Hypertherm HySpeed HT2000LHF

Questions and Answers

K
Kelly ArnoldAug 16, 2025
What to do if Hypertherm HySpeed HT2000LHF Welding System stops cutting during cut, or cuts poorly?
- T
  Tracey MckinneyAug 16, 2025
  If your Hypertherm Welding System stops cutting or cuts poorly, here's what to check: * Ensure the work cable is properly connected and not broken; repair or connect it as needed. * Verify good contact between the work cable and the workpiece. * Check gas inlet pressures and plasma/shield gas pressures in TEST and RUN modes, consulting the Cut Charts. * Confirm the arc current setting matches the metal type and thickness you're cutting, as per the Cut Charts. * Allow the power supply to cool down if it has overheated. If these steps don't resolve the issue, the choppers may be defective.
L
Lisa HansenAug 19, 2025
Why Hypertherm HySpeed HT2000LHF Welding System doesn't turn on when pressing the power button?
- M
  michaelvasquezSep 12, 2025
  If the green POWER ON button on your Hypertherm Welding System doesn't turn on the fans or the indicator light, check the following: 1. Ensure the POWER ON switch is working correctly, as it should be normally open. 2. Verify the POWER OFF switch is functioning correctly, as it should be normally closed. 3. Confirm the presence of a jumper for PB2A and PB2B at TB5. If there's no optional remote I/O cable, TB5 terminals 1&2 and 4&5 need a jumper. 4. Inspect the associated wiring for good contact; repair or replace if necessary.
L
leemichaelAug 25, 2025
What to do if Hypertherm HySpeed HT2000LHF power is on but the fans are not running?
- M
  Matthew LambertAug 26, 2025
  If the POWER ON indicator lights up but the fans don't start on your Hypertherm Welding System, check the following: * Verify that CR2 on the power distribution board PCB1 is switching when the POWER ON button is pressed. If CR2 is defective, replace PCB1. * Ensure the connector from the power distribution board is securely seated. Check pins, connectors, and wiring for continuity; repair or replace if necessary.
A
Austin ParkAug 28, 2025
Why is there no pilot arc on my Hypertherm Welding System?
- E
  Eduardo LoweAug 28, 2025
  If your Hypertherm Welding System has the POWER ON and DC ON indicators lit and there's high frequency, but no pilot arc, try the following: * Check if the pilot arc relay CR1 is closing after the START command. If it's not closing, use an AC voltmeter to see if 120VAC is coming from PCB4 after the START command is given. * If there's no 120VAC, check connectors, terminals, pins, and wiring to PCB4. * If the wiring is okay, there may be a problem with PCB4 or PCB2.
M
murraymaryAug 31, 2025
What to do if Hypertherm Welding System fans are running but the power indicator is off?
- P
  pgrantAug 31, 2025
  If the fans are running on your Hypertherm Welding System, but the green POWER ON light isn't on, try these steps: * Make sure you press and hold the POWER ON button for at least 5 seconds. * Check if relay CR1 on the power distribution board is switching when the POWER ON button is pressed. If CR1 is defective, you may need to replace PCB1.
M
Michael WaltersSep 2, 2025
Why is the TRANSFORMER LED illuminated on my Hypertherm Welding System?
- A
  Amber BlevinsSep 3, 2025
  If the TRANSFORMER LED is illuminated on your Hypertherm Welding System, it could indicate that the Main Transformer T2 or one of the choppers is overheating. You should: * Check the temperature switches (normally closed). * Check pins, connectors and wiring to temperature switches. If the issue persists, leave the fans running and try restarting the unit after one hour. If the LED remains illuminated, one of the choppers or the main transformer may need replacement.
W
William GarciaSep 6, 2025
Why is the COOLANT LEVEL LED illuminated on my Hypertherm HySpeed HT2000LHF Welding System?
- M
  Matthew LeeSep 6, 2025
  If the COOLANT LEVEL LED is illuminated on your Hypertherm Welding System, take these steps: * Check the coolant level and replenish if low. * If the coolant level is adequate, check to see if LS1 switch is closed. * Check connections and wiring from LS1 to PCB1.
A
Adam HillSep 8, 2025
How to check main contactor (CON1) or PCB4 in Hypertherm Welding System?
- J
  Jim WhiteSep 9, 2025
  If you suspect the main contactor (CON1) or PCB4 is defective in your Hypertherm Welding System, follow these steps: * Use an AC voltmeter to check for 120VAC at contactor CON1 after the START command is given. * If there's no 120VAC, inspect pins, connectors, and wiring from CON1 to PCB4. * If wiring is intact, PCB4 or PCB2 may be defective. * If there is 120VAC at CON1, measure the voltage between secondary terminals of the main transformer T2 after the START command is given. The voltage between any two of the three points connected to each chopper input should be approximately 200VAC. * If there's no voltage at any of these points, replace CON1. * If there's voltage at some, but not all, points, check the wiring and connections to and from T2.
K
Kathy Peterson MDSep 12, 2025
How to troubleshoot a defective pilot arc relay CR1 in Hypertherm Welding System?
- C
  Carmen HughesSep 12, 2025
  If you suspect that the pilot arc relay CR1 is defective in your Hypertherm Welding System, and there is 120VAC across the relay, replace CR1.
T
Tammy AndersonNov 20, 2025
What to do if Hypertherm HySpeed HT2000LHF Welding System has no high frequency and no pilot arc?
- W
  William EvansNov 21, 2025
  If your Hypertherm Welding System has the POWER ON and DC ON indicators illuminated, but no high frequency or pilot arc, consider these potential solutions: * Clean, align, and reset the spark gap electrodes to 0.020" (0.51 mm). Ensure the electrode surfaces are flat; replace if rounded. * Inspect the high voltage transformer T3 for overheating and replace if necessary. * Check for 120VAC at T3 after the START command is given. * If there's no 120VAC at T3, inspect wiring from T3 to relay board PCB4. A problem may exist with PCB4 or PCB2 if connections are good. * Remove capacitors C4, C5, and C6 and restart the system to look for a faint spark across the gaps. * Replace T3 if no spark is observed; otherwise, replace capacitors C4, C5, and C6. * Check for a shorted torch or ...

Summary

ELECTROMAGNETIC COMPATIBILITY (EMC)

EMC INTRODUCTION

Explains EMC compliance and potential interference issues.

INSTALLATION AND USE

Details user responsibilities for installation and use to achieve EMC.

ASSESSMENT OF AREA

Outlines factors for assessing potential electromagnetic problems in the area.

METHODS OF REDUCING EMISSIONS

Lists techniques to reduce electromagnetic emissions.

WARRANTY

WARNING

Warns about using non-genuine parts and the responsibility for safe use.

GENERAL

Outlines Hypertherm's warranty terms for defects in materials and workmanship.

PATENT INDEMNITY

Explains Hypertherm's policy on patent infringement suits.

LIMITATION OF LIABILITY

States limitations on Hypertherm's liability for damages.

INSURANCE

Requires the user to maintain adequate insurance coverage.

NATIONAL AND LOCAL CODES

Emphasizes adherence to local codes over manual instructions.

TRANSFER OF RIGHTS

Details conditions for transferring warranty rights.

Section 1 SAFETY

Safety Fundamentals

Covers recognizing symbols, following instructions, and understanding DANGER/WARNING/CAUTION.

Fire and Explosion Hazards

Details precautions to prevent fire and explosion hazards during cutting.

Electrical and Fume Hazards

Addresses electric shock risks and hazards from toxic fumes.

Arc and Physical Hazards

Covers injuries from plasma arcs, arc rays, and eye/skin protection.

Gas and Noise Hazards

Details compressed gas safety, noise hazards, and pacemaker/hearing aid precautions.

Warning Labels and Additional Information

Explains warning labels and lists relevant safety standards.

Section 2 SPECIFICATIONS

System Components Overview

Lists and briefly describes the main system components.

System Requirements

Specifies gas and power requirements for the system.

Power Requirements

Details electrical power requirements and input specifications.

Component Dimensions and Specifications

Provides physical dimensions, weight, and power specs for key components.

Section 3 INSTALLATION

Initial Setup and Requirements

Covers general requirements, receipt, claims, and gas needs.

Gas and Coolant System Installation

Details gas supply plumbing and torch coolant requirements.

Electrical Installation and Grounding

Covers grounding, power requirements, and line disconnect switch installation.

Component Connections and Placement

Covers unit placement, torch lifter, optional equipment, and system unit connections.

Torch Mounting and Alignment

Instructions for mounting and aligning the machine torch.

Section 4 OPERATION

System Controls Overview

Explains front panel controls for Power Supply, Gas Console, and Remote Consoles.

System Startup and Checkout

Details system checkout, gas turn-on, and power supply startup procedures.

Cutting Parameter Adjustment and Setup

Instructions for adjusting preflow/cut flow gases and checking IHS.

Torch Adjustment and Quality Optimization

Covers final torch adjustment, THC checks, and optimizing cut quality.

Cutting Procedures and Troubleshooting

Discusses common cutting faults, cut quality factors, and troubleshooting.

Cut Charts and Consumable Selection

Introduces cut charts and indexes consumables for various metals and modes.

Torch Maintenance Procedures

Details procedures for changing consumable parts and the water tube.

Section 5 MAINTENANCE

Routine Maintenance Tasks

Covers routine inspection and cleaning of torch, leads, power supply, and gas console.

System Startup and Initial Checks

Outlines the start sequence and initial checks before troubleshooting.

Troubleshooting Procedures

Addresses common problems with power, cutting, and status LEDs.

Diagnostic Procedures

Details test procedures for chopper modules and error code interpretation.

Coolant System Diagnostics and Draining

Covers coolant flow tests, pump checks, and coolant draining procedures.

Preventative Maintenance Schedule

Provides a schedule for daily, weekly, monthly, bi-annual, and annual maintenance.

Section 6 PARTS LIST

Introduction

Refers to other sections for finding part numbers.

Power Supply Components

Lists parts for the power supply's front, rear, and internal panels.

Console and Manifold Components

Lists parts for the Gas Console, Remote Consoles, and AH Manifold.

Torch and Consumable Parts

Lists parts for torches and various consumable kits.

Recommended Spare Parts

Lists recommended spare parts for power supply and gas console.

Section 7 WIRING DIAGRAMS

Diagram Interpretation and Symbols

Explains diagram format, coordinates, symbols, and torch representations.

System and Component Wiring Diagrams

Illustrates coolant flow, system interconnections, and power supply wiring diagrams.

Control and Interface Wiring Diagrams

Details wiring diagrams for control boards, IHS, and remote interfaces.

Gas Console and Timing Charts

Illustrates gas console wiring and solenoid valve timing charts for N2/O2 modes.

Appendix A ARGON-HYDROGEN CUTTING AND GOUGING

Argon-Hydrogen System Setup

Covers manifold controls, installation, and cable connections.

Argon-Hydrogen Operation Procedures

Details startup, gas control, and voltage/current adjustments for AH cutting.

Argon-Hydrogen Cutting Parameters

Presents cut charts and consumable indexes for AH cutting of various metals.

Appendix B SAFETY DATA SHEETS

Propylene Glycol Safety Data

Comprehensive safety data for propylene glycol, covering hazards, handling, and disposal.

Benzotriazole Safety Data

Comprehensive safety data for benzotriazole, covering hazards, handling, and disposal.

Appendix C INITIAL HEIGHT SENSING CONNECTIONS

IHS Cable and Probe Connections

Details connections for IHS interface, sensor cables, inductor probes, and air supply.

Initial Height Sensing Connections

Provides a diagram of IHS connections.

IHS Air Supply and Hose Assembly

Details air supply and hose assembly connections to the IHS console.

Upper Limit Switch and Cable

Details upper limit switch cable connections to the IHS console.

Appendix D ELECTROMAGNETIC COMPATIBILITY

Power Cable and EMI Filter Installation

Details power cable requirements, connection, and EMI filter installation.

EMI Filter Components

Lists the parts associated with the EMI filter.

Appendix E AIR FILTERS

Air Filter System Description

Explains the importance of air purity and a three-stage filtering process.

Appendix F AERATION MANIFOLD FOR PLASMA CUTTING ALUMINUM

Aeration Manifold Construction and Setup

Instructions for making and connecting an aeration manifold.

Appendix G IEC SYMBOLS

IEC Electrical Symbols Reference

Defines common IEC symbols used in electrical diagrams.

Appendix H SYSTEM GROUNDING

Grounding Requirements and Best Practices

Explains grounding requirements for safety, EMI, and suggests cable routing.

Work Table and Configuration Grounding

Provides guidelines for grounding the work table and alternate configurations.