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Hypertherm RT60 Operator's Manual
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Hypertherm RT60 Operator's Manual

Hypertherm RT60 Operator's Manual

Retrofit torch
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RT60 / RT60M
Retrofit Torch
Operator Manual
804880 – Revision 0

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Summary of Contents for Hypertherm RT60

  • Page 1 RT60 / RT60M Retrofit Torch Operator Manual 804880 – Revision 0...
  • Page 2 (P/N 804880) Revision 0 – July, 2004 Hypertherm, Inc. Hanover, NH USA www.hypertherm.com © Copyright 2004 Hypertherm, Inc. All Rights Reserved Hypertherm and Powermax are trademarks of Hypertherm, Inc. and may be registered in the United States and/or other countries.
  • Page 3 K.B. Warehouse Complex Singapore 417847, Republic of Singapore 65 6 841 2489 Tel 65 6 841 2490 Fax 65 6 841 2489 (Technical Service) Hypertherm (Shanghai) Consulting Co., Ltd. Suite 305, CIMIC Towers 1090 Century Boulevard, Pudong Shanghai 200120 P.R. China...
  • Page 4 The size of the surrounding area to be 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 5: Warranty

    Hypertherm system. Any damage infringement, and Hypertherm’s obligation to indemnify shall be caused by the use of other than genuine Hypertherm parts may conditioned upon Hypertherm’s sole control of, and the not be covered by the Hypertherm warranty.

  • Page 6: Table Of Contents

    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 Section 2 Specifications Specifications – RT60/RT60M ..........................2-2 Torch Dimensions.............................2-3 RT60/ RT60M Operator Manual...
  • Page 7 Hand Torch Cutting Technique .........................4-8 Piercing ................................4-9 Gouging................................4-10 Cut Charts ................................4-11 Section 5 Maintenance and Parts Routine Maintenance ..............................5-2 Inspect Consumables............................5-3 Parts ..................................5-4 Torch Consumable Configurations ........................5-4 RT60 Hand Torch Assembly..........................5-6 RT60M Machine Torch Assembly........................5-8 Accessories..............................5-10 RT60/ RT60M Operator Manual...

  • Page 8: Safety

    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 Hypertherm Plasma Systems...

  • Page 9: Recognize Safety Information

    • Do not cut pressurized cylinders, pipes, or any table to eliminate the possibility of hydrogen closed container. detonation. Refer to the Appendix section of this • Do not cut containers that have held combustible manual for aeration manifold details. materials. Hypertherm Plasma Systems 11-98...

  • Page 10: Electric Shock Can Kill

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

  • Page 11: A Plasma Arc Can Cause Injury And Burns

    Work Table Connect the work table to an earth the power cord ground. Fasten the retaining nut ground, in accordance with appropriate national or tightly. local electrical codes. • Tighten all electrical connections to avoid excessive heating. Hypertherm Plasma Systems 5/6/02...

  • Page 12: Compressed Gas Equipment Safety

    Hazardous Substances, American Welding Society Protection Association, 470 Atlantic Avenue, Boston, MA 02210 550 LeJeune Road, P.O. Box 351040, Miami, FL 33135 10. OSHA, Safety and Health Standards, 29FR 1910 U.S. Government Printing Office, Washington, D.C. 20402 Hypertherm Plasma Systems 11-98...
  • Page 13 SAFETY Hypertherm Plasma Systems 8-01...

  • Page 14: Section 1A

    Sécurité des bouteilles de gaz comprimé ....................1a-5 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 Hypertherm Systèmes plasma 1a-1 2/12/01...

  • Page 15: Identifier Les Consignes De Sécurité

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

  • Page 16: Les Chocs Électriques Peuvent Être Fatals

    • Chaque système plasma Hypertherm est conçu pour être • En cas d’utilisation d’une table à eau, s’assurer que cette utilisé uniquement avec des torches Hypertherm dernière est correctement mise à...

  • Page 17: L'arc Plasma Peut Provoquer Des Blessures Ou Des Brûlures

    Bien serrer l’écrou de retenue. Table de travail Raccorder la table de travail à la terre, • S’assurer que toutes les connexions sont bien serrées conformément aux codes de sécurité locaux ou nationaux pour éviter la surchauffe. appropriés. 1a-4 Hypertherm Systèmes plasma 5/6/02...

  • Page 18: Sécurité Des Bouteilles De Gaz Comprimé

    Les tuyaux gelés peuvent être endommagés ou éclater si • Se tenir le plus loin possible de la source de courant. l'on essaie de les dégeler avec une torche plasma. Hypertherm Systèmes plasma 1a-5 2/12/01...
  • Page 19 SÉCURITÉ 1a-6 Hypertherm Systèmes plasma 2/12/01...

  • Page 20: Specifications

    Section 2 SPECIFICATIONS In this section: Specifications – RT60/RT60M ..........................2-2 Torch Dimensions.............................2-3 RT60/ RT60M Operator Manual...
  • Page 21 SPECIFICATIONS Specifications – RT60/RT60M Air Cooled Torch Cutting Capacity Amperage Recommended capacity 3/8” (10 mm) 1/2” (13 mm) 5/8” (16 mm) Maximum capacity 5/8” (16 mm) 3/4” (19 mm) 7/8” (22 mm) Severance capacity 7/8” (22 mm) 1” (25 mm) 1-1/8”...

  • Page 22: Torch Dimensions

    SPECIFICATIONS Torch Dimensions RT60 Hand Torch Dimensions 8.9" (226 mm) 1.5" (38 mm) 3.9" (99 mm) 2.25" (57 mm) 1.00" (25 mm) RT60M Machine Torch Dimensions 15.06" (383 mm) 1.38" 1.00" (35 mm) (25 mm) 8" 2.25" (203 mm) (57mm) 32 pitch .125"...
  • Page 23 SPECIFICATIONS RT60/ RT60M Operator Manual...
  • Page 24 Section 3 SETUP In this section: Upon Receipt ................................3-2 Claims ..................................3-2 Contents of Box ................................3-2 Torch Installation ...............................3-3 RT60M Machine Torch Setup ...........................3-4 RT60M ON/OFF Pendant Connection ......................3-4 RT60M Torch Alignment ...........................3-4 RT60/ RT60M Operator Manual...

  • Page 25: Setup

    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 the nearest Hypertherm office listed in the front of this manual.

  • Page 26: Torch Installation

    Securing ring Receptacle Note: If the receptacle is missing or damaged it should be replaced with a new receptacle. Part Number Description 028522 MAX42 receptacle 028523 MAX43 receptacle 029962 Powermax800 receptacle 128493 Powermax600 receptacle 129325 Powermax900 receptacle RT60/ RT60M Operator Manual...

  • Page 27: Rt60M Machine Torch Setup

    Socket C Black Wire RT60M Torch Alignment Mount the machine torch perpendicular to the workpiece in order to get a vertical cut. Use a square to align the torch at 0° and 90°. Torch 0° 90° RT60/ RT60M Operator Manual...

  • Page 28: Operation

    Adjust Gas Pressure and Current Setting.........................4-5 Hand Torch Operation...............................4-6 Safety Trigger Operation ..........................4-6 Attach the Work Clamp ............................4-7 Starting a Cut from the Edge of the Workpiece....................4-7 Hand Torch Cutting Technique .........................4-8 Piercing ................................4-9 Gouging................................4-10 Cut Charts ................................4-11 RT60/ RT60M Operator Manual...

  • Page 29: Installing Torch Consumables

    The plasma arc will quickly burn through gloves and skin. Make sure power is OFF before changing consumables. Shield Retaining Cap Nozzle Electrode Swirl Ring Note: Cap-on sensor disables the torch when the consumables are removed. Lightly hand tighten. RT60/ RT60M Operator Manual...

  • Page 30: Torch Consumable Configurations

    Electrode Swirl Ring Shield 120929 120928 120932 120926 120925 120929 120928 120931 Retaining Cap Nozzle Electrode Swirl Ring Shield 120926 120925 120977 120928 220059 Retaining Cap Nozzle Electrode Swirl Ring Shield 120926 220327 220325 120928 220329 RT60/ RT60M Operator Manual...
  • Page 31 * Use an ohmic sensing cap when a compatible torch height contoller is installed. 40A-60A ** In CE countries, unshielded 220061 consumables may only be used in mechanized torch applications. Maintain torch-to-work distance of approximately 1/8 inch (3mm). RT60/ RT60M Operator Manual...

  • Page 32: Adjust Gas Pressure And Current Setting

    Pull regulator knob to unlock. Torch Lead Length 7.5 m 15 m Cutting 70 psi 75 psi 4.8 BAR 5.2 BAR Gouging 50 psi 60 psi 3.4 BAR 4.1 BAR Set pressure according to process and lead length. RT60/ RT60M Operator Manual...

  • Page 33: Hand Torch Operation

    • Keep away from the torch tip. • Do not hold the workpiece, and keep your hands clear of the cutting path. • Never point the torch toward yourself or others. • Never use with Pendant Switch. Safety Trigger Operation RT60/ RT60M Operator Manual...

  • Page 34: Attach The Work Clamp

    Hold the torch nozzle vertical at the edge of the workpiece. Start cutting from the edge of the workpiece. Pause at the edge until the arc has completely cut through the workpiece. Then, proceed with the cut. RT60/ RT60M Operator Manual...

  • Page 35: Hand Torch Cutting Technique

    • To cut thin material, reduce the amps until you get the best quality cut. • For straight-line cuts, use a straight edge as a guide. To cut circles, use a template or a Hypertherm circle cut guide, Part No. 027668. RT60/ RT60M Operator Manual...

  • Page 36: Piercing

    Fire the torch at an angle to the workpiece, then slowly rotate it to an upright position. When sparks are exiting from the bottom of the workpiece, the arc has pierced through the material. When the pierce is complete, proceed with the cut. RT60/ RT60M Operator Manual...

  • Page 37: Gouging

    Maintain a 45° angle, approximately, from the workpiece. Feed into the gouge. 45° Note: A heat shield is available for added hand and torch protection, Part No. 220049. Direction of travel RT60/ RT60M Operator Manual 4-10...
  • Page 38 Optimum travel speeds provide the best cut angle, least dross and best cut surface finish. Remember that cut charts are intended to provide a good starting point for each different cut assignment. Every cutting system requires “fine tuning” for each cutting application in order to obtain the desired cut quality. RT60/ RT60M Operator Manual 4-11...
  • Page 39 Optimum travel speeds provide the best cut angle, least dross and best cut surface finish. Remember that cut charts are intended to provide a good starting point for each different cut assignment. Every cutting system requires “fine tuning” for each cutting application in order to obtain the desired cut quality. RT60/ RT60M Operator Manual 4-12...
  • Page 40 Optimum travel speeds provide the best cut angle, least dross and best cut surface finish. Remember that cut charts are intended to provide a good starting point for each different cut assignment. Every cutting system requires “fine tuning” for each cutting application in order to obtain the desired cut quality. RT60/ RT60M Operator Manual 4-13...
  • Page 41 Optimum travel speeds provide the best cut angle, least dross and best cut surface finish. Remember that cut charts are intended to provide a good starting point for each different cut assignment. Every cutting system requires “fine tuning” for each cutting application in order to obtain the desired cut quality. RT60/ RT60M Operator Manual 4-14...

  • Page 42: Maintenance And Parts

    Section 5 MAINTENANCE AND PARTS In this section: Routine Maintenance ..............................5-2 Inspect Consumables............................5-3 Parts ..................................5-4 Torch Consumable Configurations ........................5-4 RT60 Hand Torch Assembly..........................5-6 RT60M Machine Torch Assembly........................5-8 Accessories..............................5-10 RT60/ RT60M Operator Manual...

  • Page 43: Routine Maintenance

    Check pressure hose, filter Replace damaged power Replace damaged element, and connections cord or plug. torch lead. for leaks. Clean the inside of the power supply with air pressure or 6 Months vacuum. RT60/ RT60M Operator Manual...

  • Page 44: Inspect Consumables

    Damage or debris Replace Central bore (I.D.) Does electrode slide easily? Replace Gas holes Blocked holes Replace Torch O-ring External surfaces Damage or wear Replace Dry surface Apply a thin film of Hypertherm grease (Part No. 027055) RT60/ RT60M Operator Manual...

  • Page 45: Torch Consumable Configurations

    Electrode Swirl Ring Shield 120929 120928 120932 120926 120925 120929 120928 120931 Retaining Cap Nozzle Electrode Swirl Ring Shield 120926 120925 120977 120928 220059 Retaining Cap Nozzle Electrode Swirl Ring Shield 120926 220327 220325 120928 220329 RT60/ RT60M Operator Manual...
  • Page 46 * Use an ohmic sensing cap when a compatible torch height contoller is installed. 40A-60A ** In CE countries, unshielded 220061 consumables may only be used in mechanized torch applications. Maintain torch-to-work distance of approximately 1/8 inch (3mm). RT60/ RT60M Operator Manual...

  • Page 47: Rt60 Hand Torch Assembly

    MAINTENANCE AND PARTS RT60 Hand Torch Assembly Item Part Number Description Quantity 083215* RT60 Hand Torch Assembly with 25 ft (7.6 m) Lead 083216* RT60 Hand Torch Assembly with 50 ft (15.2 m) Lead 128564 Torch Main Body Replacement 027889 Retaining Clip...
  • Page 48 MAINTENANCE AND PARTS RT60/ RT60M Operator Manual...

  • Page 49: Rt60M Machine Torch Assembly

    25 ft (7.6 m) Torch Lead Replacement Kit 128925 50 ft (15.2 m) Torch Lead Replacement Kit 128926 RT60/RT60M Quick Disconnect Repair Kit 128645 Torch Mounting Kit (for reassembly after installation) * Top assembly includes the following consumables (See page 6 for details of consumable parts):...
  • Page 50 MAINTENANCE AND PARTS RT60/ RT60M Operator Manual...

  • Page 51: Accessories

    On/Off Pendant with Lead, 50 ft (15.2 m) 128062 On/Off Pendant with Lead, 75 ft (23 m) 027668 Circle Cutting Guide Assembly 027684 Replacement Bushing for Circle Cutting Guide Assembly 220049 Hand Heat Shield, Gouging RT60/ RT60M Operator Manual 5-10...

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