/8 HexCp SST † Part number for spark gap assembly before RHF console # 2000-005000 is 009350 †† Part number for capacitors before RHF console # 2000-005000 is 009280 HySpeed HT2000 Instruction Manual 9-23...
  • Page 199 PARTS LIST Figure 9-13 Gas Console HySpeed HT2000 Instruction Manual 9-24...

  • Page 200: Gas Console

    Gauge, Press 160#/Bar 2" Dia. 022020 Gauge, Press 160#/Bar 2" Dia. 015299* Filter:.10 Micron 1/8FPT Brass Inline FL1, FL2 004718** Manifold, valve * Located behind O and N inlet connections ** Located behind solenoid valves HySpeed HT2000 Instruction Manual 9-25...
  • Page 201 PARTS LIST 15 16 10 12 15 16 14 17 Figure 9-14 Motor Valve Console HySpeed HT2000 Instruction Manual 9-26...

  • Page 202: Motor Valve Console

    Receptacle, 23-37, Std Sex 008176 Pin, 20-24 AWG Type III+ 008186 Socket, 20-24 AWG Type III+ 015299 Filter:.10Micron 1/8FPT Brass In Line 004718 Maniflold:Motor Valve 046077 Tubing:1/4"OD .04W Blue Nylon * SV4B located behind SV4A HySpeed HT2000 Instruction Manual 9-27...
  • Page 203 PARTS LIST 14 15 Figure 9-15 Remote V/C – Digital (DR) Control Station HySpeed HT2000 Instruction Manual 9-28...
  • Page 204 Heatsink, DR/PR SR V/C 042059 IC, LM340AK-5.0 009274 Capacitor, 2600 UF 15VDC 008097 Terminal, PC HHS 2022C 008098 Terminal, PC CAM 041076 PC BD Assy Rem Volt Disp 041077 PC BD Assy Rem Curr Disp HySpeed HT2000 Instruction Manual 9-29...
  • Page 205 PARTS LIST Figure 9-16 Remote V/C – Programmable (PR) Control Station HySpeed HT2000 Instruction Manual 9-30...

  • Page 206: Remote V/C - Programmable (Pr) Control Station

    Heatsink, DR/PR SR V/C 009274 Capacitor, 2600 UF 15VDC 042059 IC, LM340AK-5.0 008097 Terminal, PC HHS 2022C 008098 Terminal, PC CAM 041076 PC BD Assy, Rem Volt Disp 041077 PC BD Assy, Rem Curr Disp HySpeed HT2000 Instruction Manual 9-31...
  • Page 207 PARTS LIST Figure 9-17 IHS Console HySpeed HT2000 Instruction Manual 9-32...

  • Page 208: Ihs Console

    Adapter, 1/4 NPT x #4 015100 Adapter, 1/4 NPT x 1/4 Poly 015502 Nipple, 1/4 x CL 024038 Hose Assy, #4 x 7" 041043 PC BD Assy UW-IHS 041023 Power Source, IHS 008094 Terminal Strip (8) HySpeed HT2000 Instruction Manual 9-33...
  • Page 209 Cable: HT2000 H35 Manifold Press. Sw. 008195 CACLP:CPC Size 11 008205 Pin: 18-16 AWG Type III + CRP 008807 Receptacle Shell:CPC 11-4 14X1 047055 Cable, 18-2 TW PR, Unshielded 6 ft 15 16 Figure 9-18 Argon-Hydrogen Manifold HySpeed HT2000 Instruction Manual 9-34...

  • Page 210: 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, Elapsed Time LCD – 003140 Relay:120VAC DP AU Cont (See HT2000 wiring diagram) 11X1 Figure 9-19 Timer/Counter HySpeed HT2000 Instruction Manual 9-35...
  • Page 211 PARTS LIST Figure 9-20 HT2000 Torch – 2" (50 mm) Diameter Mounting Sleeves HySpeed HT2000 Instruction Manual 9-36...

  • Page 212: Hyspeed Ht2000 Machine Torch

    Cable, Torch Off-Valve 024354 Hose SA, 3/16 Blu LH 'A' * Hyspeed consumables are for cutting mild steel with Oxygen at 200A only. HySpeed HT2000 Stainless Steel Machine Torch with 2" (50 mm) Dia. Sleeve – 128367 Part Item Number...
  • Page 213 PARTS LIST Figure 9-20A HySpeed HT2000 Torch – 1-3/4" (45 mm) Diameter Mounting Sleeve HySpeed HT2000 Instruction Manual 9-38...

  • Page 214: Torch Mounting Bracket

    PARTS LIST HySpeed HT2000 Machine Torch with 1-3/4" (44 mm) Dia. Sleeve – 128141 Part Item Number Description Designator Qty. 128141 HT2000 Opt. Machine Torch Assy w/Valve 120837 Nozzle Retaining Cap with IHS tab 020424 Shield, MAX200/HT2000 200A 120584 HT2000 Machine Torch Main Body...
  • Page 215 023052 028768 60 ft (18.3 m) Figure 9-21 HT2000 Torch Leads See page 9-36 for graphic. See page 9-37 for part numbers Figure 9-22 Cable & Hose from Motor Valve Console to Off-Valve on Torch HySpeed HT2000 Instruction Manual 9-40...
  • Page 216 023614 150 ft (45.8 m) 123042 60 ft (18.3 m) 023645 200 ft (61 m) 023612 75 ft (22.9 m) 123075 85 ft (25.9 m) Figure 9-25 HT2000 RHF Cable – PS to RHF Console HySpeed HT2000 Instruction Manual 9-41...
  • Page 217 023848 125 ft (38.1 m) 123047 60 ft (18.3 m) 023849 150 ft (45.8 m) 023846 75 ft (22.9 m) 023850 200 ft (61 m) Figure 9-28 Machine Interface Cable – PS to Machine I/O HySpeed HT2000 Instruction Manual 9-42...
  • Page 218 75 ft (22.9 m) 023899 250 ft (76.3 m) 023838 100 ft (30.5 m) 023900 275 ft (83.9 m) 023901 300 ft (91.5 m) Figure 9-31 Power Supply/Programmable Remote (PR) Cable – PS to PR V/C HySpeed HT2000 Instruction Manual 9-43...
  • Page 219 2 ft (0.6 m) 023869 40 ft (12.2 m) Part No. Length 023889 2 ft (0.6 m) 023870 40 ft (12.2 m) Figure 9-34 Cables from IHS to Sensors Part No. 005074 Figure 9-35 Inductive Sensor Assembly HySpeed HT2000 Instruction Manual 9-44...
  • Page 220 75 ft (22.9 m) 100 ft (30.5 m) 150 ft (45.8 m) 200 ft (61 m) Item 024144 024144 024144 024144 024144 024144 023869/023870 023869/023870 023869/023870 023869/023870 023869/023870 023869/023870 023859 023860 023861 023862 023863 023864 HySpeed HT2000 Instruction Manual 9-45...
  • Page 221 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 9-39 Oxygen Supply Hose – Oxygen Supply to Gas Console HySpeed HT2000 Instruction Manual 9-46...
  • Page 222 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 9-42 Plasma Cut Flow Gas Hosing – Gas Console to Motor Valve Console HySpeed HT2000 Instruction Manual 9-47...
  • Page 223 25 ft (7.6 m) 024468 75 ft (22.9 m) 024071 30 ft (9.2 m) 024523 100 ft (30.5 m) 024356 35 ft (10.7 m) Figure 9-45 Shield Gas Sense Hose – Gas Console to RHF Console HySpeed HT2000 Instruction Manual 9-48...
  • Page 224 150 ft (45.8 m) 128052 60 ft (18.3 m) 128064 170 ft (51.9 m) 028443 75 ft (22.9 m) 028637 200 ft (61 m) Figure 9-48 Cooling Hose Set – Power Supply to RHF Console HySpeed HT2000 Instruction Manual 9-49...
  • Page 225 PARTS LIST HySpeed HT2000 Consumable Starter Kit #128824 Figure 9-49 HySpeed HT2000 Starter Consumable Parts Part Item Number Description Qty. 128824 Kit: HySpeed HT2000 ConsumableStarter 001285 Box: Gray Plastic 220239 Shield, Hyspeed 200A 220242 Nozzle Retaining Cap with IHS tab, HySpeed 200A...
  • Page 226 PARTS LIST HySpeed HT2000 Consumable Parts Kit #128825 Figure 9-50 HySpeed HT2000 Consumable Parts Part Item Number Description Qty. 128825 Kit: HySpeed HT2000 Consumable Parts 001067 Box: Gray Plastic 220239 Shield, Hyspeed 200A 020424 Shield, 200A 020448 Shield, 100A 220242...
  • Page 227 Electrode: HT2000 100A LL 020963 Water Tube:PAC200T/2000 Electd Cool 027055 Lubricant, Silicon, 1/4 Oz Tube 027194 Wrench, Nozzle, 3/4" 027524 Wrench, Nozzle, 1" 044027 O-Ring, Buna-N 027347 Tool: Water Tube Removal 004147 Electrode Gauge Assy HySpeed HT2000 Instruction Manual 9-52...
  • Page 228 Nozzle, HT2000 200A Oxygen Extended 120833 Swirl Ring: HT2000 O2 120258 Electrode:HT2000 Extended 120257 Water Tube:Electd Cool Extended 027055 Lubricant, Silicon, 1/4 Oz Tube 027194 Wrench, Nozzle, 3/4" 044027 O-Ring, Buna-N 027347 Tool: Water Tube Removal HySpeed HT2000 Instruction Manual 9-53...

  • Page 229: Lead Packages

    028624 20 ft (6.2 m) 028625 25 ft (7.6 m) 028626 30 ft (9.1 m) 028627 35 ft (10.6 m) 028654 50 ft (15 m) 028655 75 ft (23 m) 028656 100 ft (30 m) HySpeed HT2000 Instruction Manual 9-54...

  • Page 230: Recommended Spare Parts

    004061 Electrode:Sprk Gap 1/8 x 1.6 9-23 029317 HV Transformer SA, 5000V, 20 ma 9-21 005227 Switch, Pressure 12 psi 9-21 006032 Solenoid Valve:150# 1/4 FPT 120V NC 9-21 006106 Solenoid Valve: 120VAC 1/8FPT 9-21 HySpeed HT2000 Instruction Manual 9-55...

  • Page 231: Gas Console

    9-25 022008 Gauge: Pressure, 100 psi/bar, Panel Mnt 9-25 Motor Valve Console Part Number Description Designation Qty. Pg. Ref. 006109 Sol. Valve:150# Manf 120V 2-Way NC 9-27 006063 Motor Valve: Electric 1/8FPT .125 Orifice 9-27 HySpeed HT2000 Instruction Manual 9-56...

  • Page 232: Wiring Diagrams

    Within different sections, the same designation may appear. Be certain to check the dotted box label when looking for or cross-referencing parts. Wiring Diagram Symbols Wiring diagram symbols and their identification precede the system wiring diagrams in this section. HySpeed HT2000 Instruction Manual 10-1...
  • Page 233 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 234 Time Delay Closed, Switch, Level, Torch Symbols 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 256 Solenoid valve status for N timing chart or Air Cutting Mode Component Idle Cutflow Preflow SV1A SV1B SV4A SV4B...
  • Page 258 Solenoid valve status for O timing chart or Air Cutting Mode Component Idle Cutflow Preflow SV1A SV1B SV4B SV4B...
  • Page 260 Solenoid valve status for O timing chart or Air Cutting Mode Component Idle Cutflow Preflow SV1A SV1B SV4B SV4B...
  • Page 262 Coolant Flow Diagram...

  • Page 264: Iec Symbols

    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. HySpeed HT2000 Instruction Manual...
  • Page 265 APPENDIX A HySpeed HT2000 Instruction Manual...

  • Page 266: Propylene Glycol Safety Data

    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 HySpeed HT2000 Instruction Manual...
  • Page 267 HySpeed HT2000 Instruction Manual...
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  • Page 270 HySpeed HT2000 Instruction Manual...
  • Page 271 % of Propylene Glycol Figure b-1 Freezing Point of Propylene Glycol Solution HySpeed HT2000 Instruction Manual...
  • Page 272 HySpeed HT2000 Instruction Manual...
  • Page 273 HySpeed HT2000 Instruction Manual...
  • Page 274 HySpeed HT2000 Instruction Manual...
  • Page 275 HySpeed HT2000 Instruction Manual b-10...
  • Page 276 Appendix C AERATION MANIFOLD FOR PLASMA CUTTING ALUMINUM In this section: Aeration Manifold for Plasma Cutting Aluminum ......................c-2 Introduction...............................c-2 Making an Aeration Manifold..........................c-2 HySpeed HT2000 Instruction Manual...

  • Page 277: Aeration Manifold

    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 c-1 Aeration Manifold HySpeed HT2000 Instruction Manual...

  • Page 278: Air Filters

    Gas purity is critical for maximizing consumable parts life, as well as for producing the highest quality cutting which Hypertherm plasma equipment can achieve. Plasma air must be clean, dry and oil-free, and air must be delivered at the pressure and flow rate specified for each plasma system. If the air supply contains moisture, oil or dirt particles, cut quality will be lowered and consumable parts life will be shortened, which increase production costs.
  • Page 279 APPENDIX D HySpeed HT2000 Instruction Manual...

  • Page 280: Electromagnetic Compatibility (Emc

    Appendix E ELECTROMAGNETIC COMPATIBILITY (EMC) In this section: General ..................................e-2 Power Cable ................................e-2 Connect Power Cable ...............................e-2 Power Supply ..............................e-2 Line Disconnect Switch ............................e-4 EMI Filter Parts List ..............................e-5 HySpeed HT2000 Instruction Manual...

  • Page 281: General

    Power Supply 1. Locate the EMI filter on the top rear of the power supply (see Figure e-1). Strain Relief EMI Filter HySpeed HT2000 Figure e-1 Power Supply with EMI Filter – Side View HySpeed HT2000 Instruction Manual...
  • Page 282 4. Connect leads L1 to U, L2 to V, and L3 to W terminals of TB1 (see Figure e-3). Ensure that all connections are tight to avoid excessive heating. 5. Connect the ground lead to terminal marked PE at TB1 (see Figure e-3). HySpeed HT2000 Instruction Manual...

  • Page 283: Line Disconnect Switch

    Connecting the power cable to the line disconnect switch must conform to national or local electrical codes. This work should be performed only by qualified, licensed personnel. See Power Requirements and Line Disconnect Switch on page 3-5. HySpeed HT2000 Instruction Manual...

  • Page 284: Emi Filter Parts List

    APPENDIX E EMI Filter Parts List Item Number Description Qty. 001557 Cover:Hyspeed HT2000-CE Electronic Filter Enclosure 001558 Enclosure:Hyspeed HT2000-CE Electronic Filter 001559 Cover:Hyspeed HT2000-CE Top 008489 Bushing:1.97 ID X 2.5 Hole Black-Snap 008610 Strain Relief:1-1/2NPT 1.5ID 2-Screw 029316 TB1 Input-Power SA:200/2000/4X00/HD...
  • Page 285 APPENDIX E HySpeed HT2000 Instruction Manual...

  • Page 286: System Grounding

    RHF console directly to the power supply. 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 HySpeed HT2000 Instruction Manual...

  • Page 287: Work Table Grounding

    (frequencies above 150 Khz). The more turns the better. A suitable ferrite choke can be made by wrapping 10 turns or more of the ground lead through Magnetics part number 77109-A7, Fair-Rite part number 59-77011101, or other equivalent ferrite choke. Locate the choke as close as possible to the plasma power supply. HySpeed HT2000 Instruction Manual...
  • Page 288 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. HySpeed HT2000 Instruction Manual...
  • Page 289 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. HySpeed HT2000 Instruction Manual...

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