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Hypertherm HT4001 manual available for free PDF download: Instruction Manual
Hypertherm HT4001 Instruction Manual (270 pages)
Plasma Arc Cutting System
Brand:
Hypertherm
| Category:
Cutter
| Size: 9 MB
Table of Contents
English
18
Bumped Page
6
Table of Contents
18
Recognize Safety Information
27
Follow Safety Instructions
27
Cutting Can Cause Fire or Explosion
27
Electric Shock Can Kill
28
Cutting Can Produce Toxic Fumes
28
A Plasma Arc Can Cause Injury and Burns
29
Arc Rays Can Burn Eyes and Skin
29
Grounding Safety
29
Compressed Gas Equipment Safety
30
Gas Cylinders Can Explode if Damaged
30
Noise Can Damage Hearing
30
Pacemaker and Hearing Aid Operation
30
A Plasma Arc Can Damage Frozen Pipes
30
Additional Safety Information
30
Warning Lable
31
Warning Label
31
Français
32
Section 1A Sécurité
32
Danger Avertissement Précaution
33
Risque D'explosion Argon-Hydrogène Et Méthane
33
Détonation de L'hydrogène Lors du Coupage de L'aluminium
33
Les Chocs Électriques Peuvent Être Fatals
34
Identifier Les Consignes de Sécurité
33
Le Coupage Peut Provoquer un Incendie Ou Une Explosion
33
Suivre Les Instructions de Sécurité
33
Les Chocs Électriques Peuvent Ê T Re Fatals
34
Le Coupage Peut Produire des Vapeurs Toxiques
34
Prévention des Chocs Électriques
34
L'arc Plasma Peut Provoquer des Blessures Ou des Brûlures
35
L'arc Plasma Peut Provoquer des Blessures Ou des Brû L Ures
35
Mise À la Masse Et À la Terre
35
Les Rayons de L'arc Peuvent Brûler Les Yeux Et la Peau
35
Les Rayons de L'arc Peuvent Brû L er Les Yeux Et la Peau
35
Torches À Allumage Instantané
35
Sécurité des Bouteilles de Gaz Comprimé
36
Les Bouteilles de Gaz Comprimé Peuvent Exploser en Cas de Dommages
36
Le Bruit Peut Provoquer des Problèmes Auditifs
36
Pacemakers Et Prothéses Auditives
36
Pacemakers Et Prothèses Auditives
36
Un Arc Plasma Peut Endommager Les Tuyaux Gelés
36
Étiquette de Sécurité
37
Section 2 DESCRIPTION & SPECIFICATIONS
38
Description
39
Description & Specifications
39
HT4001 Power Supply
39
Remote High Frequency (RHF) Console
39
Gas Console
40
Motor Valve Console
40
Remote Voltage/Current (V/C) Control - Optional
40
Timer/Counter - Optional
41
Water Chiller - Optional
41
Initial Height Sensing (IHS) - Optional
41
H-401 Slave Power Supply - Optional
41
Water Muffler - Optional
41
Specifications
42
System Requirements
42
HT4001 Power Supply
42
HT4001 Power Supply with Slave
42
IEC Symbols Used
50
Figure 2-1 Overall Dimensions - HT4001 Power Supply
43
Figure 2-3 PAC620 Bevel Torch Assembly with Dimensions
44
PAC620 Machine Torches
44
Remote High Frequency Console
45
Digital Remote (DR) V/C Control (077012
46
Programmable Remote (PR) V/C Control (077013
46
Gas Console
47
Motor Valve Console
47
Figure 2-2 PAC620 Standard Torch Assembly with Dimensions
44
Figure 2-8 Mounting Dimensions - Initial Height Sensing
48
Initial Height Sensing
48
Timer/Counter
48
Water Chiller
49
H-401 Power Supply
49
Water Muffler
49
Section 3 PRE-INSTALLATION
52
Introduction
52
Gas Requirements
52
Water Supply Requirements
53
Grounding Requirements
54
Power Requirements
54
Line Disconnect Switch
55
Power Cables
55
Positioning the Power Supplies
56
Transformer Configurations
57
Figure 3-1 240V Transformer
57
Figure 3-2 480V Transformer
57
Figure 3-3 200V Transformer
58
Figure 3-4 380V Transformer
58
Figure 3-5 400V Transformer
59
Figure 3-6 415V Transformer
59
Figure 3-7 575V Transformer
60
Figure 3-8 600V Transformer
60
Connecting the Power
61
Figure 3-9 Power Cable Connections
61
Torch Lifter Requirement
62
Optional Equipment
62
Water Muffler
62
Initial Height Sensing (IHS)
63
Section 4 INSTALLATION
65
Upon Receipt
65
Claims
65
Module Grounding and Grounding Checks
66
Noise Levels (Decibels)
66
Figure 4-1 Noise Levels (Decibels)
66
System Units Placement
67
Figure 4-2 Typical HT4001 System Component Placement for Gantry Cutter
67
HT4001 Interconnection Reference Map
68
Figure 4-3 HT4001 Interconnect System Diagram with IHS, Water Muffler and Slave
68
Power Supply Connections
69
Positive Lead Connection - PS to Work Table
70
Figure 4-5 RHF Cable Connections - PS to RHF Console
72
Figure 4-6 Gas Console Cable Connection - PS to Gas Console
74
Figure 4-7 Machine Interface I/O Cable Connection - PS to Computer Interface
76
Figure 4-8 Machine Interface V/C Cable Connection - PS to Computer Interface
78
Figure 4-9 Remote Serial and V/C Cables - PS to Remote V/C
80
Figure 4-10 Timer/Counter Cable and IHS Cable Connections - PS to T/C; PS to IHS
82
Figure 4-11 Water Muffler Connections - PS to Water Muffler
84
RHF Console Connections
85
Figure 4-12 RHF Connections to Water Chiller and Gas Console
86
Figure 4-13 RHF Connections to Torch - Shielded Leads
88
Gas Console Connections
89
Figure 4-14 Gas Console Connections - Gas Console to Gas Supplies; Gas Console to Torch
90
Figure 4-15 Gas Console Connections - Gas Console to Motor Valve Console
92
Motor Valve Console Connections
93
Figure 4-16 Motor Valve Console to Torch Connections
94
Initial Height Sensing Connections
95
Figure 4-17 Initial Height Sensing Connections
96
Figure 4-18 Initial Height Sensing Upper Limit Switch Connections
98
Optional Power Supply Connections
99
Figure 4-19 Hold Cable Connections to TB3
100
Mounting the Machine Torch
101
Torch Alignment
101
Section 5 OPERATION
102
Controls and Indicators
103
HT4001 Power Supply Front Panel
103
HT4001 Power Supply Rear Panel Control
103
Figure 5-1 Power Supply Front Panel Indicators
104
Figure 5-3 Gas Console Front Panel Controls and Indicators
106
Digital Remote (DR) V/C Module
107
Figure 5-4 Digital Remote (DR) V/C Front Panel Controls and Indicators
107
Programmable Remote (PR) V/C Module
108
Timer/Counter
108
Figure 5-5 Programmable Remote (PR) V/C Front Panel Indicators
108
Pre-Operation System Checkout
109
Final Torch Adjustment
112
Figure 5-8 Torch with Inductive Probes
112
Daily Start-Up
114
Figure 5-9 Gas Console Reference - Daily Startup
115
Cutting Techniques
116
How to Get Better Cut Quality
116
Dross Conditions
117
Shape of Cut Surface
117
How to Get Longer Consumable Life
118
How to Get Better Pierces
119
How to Increase Cutting Speed
119
Common Cutting Faults
120
Cut Charts
120
Technical Questions
120
Cut Chart and Consumable Parts Index
121
Changing Consumable Parts
134
Removal and Inspection
134
Replacement
134
Figure 5-10 Changing Consumable Parts
135
Changing the Water Tube
136
Figure 5-11 Changing the Water Tube
136
Section 6 PARTS LIST
138
Introduction
138
Finding Part Numbers
138
HT4001 Interconnection Reference Map
139
HT4001 Power Supply
139
Gas Console
139
Motor Valve Console
139
IHS Console
139
Figure 6-1 HT4001 Power Supply - Outside Front Panel
140
HT4001 Power Supply
141
Figure 6-2 HT4001 Power Supply - Inside Front Panel
142
Figure 6-3 HT4001 Power Supply - Front Bail
144
Figure 6-4 HT4001 Power Supply - Rear Bail
146
Figure 6-5 HT4001 Power Supply - Inside Floor
148
Figure 6-6 HT4001 Power Supply - Rear Wall Inside
150
Figure 6-7 HT4001 Power Supply - Rear Wall Outside
152
Figure 6-8 Remote High Frequency Console
154
Remote High Frequency Console
155
Figure 6-9 Gas Console
156
Gas Console
157
Figure 6-10 Motor Valve Console
158
Motor Valve Console
159
Figure 6-11 Remote V/C - Digital (DR) Control Module
160
Remote V/C - Programmable (PR) Control Module
162
Figure 6-13 IHS Console
164
IHS Console
165
Timer/Counter
166
Positive Lead - PS to Work Table and PS to Slave
167
Figure 6-18 Gas Console Cable - PS to Gas Console
168
Figure 6-21 Remote Serial Cable - PS to Remote V/C
169
Figure 6-24 IHS Interface Cable - PS to IHS
170
Figure 6-27 Cooling Hose Set - RHF Console to Water Chiller
171
Figure 6-29 Shielded Torch Leads - RHF Console to Torch
172
Figure 6-31 Nitrogen Supply Hose - Gas Console to Nitrogen Supply
173
Figure 6-34 Cut Flow Gas Hose - Gas Console to Motor Valve Console
174
Figure 6-37 Air Hose Assembly - IHS Module to Inductive Sensor Air Cylinder
175
Figure 6-40 Hold Cable - PS to Second HT4001 Power Supply
176
PAC620 Machine Torch Assembly
177
Torch Mounting Bracket
177
Consumable Parts Kits
178
Figure 6-45 Consumable Parts - PAC620 400A Bevel
179
Figure 6-46 Consumable Parts - PAC620 760A Standard
180
Figure 6-47 Consumable Parts - PAC620 760A Bevel
181
Recommended Spare Parts
183
Power Supply
183
Remote High Frequency Console
183
Gas Console
183
IHS System and Components
184
IHS Leads Packages and Components
184
Section 7 MAINTENANCE
185
Introduction
186
Routine Maintenance
187
Torch and Torch Leads
187
Power Supplies
187
Gas Console
188
Motor Valve Console
188
Remote HF Console
188
HT4001 Initialization and Sequence of Operation
189
Power Distribution Board PCB1
190
Initial Checks
195
Figure 7-1 Primary Power Measurement Location - HT4001
196
Figure 7-2 Power Distribution Board PCB1
197
Troubleshooting
198
STATUS LED Troubleshooting
204
Figure
206
Chopper Module Test Procedure
206
Figure 7-3 Chopper Module - Front View
207
Relay Board PCB4 Status Indicators
208
Relay Board PCB4 in O 2 Test Preflow
209
Relay Board PCB4 in N
209
Test Cut Flow
210
Relay Board PCB4 in N
210
Figure 7-9 Relay Board PCB4 in RUN Mode
211
Error Codes
212
Torch Coolant Draining
214
Appendix A H-401 Power Supply as Slave
215
H-401 Slave Modification
216
Current Setpoint PCB Installation
217
Current Setpoint PCB Connections
217
Figure A-1 Current Setpoint PCB Installation
217
Figure A-2 Current Setpoint PCB Connections
219
H-401 Slave Connections
220
Figure A-4 H-401 Power Cable Connections
221
Figure A-5 Slave Cable - HT4001 Power Supply to H-401 Slave Power Supply
223
HT4001 Power Supply to Work Table and RHF Console
225
Appendix B AERATION MANIFOLD
226
Aeration Manifold for Plasma Cutting Aluminum
227
Appendix C Electromagnetic Compatibility
228
EMC Introduction
229
General
230
Figure C-2 HT4001 Power Supply with EMI Filter Cover off
231
Figure C-3 Power Cable Connections to TB5
232
EMI Filter Parts List
233
Appendix D Power Cable Installation for 200/220V Power Supplies
235
General
235
Figure D-2 HT4001 Power Supply with Terminal Box Cover off
236
Figure D-3 Power Cable Connections to TB5
237
Appendix E Benzotriazole Safety Data
248
Appendix F System Grounding
248
Figure F-1 Recommended Ground Connection Configuration
249
Figure F-2 Alternate Ground Connection Configuration
250
Standards Index
251
Section 8 WIRING DIAGRAMS
253
Wiring Diagrams
254
Power Supply
265
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