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Welding System
HySpeed HT2000
Hypertherm HySpeed HT2000 User Manual
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INST
ALLA
TION
HySpeed H
T2000
Instruction Manual
4-17
19
Figure 4-10
Power Supply Connections to Remote V/C Modules
Programmable Remote – Rear
Digital Remote – Rear
Power Supply – Rear
8
9
11
10
10
10
11
5X1
5X1
5X2
69
71
Table of Contents
Default Chapter
14
Table of Contents
14
Section 1 SAFETY
21
Cutting Can Cause Fire or Explosion
21
Follow Safety Instructions
21
Cutting Can Produce Toxic Fumes
22
Electric Shock Can Kill
22
A Plasma Arc Can Cause Injury and Burns
23
Arc Rays Can Burn Eyes and Skin
23
Grounding Safety
23
A Plasma Arc Can Damage Frozen Pipes
24
Additional Safety Information
24
Compressed Gas Equipment Safety
24
Gas Cylinders Can Explode if Damaged
24
Noise Can Damage Hearing
24
Pacemaker and Hearing Aid Operation
24
Warning Label
25
Section 1A
26
Sécurité
26
Identifier Les Consignes de Sécurité
27
Suivre Les Instructions de Sécurité
27
Le Coupage Peut Provoquer un Incendie Ou Une Explosion
27
Les Chocs Électriques Peuvent Être Fatals
28
Le Coupage Peut Produire des Vapeurs Toxiques
28
L'arc Plasma Peut Provoquer des Blessures Ou des Brûlures
29
Mise À la Masse Et À la Terre
29
Les Rayons de L'arc Peuvent Brûler Les Yeux Et la Peau
29
Sécurité des Bouteilles de Gaz Comprimé
30
Les Bouteilles de Gaz Comprimé Peuvent Exploser en Cas de Dommages
30
Le Bruit Peut Provoquer des Problèmes Auditifs
30
Pacemakers Et Prothéses Auditives
30
Étiquette de Sécurité
31
Specifications
32
Introduction
33
Power Supply
33
Remote High Frequency (RHF) Console
33
Remote High Frequency Console
33
Gas Console
34
Motor Valve Console
34
Remote Voltage/Current (V/C) Control
34
Initial Height Sensing (IHS)
35
Timer/Counter
35
Water Muffler
35
System Requirements
36
Power Supply
36
Power Supply
37
Pre-Installation
42
Introduction
43
Gas Requirements
43
Air as Plasma Gas
43
Oxygen, Nitrogen, or Argon/Hydrogen as Plasma Gas
44
Shield Gas
44
Torch Coolant Requirements
45
Grounding Requirements
45
Power Requirements
46
Line Disconnect Switch
46
Power Cable
46
Positioning the Power Supply
47
Electrical Configurations
48
240/480V Linkboard Configurations
48
220/380/415V Transformer T1 and T2 Configurations
49
Connecting the Power
51
Torch Lifter Requirement
52
Optional Equipment
52
Water Muffler
52
Initial Height Sensing (IHS)
53
Installation
54
Upon Receipt
55
Claims
55
Remote High Frequency (RHF) Console
55
Gas Console
55
Remote Voltage/Current (V/C) Control
55
Initial Height Sensing (IHS)
55
Digital Remote (DR) V/C Control
55
Programmable Remote (PR) V/C Control
55
Module Grounding and Grounding Checks
56
Noise Levels
56
System Units Placement
57
Power Supply Connections
59
Initial Height Sensing (IHS) Connections
73
Initial Height Sensing (IHS) Connections
74
Gas Console Connections
77
RHF and Motor Valve Consoles to Torch Connections
81
Routing the Torch Leads
81
Connecting the HF Torch Leads to the RHF Console
81
Connecting the HF Torch Leads to the Torch
83
Connecting the Off-Valve Cable and Plasma Hose from the Torch to the Motor Valve Console
83
Optional Power Supply Connections
85
Timer/Counter to Power Supply
85
Hold Cable Connections (When Using Multi-Torch Systems)
85
Argon-Hydrogen Connections
87
Mounting the Machine Torch
87
Torch Alignment
87
Section 5 POST-INSTALLATION
89
Introduction
89
System Checkout
90
Set Switches and Check Torch
90
Turn Gases on
90
Turn Power Supply on and Adjust Voltage/Current
90
Adjust Preflow Gases
92
Adjust Cut Flow Gases and Check Initial Height Sensing (IHS)
92
Final Torch Adjustment
93
Check Torch Height Control (THC) and V/C Module
93
Operation
96
Front Panel Controls and Indicators
97
Power Supply
97
STATUS Indicators before Startup
98
Gas Console
99
Digital Remote (DR) V/C Module
101
Programmable Remote (PR) V/C Module
102
Timer / Counter
102
Noise Levels (Decibels)
103
Daily Start-Up
104
Check Torch
104
Turn Gases on
104
Turn Power Supply on and Adjust Voltage/Current
105
Adjust Preflow Gases
105
Adjust Cut Flow Gases and Prepare for Cutting
106
Common Cutting Faults
106
Technical Questions
107
Cut Charts
107
Conversions
107
Changing Consumable Parts
132
Removal and Inspection
132
Replacement
133
Changing the Water Tube
134
How to Optimize Cut Quality
135
Tips for Table and Torch
135
Plasma Set-Up Tips
135
Maximize the Life of Consumable Parts
135
Additional Factors of Cut Quality
136
Additional Improvements
137
Operation: Argon-Hydrogen Manifold
138
Front Panel Controls and Indicators
139
Installation
140
Operation
143
Check Torch
143
Turn Gases on
143
Turn Power Supply on and Adjust Voltage/Current
144
Adjust H35 Gas Flow
144
After Cutting with Argon-Hydrogen
145
Maintenance
146
Introduction
147
Routine Maintenance
148
Torch and Torch Leads
148
Power Supply
148
Gas Console
149
Motor Valve Console
149
RHF Console
150
Startup Sequence
150
Initial Checks
152
Troubleshooting
155
STATUS LED Troubleshooting
160
Chopper Module Test Procedure
164
Error Codes
166
Analog Board LED Functions
167
Relay Board LED Function List
168
Relay Board LED Status Conditions
168
Coolant Flow Test Procedure
170
Check Reservoir Coolant
170
Verify Flow Rate Return from Torch
170
Verify Flow Rate to Torch
171
Check Pump, Motor and Solenoid Valve
172
Torch Coolant Draining
173
Preventive Maintenance Schedule
174
Parts List
176
Introduction
177
System Parts Diagram
177
Power Supply
178
Front Panel
180
Control Panel
181
Base Plate and Components
182
Center Wall Right Side
184
Center Wall Left Side
186
Front Wall Inside
188
Rear Wall Inside
190
High Frequency and I/O PCB
192
Rear Wall Outside
194
Remote High Frequency Console
196
Spark Gap Assembly
198
Gas Console
200
Motor Valve Console
202
Remote V/C - Programmable (PR) Control Station
206
IHS Console
208
Timer/Counter
210
Hyspeed HT2000 Machine Torch
212
Hyspeed HT2000 Stainless Steel Machine Torch
212
Torch Mounting Bracket
212
Torch Mounting Bracket
214
Lead Packages
229
Power Supply to Remote High Frequency Console - Cables and Hoses
229
Remote High Frequency Console to Gas Console - Hoses
229
Gas Console to Motor Valve Console - Hoses
229
Recommended Spare Parts
230
Power Supply
230
Remote High Frequency Console
230
Gas Console
231
Motor Valve Console
231
Wiring Diagrams
232
Introduction
232
Wiring Diagram Symbols
232
Appendix A IEC SYMBOLS
264
IEC Symbols Used
264
Iec Symbols
264
Propylene Glycol Safety Data
266
Benzotriazole Safety Data
266
Appendix B PROPYLENE GLYCOL SAFETY DATA
277
Aeration Manifold
277
Appendix C AERATION MANIFOLD
278
Air Filters
278
Appendix D AIR FILTERS
280
Electromagnetic Compatibility (Emc
280
Appendix E ELECTROMAGNETIC COMPATIBILITY (EMC)
281
General
281
Power Cable
281
Connect Power Cable
281
Power Supply
281
Line Disconnect Switch
283
EMI Filter Parts List
284
Appendix F SYSTEM GROUNDING
286
System Grounding Requirements
286
Suggested Ground Cable Routing
286
Power Supply
286
Equipment Grounding
286
Work Table Grounding
287
System Grounding
286
4
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Hypertherm HySpeed HT2000 Specifications
General
Brand
Hypertherm
Model
HySpeed HT2000
Category
Welding System
Language
English
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