Hypertherm HySpeed HT2000 User Manual (English)

Questions and Answers:

R
Robert DeleonAug 8, 2025
What to do if green POWER ON indicator is illuminated, START command is given, DC ON indicator is illuminated, but there is no high frequency and no pilot arc in Hypertherm HySpeed HT2000?
- C
  cherylmooreAug 8, 2025
  If your Hypertherm Welding System has power, but lacks high frequency and a pilot arc, consider these potential causes: * Check for a spark between the spark gap electrodes. Clean, align, and reset the electrode gaps to .020" (0.51 mm) if needed. Ensure the electrode surfaces between the gaps are flat; replace if rounded and reset the gap. * Inspect the high voltage transformer T1 in the RHF console for overheating, and replace T1 if necessary. * Confirm there is 120VAC at T1 after the START command is given. Note that door interlock switches S1 and S2 must be closed to pass the START sequence. * If there is no 120VAC at T1, 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.
W
William MaldonadoAug 13, 2025
What to do if green POWER ON indicator is illuminated, torch START command is given, DC ON indicator illuminates, there is high frequency, but there is no pilot arc in Hypertherm HySpeed HT2000 Welding System?
- M
  Matthew GreenAug 13, 2025
  If your Hypertherm Welding System has power and high frequency, but no pilot arc, consider these potential causes: * Check if the pilot arc relay CR1 is closing (getting 120VAC from the relay board PCB4). See if the CR1 relay contacts close after the START command is given. * If there is 120VAC across the relay and CR1 does not close, replace CR1 because Pilot arc relay CR1 may be defective. * With an AC voltmeter, see if contactor CON1 is getting 120VAC after START command is given, because Main contactor (CON1) or PCB4 may be defective.
R
roy47Aug 18, 2025
Why fans are not operating and the green POWER ON indicator does not illuminate when the green POWER ON pushbutton switch PB1 is pressed in Hypertherm Welding System?
- T
  Taylor WallAug 18, 2025
  If the fans and POWER ON indicator fail to activate when pressing the POWER ON button on your Hypertherm Welding System, check the following: * Ensure the POWER ON switch is functioning correctly and making good contact. The POWER ON switch is normally open. * Verify the POWER OFF switch is functioning correctly and making good contact. The POWER OFF switch is normally closed. * Inspect the associated wiring for good contact; repair or replace as necessary.
V
Veronica BoltonAug 23, 2025
What to do if fans are not running when the green POWER ON pushbutton switch PB1 is pressed and the POWER ON indicator illuminates in Hypertherm HySpeed HT2000 Welding System?
- J
  Jason BridgesAug 23, 2025
  If the POWER ON indicator illuminates but the fans don't run when you press the POWER ON button on your Hypertherm Welding System, check these potential causes: * Verify that CR2 switches when the POWER ON pushbutton is pressed. See Figure 8-2 for location of CR2. If CR2 is defective, replace PCB1, because CR2 on the power distribution board may be defective. * Check pins, connectors and associated wiring for good continuity. Repair or replace if necessary, because Connector from power distribution board may not be seated securely.
S
Sean FloresAug 28, 2025
What to do if the green POWER ON indicator does not illuminate when the green POWER ON pushbutton switch PB1 is pressed and the fans are operating in Hypertherm HySpeed HT2000?
- J
  Jonathan GeorgeAug 28, 2025
  If the fans operate but the POWER ON indicator doesn't light up when pressing the POWER ON button on your Hypertherm Welding System, consider the following: * Ensure you press and hold PB1 for a minimum of 5 seconds, because Pushbutton PB1 may was not held down for a long enough period of time. * Check that CR1 switches when the POWER ON pushbutton is pressed. See Figure 8-2 for location of CR1. If CR1 is defective, replace PCB1, because Relay CR1 on the power distribution board may be defective. * To troubleshoot STATUS fault conditions, see Status LED Troubleshooting later in this section, because One or more of the STATUS LEDs may remains illuminated, indicating a fault condition.

Hypertherm HySpeed HT2000 Specifications

General

Brand	Hypertherm
Model	HySpeed HT2000
Category	Welding System
Language	English

Summary

ELECTROMAGNETIC COMPATIBILITY (EMC)

EMC INTRODUCTION

Explains the purpose of EMC compliance and system design.

INSTALLATION AND USE

Details user responsibilities for installation and use of equipment.

ASSESSMENT OF AREA

Guides assessment of potential electromagnetic interference sources.

METHODS OF REDUCING EMISSIONS

Discusses methods to reduce EMI, including mains supply and shielding.

Earthing of Workpiece

Guidance on earthing the workpiece for EMI reduction.

Screening and Shielding

Methods for screening and shielding to reduce interference.

WARRANTY

WARNING

Emphasizes using genuine parts and potential warranty voiding.

GENERAL

Details warranty coverage, duration, and return process.

PATENT INDEMNITY

Hypertherm's obligation regarding patent infringement claims.

LIMITATION OF LIABILITY

Limits liability for consequential damages.

LIABILITY CAP

Caps liability to the amount paid for the product.

INSURANCE

Requirement for user to maintain insurance.

NATIONAL AND LOCAL CODES

National and local codes take precedence over manual instructions.

TRANSFER OF RIGHTS

Conditions for transferring warranty rights.

SAFETY

Recognize Safety Information

Explains safety symbols and their meaning.

Follow Safety Instructions

Emphasizes reading and following safety messages.

Cutting Can Cause Fire or Explosion

Hazards related to fire and explosion during cutting.

Electric Shock Can Kill

Hazards of electric shock and prevention measures.

Cutting Can Produce Toxic Fumes

Hazards of toxic fumes and gases, and ventilation requirements.

A Plasma Arc Can Cause Injury and Burns

Risks associated with plasma arc contact.

Arc Rays Can Burn Eyes and Skin

Hazards of arc rays and protective measures.

Grounding Safety

Importance of proper grounding for safety and EMI.

Compressed Gas Equipment Safety

Safety precautions for compressed gas systems.

Noise Can Damage Hearing

Risks of prolonged noise exposure and protection.

Pacemaker and Hearing Aid Operation

Precautions for users with pacemakers/hearing aids.

A Plasma Arc Can Damage Frozen Pipes

Warning about using plasma torch on frozen pipes.

Additional Safety Information

Lists relevant safety standards and references.

Warning Label

Explains the meaning of warning labels on the equipment.

SPECIFICATIONS

Introduction

Overview of the HT2000 system's capabilities.

Power Supply

Description of the power supply unit's components.

Remote High Frequency (RHF) Console

Details of the RHF console's function and features.

Gas Console

Description of the gas console's controls and functions.

Motor Valve Console

Description of the motor valve console's components.

Argon-Hydrogen Console

Description of the optional argon-hydrogen console.

Remote Voltage/Current (V/C) Control

Description of the V/C control options.

Initial Height Sensing (IHS)

Description of the Initial Height Sensing system.

Timer/Counter

Description of the timer/counter function.

Water Muffler

Description of the optional water muffler.

Specifications

Details system requirements and specifications.

System Requirements

Outlines overall system requirements.

Power Requirements

Details electrical input requirements and fuse sizes.

Gas Requirements

Specifies types and quality of gases required.

Power Supply

Lists input power voltage and current ratings.

Dimensions and Weight (Power Supply)

Provides physical dimensions and weight of the power supply.

HySpeed HT2000 Machine Torches

Technical details for machine torches.

Dimensions and Weight (RHF Console)

Physical dimensions and weight of RHF console.

Dimensions and Weight (Gas Console)

Physical dimensions and weight of gas console.

Dimensions and Weight (Motor Valve Console)

Physical dimensions and weight of motor valve console.

Dimensions and Weight (Argon-Hydrogen Manifold)

Physical dimensions and weight of the A-H manifold.

Controls (Digital Remote V/C)

Explains controls and displays on the DR V/C module.

Dimensions and Weight (Digital Remote V/C)

Physical dimensions and weight of DR V/C control.

Controls (Programmable Remote V/C)

Details the PR V/C control functions.

Dimensions and Weight (Programmable Remote V/C)

Physical dimensions and weight of PR V/C control.

Dimensions and Weight (IHS Console)

Physical dimensions and weight of IHS console.

Dimensions and Weight (Timer/Counter)

Physical dimensions and weight of timer/counter.

PRE-INSTALLATION

Introduction

Purpose and overview of pre-installation steps.

Gas Requirements

Details required gas types and specifications.

Shield Gas

Requirements for shield gas.

Torch Coolant Requirements

Specifications for torch coolant.

Grounding Requirements

Essential grounding specifications for safety and EMI.

Power Requirements

Electrical power supply requirements.

Line Disconnect Switch

Installation and function of the line disconnect switch.

Power Cable

Guidelines for selecting and installing power cables.

Positioning the Power Supply

Recommendations for placing the power supply unit.

Electrical Configurations

How to configure electrical settings.

240/480V Linkboard Configurations

Linkboard configuration for voltage selection.

220/380/400/415V Transformer T1 and T2 Configurations

Transformer configuration for voltage selection.

Connecting the Power

Steps for connecting the main power supply.

Torch Lifter Requirement

Specifications for the torch lifter.

Optional Equipment

Information on optional equipment.

Water Muffler

Requirements for the water muffler.

Initial Height Sensing (IHS)

Requirements for the IHS system.

INSTALLATION

Upon Receipt

Procedures for checking system components upon delivery.

Claims

Procedures for filing claims for damaged or missing merchandise.

Module Grounding and Grounding Checks

Ensures proper grounding for safety and EMI.

Noise Levels

Information on system noise levels.

System Units Placement

Guidelines for positioning system components.

Power Supply Connections

How to connect the power supply.

Initial Height Sensing (IHS) Connections

Steps for connecting the IHS system.

Gas Console Connections

How to connect the gas console.

RHF and Motor Valve Consoles to Torch Connections

Connecting RHF/Motor Valve consoles to the torch.

Connecting the HF Torch Leads to the RHF Console

Steps to connect HF torch leads to RHF console.

Connecting the HF Torch Leads to the Torch

Steps to connect HF torch leads to the torch.

Connecting the Off-Valve Cable and Plasma Hose from the Torch to the Motor Valve Console

Connecting off-valve cable and plasma hose to motor valve console.

Optional Power Supply Connections

Connections for optional power supplies.

Timer/Counter to Power Supply

Connecting timer/counter to power supply.

Hold Cable Connections (When using Multi-Torch Systems)

Connecting hold cables for multi-torch systems.

Argon-Hydrogen Connections

Connects the argon-hydrogen manifold.

Mounting the Machine Torch

Steps for mounting the machine torch.

Torch Alignment

Procedures for aligning the machine torch.

POST-INSTALLATION

Introduction

Purpose of post-installation checkout.

System Checkout

Procedure for checking the installed system.

Set Switches and Check Torch

Initial switch settings and torch check.

Turn Gases On

Steps to turn on system gases.

Turn Power Supply On and Adjust Voltage/Current

Powering up and adjusting voltage/current.

Adjust Preflow Gases

Adjusting preflow gas settings.

Adjust Cut Flow Gases and Prepare for Cutting

Steps to set cut flow gases and prepare for cutting.

Common Cutting Faults

Lists common cutting problems and their causes.

Final Torch Adjustment

Final adjustments to the torch height.

Check Torch Height Control (THC) and V/C Module

Verifying THC and V/C module operation.

OPERATION

Front Panel Controls and Indicators

Overview of front panel controls and indicators.

Power Supply

Details power supply controls and status indicators.

STATUS Indicators Before Startup

Explains status indicators before startup.

Gas Console

Overview of gas console controls.

Digital Remote (DR) V/C Module

Description of DR V/C module controls.

Programmable Remote (PR) V/C Module

Description of PR V/C module controls.

Timer / Counter

Operation of the timer/counter.

Noise Levels (Decibels)

Information on system noise levels.

Daily Start-Up

Daily startup procedure for the system.

Check Torch

Inspection of torch and consumables.

Turn Gases On

Steps to turn on system gases.

Turn Power Supply On and Adjust Voltage/Current

Powering up and adjusting voltage/current.

Adjust Preflow Gases

Adjusting preflow gas settings.

Adjust Cut Flow Gases and Prepare for Cutting

Setting cut flow gases and preparing for cutting.

Common Cutting Faults

Lists common cutting problems and causes.

Technical Questions

Troubleshooting support and contact information.

Cut Charts

Provides data for successful plasma arc cutting.

Conversions

Unit conversion factors for cutting parameters.

CUT CHART AND CONSUMABLE PARTS INDEX

Index for cut charts and consumable parts.

Mild Steel - Beveling Consumables

Cut charts for beveling mild steel.

Mild Steel Gouging

Operating parameters for mild steel gouging.

Stainless Steel or Aluminum Gouging

Operating parameters for gouging stainless steel/aluminum.

Changing Consumable Parts

Procedures for replacing consumable parts.

Removal and Inspection

Steps for removing and inspecting parts.

Replacement

Procedures for replacing parts.

Changing the Water Tube

Instructions for changing the water tube.

How to Optimize Cut Quality

Tips for improving cut quality.

Tips for Table and Torch

Advice on table and torch alignment and maintenance.

Plasma Set-up Tips

Tips for plasma system setup.

Maximize the Life of Consumable Parts

Strategies to maximize consumable life.

Additional Factors of Cut Quality

Factors influencing cut quality.

Piercing

Details on the piercing process.

How to Increase Cutting Speed

Methods to increase cutting speed.

OPERATION: ARGON-HYDROGEN MANIFOLD

Front Panel Controls and Indicators

Controls and indicators for the A-H manifold.

Installation

Steps for installing the A-H manifold.

Operation

Procedures for operating the A-H manifold.

Check Torch

Checking the torch before A-H operation.

Turn Gases On

Steps to turn on A-H gases.

Turn Power Supply On and Adjust Voltage/Current

Powering up and adjusting voltage/current for A-H.

Adjust H35 Gas Flow

Adjusting the H35 gas flow rate.

After Cutting with Argon-Hydrogen

Post-operation steps for A-H.

MAINTENANCE

Introduction

Overview of maintenance procedures.

Routine Maintenance

Regular maintenance tasks for system upkeep.

Torch and Torch Leads

Inspection of torch and leads.

Power Supply

Inspection and cleaning of the power supply.

Gas Console

Inspection and cleaning of the gas console.

Motor Valve Console

Inspection and cleaning of the motor valve console.

RHF Console

Inspection and cleaning of the RHF console.

Startup Sequence

Flowchart for system startup.

Initial Checks

Procedure for initial system checks.

Troubleshooting

Guide for diagnosing and resolving problems.

STATUS LED Troubleshooting

Troubleshooting based on status LED indicators.

Chopper Module Test Procedure

Steps to test the chopper module.

Error Codes

List and explanation of error codes.

Analog Board LED Functions

Explanation of analog board LEDs.

Relay Board LED Function List

List of relay board LED functions.

Relay Board LED Status Conditions

Conditions indicated by relay board LEDs.

Coolant Flow Test Procedure

Procedure to test coolant flow.

Check Reservoir Coolant

Steps to check coolant level.

Verify Flow Rate Return from Torch

Procedure to verify coolant flow return.

Verify Flow Rate to Torch

Procedure to verify coolant flow to torch.

Check Pump, Motor and Solenoid Valve (V1)

Checks on pump, motor, and solenoid valve.

Torch Coolant Draining

Procedure for draining torch coolant.

Preventive Maintenance Schedule

Schedule for routine maintenance tasks.

PARTS LIST

Introduction

Explains the format for listing and calling out parts.

System Parts Diagram

Diagram showing system components and references.

Power Supply

List of parts for the power supply.

Front Panel

Parts list for the power supply front panel.

THC Assembly

Parts list for the THC assembly.

Control Panel

Parts list for the power supply control panel.

Base Plate and Components

Parts list for base plate components.

Center Wall Right Side

Parts list for the center wall right side of the power supply.

Center Wall Left Side

Parts list for the center wall left side of the power supply.

Front Wall Inside

Parts list for the front wall interior of the power supply.

Rear Wall Inside

Parts list for the rear wall interior of the power supply.

High Frequency and I/O PCB

Parts list for the HF and I/O PCB.

Rear Wall Outside

Parts list for the rear wall exterior of the power supply.

Remote High Frequency Console (#073067)

Parts list for the RHF console.

Spark Gap Assembly

Parts list for the spark gap assembly.

Gas Console (#073218)

Parts list for the gas console.

Motor Valve Console (#073219)

Parts list for the motor valve console.

Remote V/C – Digital (DR) Control Station (#073007)

Parts list for the DR V/C control station.

Remote V/C – Programmable (PR) Control Station (#055004)

Parts list for the PR V/C control station.

IHS Console (#053016)

Parts list for the IHS console.

Argon-Hydrogen Manifold (#073109)

Parts list for the argon-hydrogen manifold.

HySpeed HT2000 Machine Torch (2" Sleeve)

Parts list for the 2" sleeve machine torch.

HySpeed HT2000 Stainless Steel Machine Torch (2" Sleeve)

Parts list for the 2" sleeve stainless steel machine torch.

Torch Mounting Bracket (2" Sleeve)

Parts list for the 2" sleeve torch mounting bracket.

HySpeed HT2000 Machine Torch (1-3/4" Sleeve)

Parts list for the 1-3/4" sleeve machine torch.

Torch Mounting Bracket (1-3/4" Sleeve)

Parts list for the 1-3/4" sleeve torch mounting bracket.

Pilot Arc Cable

Parts list for pilot arc cables.

Negative Lead and Work Cable

Parts list for negative lead and work cables.

HT2000 RHF Cable

Parts list for the HT2000 RHF cable.

Gas Console Cable

Parts list for gas console cables.

Motor Valve Console Cable

Parts list for motor valve console cables.

Machine Interface Cable

Parts list for machine interface cables.

Machine Interface V/C Cable

Parts list for machine interface V/C cables.

Remote V/C Cable (PS to Digital/Programmable)

Parts list for remote V/C cables.

Power Supply/Programmable Remote (PR) Cable

Parts list for PS to PR V/C cables.

Water Muffler Pump Cable

Parts list for water muffler pump cable.

Initial Height Sensing Cable

Parts list for IHS cables.

Cables from IHS to Sensors

Parts list for cables connecting IHS to sensors.

Inductive Sensor Assembly

Parts list for the inductive sensor assembly.

HySpeed HT2000 Consumable Starter Kit (#128824)

List of parts in the starter consumable kit.

HySpeed HT2000 Consumable Parts Kit (#128825)

List of parts in the consumable parts kit.

HT2000 Standard Consumable Parts Kit (#028602)

List of parts in the standard consumable kit.

HT2000 Beveling Consumable Parts Kit (#128406)

List of parts in the beveling consumable kit.

Lead Packages

List of parts for lead packages.

Power Supply to RHF Console Cables and Hoses

Parts for PS to RHF console cables and hoses.

RHF Console to Gas Console Hoses

Hoses for RHF console to gas console.

Gas Console to Motor Valve Console Hoses

Hoses for gas console to motor valve console.

Recommended Spare Parts - Power Supply

Recommended spare parts for the power supply.

Recommended Spare Parts - RHF Console

Recommended spare parts for the RHF console.

Recommended Spare Parts - Gas Console

Recommended spare parts for the gas console.

Recommended Spare Parts - Motor Valve Console

Recommended spare parts for the motor valve console.

WIRING DIAGRAMS

Introduction

Explains the format and organization of wiring diagrams.

Wiring Diagram Symbols

Identification of standard wiring diagram symbols.

Torch Symbols

Symbols representing torch components.

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Hypertherm HySpeed HT2000 User Manual

Table of Contents

Questions and Answers:

Hypertherm HySpeed HT2000 Specifications

Summary

ELECTROMAGNETIC COMPATIBILITY (EMC)

EMC INTRODUCTION

INSTALLATION AND USE

ASSESSMENT OF AREA

METHODS OF REDUCING EMISSIONS

Earthing of Workpiece

Screening and Shielding

WARRANTY

WARNING

GENERAL

PATENT INDEMNITY

LIMITATION OF LIABILITY

LIABILITY CAP

INSURANCE

NATIONAL AND LOCAL CODES

TRANSFER OF RIGHTS

SAFETY

Recognize Safety Information

Follow Safety Instructions

Cutting Can Cause Fire or Explosion

Electric Shock Can Kill

Cutting Can Produce Toxic Fumes

A Plasma Arc Can Cause Injury and Burns

Arc Rays Can Burn Eyes and Skin

Grounding Safety

Compressed Gas Equipment Safety

Noise Can Damage Hearing

Pacemaker and Hearing Aid Operation

A Plasma Arc Can Damage Frozen Pipes

Additional Safety Information

Warning Label

SPECIFICATIONS

Introduction

Power Supply

Remote High Frequency (RHF) Console

Gas Console

Motor Valve Console

Argon-Hydrogen Console

Remote Voltage/Current (V/C) Control

Initial Height Sensing (IHS)

Timer/Counter

Water Muffler

Specifications

System Requirements

Power Requirements

Gas Requirements

Power Supply

Dimensions and Weight (Power Supply)

HySpeed HT2000 Machine Torches

Dimensions and Weight (RHF Console)

Dimensions and Weight (Gas Console)

Dimensions and Weight (Motor Valve Console)

Dimensions and Weight (Argon-Hydrogen Manifold)

Controls (Digital Remote V/C)

Dimensions and Weight (Digital Remote V/C)

Controls (Programmable Remote V/C)

Dimensions and Weight (Programmable Remote V/C)

Dimensions and Weight (IHS Console)

Dimensions and Weight (Timer/Counter)

PRE-INSTALLATION

Introduction

Gas Requirements

Shield Gas

Torch Coolant Requirements

Grounding Requirements

Power Requirements

Line Disconnect Switch

Power Cable

Positioning the Power Supply

Electrical Configurations

240/480V Linkboard Configurations

220/380/400/415V Transformer T1 and T2 Configurations

Connecting the Power

Torch Lifter Requirement

Optional Equipment