High Frequency Console

Gas Panel and High Frequency Console

Instruction Manual802960 – Revision 2

Integrated Plasma SystemFor use with the TM

HT2000®

NOTICE

Use the HT2000 instruction manual, 802070, as well as this manual, 802960, to install, operateand maintain the HT2000 with Titan system.

• This manual contains information to install and operate the HT2000 with Titan system. Aparts list for the gas panel and high frequency console is also included.

• See the 802070 manual for general maintenance and information relevant to the HT2000power supply and accessories.

HT2000

Gas Panel and High Frequency Consolefor

Instruction Manual(P/N 802960)

Revision 2 – April, 2001

© Copyright 2001 Hypertherm, Inc.All Rights Reserved

Hypertherm, HT, HyLife, and LongLife are trademarks of Hypertherm, Inc. and may be registered in the United States and/or other countries

Hypertherm, Inc.Hanover, NH USA

www.hypertherm.com

Hypertherm, Inc.

Etna Road, P.O. Box 5010Hanover, NH 03755 USA603-643-3441 Tel (Main Office)603-643-5352 Fax (All Departments)800-643-9878 Tel (Technical Service)800-737-2978 Tel (Customer Service)

Hypertherm Automation

5 Technology DriveWest Lebanon, NH 03755 USA603-298-7970 Tel 603-298-7977 Fax

Hypertherm Plasmatechnik GmbH

Technologiepark HanauRodenbacher Chaussee 6 63457 Hanau-Wolfgang, Deutschland49 6181 58 2100 Tel 49 6181 58 2134 Fax49 6181 58 2123 (Technical Service)

Hypertherm Singapore Pte Ltd

No. 19 Kaki Bukit Road 2 K.B. Warehouse Complex Singapore 417847, Republic of Singapore65 6 841 2489 Tel 65 6 841 2490 Fax 65 6 841 2489 (Technical Service)

Japan

1952-14 Yata-NatsumegiMishima City, Shizuoka Pref.411-0801 Japan81 0 559 75 7387 Tel81 0 559 75 7376 Fax

Hypertherm UK Ltd

9 Berkeley Court, Manor Park Runcorn, Cheshire, England WA7 1TQ44 1928 579 074 Tel 44 1928 579 604 Fax

France

15 Impasse des Rosiers95610 Eragny, France00 800 3324 9737 Tel 00 800 4973 7329 Fax

Hypertherm S.r.L.

Via Torino 220123 Milano, Italia39 02 725 46 312 Tel 39 02 725 46 400 Fax39 02 725 46 314 (Technical Service)

Hypertherm Europe B.V.

Vaartveld 94704 SE Roosendaal, Nederland31 165 596908 Tel 31 165 596901 Fax

Hypertherm B.V. (ETSO)

Vaartveld 94704 SE Roosendaal, Nederland00 800 49 73 7843 – toll-free in Europe

31 165 596900 Tel31 165 596901 Fax

Hypertherm Brasil Ltda.

Rua Visconde de Santa Isabel, 20 – Sala 611Vila Isabel, RJ Brasil CEP 20560-12055 21 2278 6162 Tel55 21 2578 0947 Fax

2/12/03

ELECTROMAGNETIC COMPATIBILITY (EMC)

EMC INTRODUCTION

Hypertherm's CE-marked equipment is builtin compliance with standard EN50199. Theequipment should be installed and used inaccordance with the information below toachieve electromagnetic compatibility.

The limits required by EN50199 may not beadequate to completely eliminate interfer-ence when the affected equipment is inclose proximity or has a high degree ofsensitivity. In such cases it may be neces-sary to use other measures to furtherreduce interference.

This plasma equipment is designed for useonly in an industrial environment.

INSTALLATION AND USE

The user is responsible for installing andusing the plasma equipment according tothe manufacturer's instructions. If electro-magnetic disturbances are detected then itshall be the responsibility of the user to re-solve the situation with the technical assis-tance of the manufacturer. In some casesthis remedial action may be as simple asearthing the cutting circuit, see Earthing ofWorkpiece. In other cases it could involveconstructing an electromagnetic screenenclosing the power source and the workcomplete with associated input filters. In allcases electromagnetic disturbances mustbe reduced to the point where they are nolonger troublesome.

ASSESSMENT OF AREA

Before installing the equipment the usershall make an assessment of potential elec-tromagnetic problems in the surroundingarea. The following shall be taken intoaccount:a. Other supply cables, control cables,signalling and telephone cables; above,below and adjacent to the cutting equip-ment.b. Radio and television transmitters andreceivers.c. Computer and other control equipment.d. Safety critical equipment, for exampleguarding of industrial equipment.e. Health of the people around, for example the use of pacemakers and hear-ing aids.f. Equipment used for calibration or mea-surement.g. Immunity of other equipment in the en-vironment. User shall ensure that otherequipment being used in the environment iscompatible. This may require additionalprotection measures.h. Time of day that cutting or other activitiesare to be carried out.

Earthing of Workpiece

Where the workpiece is not bonded to earthfor electrical safety, nor connected to earthbecause of its size and position, for example,ship's hull or building steelwork, a connectionbonding the workpiece to earth may reduceemissions in some, but not all instances.Care should be taken to prevent the earthingof the workpiece increasing the risk of injuryto users, or damage to other electrical equip-ment. Where necessary, the connection ofthe workpiece to earth should be made by adirect connection to the workpiece, but insome countries where direct connection isnot permitted, the bonding should beachieved by suitable capacitances selectedaccording to national regulations.

Note. The cutting circuit may or may not beearthed for safety reasons. Changing theearthing arrangements should only be au-thorized by a person who is competent toassess whether the changes will increasethe risk of injury, for example, by allowingparallel cutting current return paths whichmay damage the earth circuits of otherequipment. Further guidance is given in IECTC26 (sec)94 and IEC TC26/108A/CD ArcWelding Equipment Installation and Use.

Screening and Shielding

Selective screening and shielding of othercables and equipment in the surroundingarea may alleviate problems of interference.Screening of the entire plasma cuttinginstallation may be considered for specialapplications

The size of the surrounding area to beconsidered will depend on the structure ofthe building and other activities that are tak-ing place. The surrounding area may extendbeyond the boundaries of the premises.

METHODS OF REDUCING EMISSIONS

Mains Supply

Cutting equipment must be connected to themains supply according to the manufactur-er's recommendations. If interferenceoccurs, it may be necessary to takeadditional precautions such as filtering ofthe mains supply. Consideration should begiven to shielding the supply cable of per-manently installed cutting equipment, inmetallic conduit or equivalent. Shieldingshould be electrically continuous throughoutits length. The shielding should be connect-ed to the cutting mains supply so that goodelectrical contact is maintained between theconduit and the cutting power sourceenclosure

Maintenance of Cutting Equipment

The cutting equipment must be routinelymaintained according to the manufacturer'srecommendations. All access and servicedoors and covers should be closed andproperly fastened when the cuttingequipment is in operation. The cuttingequipment should not be modified in anyway except for those changes and adjust-ments covered in the manufacturer'sinstructions. In particular, the spark gaps ofarc striking and stabilizing devices shouldbe adjusted and maintained according tothe manufacturer's recommendations.

Cutting Cables

The cutting cables should be kept as shortas possible and should be positioned closetogether, running at or close to the floorlevel.

Equipotential Bonding

Bonding of all metallic components in thecutting installation and adjacent to it shouldbe considered. However, metallic compo-nents bonded to the workpiece will increasethe risk that the operator could receive ashock by touching these metalliccomponents and the electrode at the sametime. The operator should be insulated fromall such bonded metallic components.

Hypertherm Plasma Systems i

WARRANTY

ii Hypertherm Plasma Systems9-01

WARNINGGenuine Hypertherm parts are the factory-recommendedreplacement parts for your Hypertherm system. Any damagecaused by the use of other than genuine Hypertherm parts maynot be covered by the Hypertherm warranty.

WARNINGYou are responsible for the safe use of the Product.Hypertherm does not and cannot make any guarantee orwarranty regarding the safe use of the Product in yourenvironment.

GENERALHypertherm, Inc. warrants that its Products shall be free fromdefects in materials and workmanship, if Hypertherm is notifiedof a defect (i) with respect to the power supply within a periodof two (2) years from the date of its delivery to you, with theexception of G3 Series power supplies, which shall be within aperiod of three (3) years from the date of delivery to you, and(ii) with respect to the torch and leads within a period of one (1)year from its date of delivery to you. This warranty shall notapply to any Product which has been incorrectly installed,modified, or otherwise damaged. Hypertherm, at its soleoption, shall repair, replace, or adjust, free of charge, anydefective Products covered by this warranty which shall bereturned with Hypertherm’s prior authorization (which shall notbe unreasonably withheld), properly packed, to Hypertherm’splace of business in Hanover, New Hampshire, or to anauthorized Hypertherm repair facility, all costs, insurance andfreight prepaid. Hypertherm shall not be liable for any repairs,replacement, or adjustments of Products covered by thiswarranty, except those made pursuant to this paragraph or withHypertherm’s prior written consent. The warranty above isexclusive and is in lieu of all other warranties, express,implied, statutory, or otherwise with respect to theProducts or as to the results which may be obtainedtherefrom, and all implied warranties or conditions ofquality or of merchantability or fitness for a particularpurpose or against infringement. The foregoing shallconstitute the sole and exclusive remedy for any breachby Hypertherm of its warranty. Distributors/OEMs may offerdifferent or additional warranties, but Distributors/OEMs arenot authorized to give any additional warranty protection to youor make any representation to you purporting to be bindingupon Hypertherm.

PATENT INDEMNITYExcept only in cases of products not manufactured byHypertherm or manufactured by a person other thanHypertherm not in strict conformity with Hypertherm’sspecifications and in cases of designs, processes, formulae, orcombinations not developed or purported to be developed byHypertherm, Hypertherm will defend or settle, at its ownexpense, any suit or proceeding brought against you allegingthat the use of the Hypertherm product, alone and not incombination with any other product not supplied by

Hypertherm, infringes any patent of any third party. You shallnotify Hypertherm promptly upon learning of any action orthreatened action in connection with any such allegedinfringement, and Hypertherm’s obligation to indemnify shall beconditioned upon Hypertherm’s sole control of, and theindemnified party’s cooperation and assistance in, the defenseof the claim.

LIMITATION OF LIABILITYIn no event shall Hypertherm be liable to any person orentity for any incidental, consequential, indirect, orpunitive damages (including but not limited to lost profits)regardless of whether such liability is based on breach ofcontract, tort, strict liability, breach of warranties, failure ofessential purpose or otherwise and even if advised of thepossibility of such damages.

LIABILITY CAPIn no event shall Hypertherm’s liability, whether suchliability is based on breach of contract, tort, strict liability,breach of warranties, failure of essential purpose orotherwise, for any claim action suit or proceeding arisingout of or relating to the use of the Products exceed in theaggregate the amount paid for the Products that gave riseto such claim.

INSURANCEAt all times you will have and maintain insurance in suchquantities and types, and with coverage sufficient andappropriate to defend and to hold Hypertherm harmless in the event of any cause of action arising from the use of theProducts.

NATIONAL AND LOCAL CODESNational and Local codes governing plumbing and electricalinstallation shall take precedent over any instructionscontained in this manual. In no event shall Hypertherm beliable for injury to persons or property damage by reason of anycode violation or poor work practices.

TRANSFER OF RIGHTSYou may transfer any remaining rights you may havehereunder only in connection with the sale of all or substantiallyall of your assets or capital stock to a successor in interest whoagrees to be bound by all of the terms and conditions of thisWarranty.

HT2000 with Titan Instruction Manual iii

Electromagnetic Compatibility (EMC).......................................................................................................................iWarranty .....................................................................................................................................................................ii

Section 1 SAFETY..................................................................................................................................................1-1Recognize Safety Information...................................................................................................................................1-2Follow Safety Instructions.........................................................................................................................................1-2Cutting Can Cause Fire or Explosion .......................................................................................................................1-2Electric Shock Can Kill..............................................................................................................................................1-3Cutting Can Produce Toxic Fumes...........................................................................................................................1-3A Plasma Arc Can Cause Injury and Burns..............................................................................................................1-4Arc Rays Can Burn Eyes and Skin ...........................................................................................................................1-4Grounding Safety......................................................................................................................................................1-4Compressed Gas Equipment Safety ........................................................................................................................1-5Gas Cylinders Can Explode If Damaged ..................................................................................................................1-5Noise Can Damage Hearing.....................................................................................................................................1-5Pacemaker and Hearing Aid Operation ....................................................................................................................1-5A Plasma Arc Can Damage Frozen Pipes................................................................................................................1-5Additional Safety Information....................................................................................................................................1-5Warning Label...........................................................................................................................................................1-6

Section 1a SÉCURITÉ........................................................................................................................................1a-1Identifier les consignes de sécurité.........................................................................................................................1a-2Suivre les instructions de sécurité ..........................................................................................................................1a-2Le coupage peut provoquer un incendie ou une explosion ....................................................................................1a-2Les chocs électriques peuvent être fatals...............................................................................................................1a-3Le coupage peut produire des vapeurs toxiques....................................................................................................1a-3L'arc plasma peut provoquer des blessures ou des brûlures .................................................................................1a-4Mise à la masse et à la terre...................................................................................................................................1a-4Les rayons de l'arc peuvent brûler les yeux et la peau...........................................................................................1a-4Sécurité des bouteilles de gaz comprimé ...............................................................................................................1a-5Les bouteilles de gaz comprimé peuvent exploser en cas de dommages .............................................................1a-5Le bruit peut provoquer des problèmes auditifs......................................................................................................1a-5Pacemakers et prothéses auditives........................................................................................................................1a-5Étiquette de sécurité ...............................................................................................................................................1a-6

Section 2 SPECIFICATIONS................................................................................................................................2-1System Components ................................................................................................................................................2-1

Power Supply ..................................................................................................................................................2-1HT2000 Machine Torch....................................................................................................................................2-1Remote High Frequency&Motor Valve Console (also called “High Frequency Console”) ...............................2-1Gas Panel ........................................................................................................................................................2-1Timer/Counter – Optional.................................................................................................................................2-1Water Muffler – Optional ..................................................................................................................................2-1

Specifications............................................................................................................................................................2-2System Requirements......................................................................................................................................2-2HT2000 Power Supply .....................................................................................................................................2-2HT2000 Machine Torch....................................................................................................................................2-3Remote High Frequency and Motor Valve (RHF&MV) Console ......................................................................2-3Gas Panel ........................................................................................................................................................2-4

TABLE OF CONTENTS

iv HT2000 with Titan Instruction Manual

Section 3 INSTALLATION ...................................................................................................................................3-1Pre-Installation..........................................................................................................................................................3-1System Units Placement...........................................................................................................................................3-1Power Supply Connections.......................................................................................................................................3-4Gas Panel Connections ............................................................................................................................................3-7RH&MV Console to Torch Connections ...................................................................................................................3-9

Routing the Torch Leads..................................................................................................................................3-9Connecting the Torch Leads to the Torch........................................................................................................3-9

Mounting the Machine Torch ..................................................................................................................................3-12Torch Alignment ............................................................................................................................................3-12

Section 4 INSTALLATION ...................................................................................................................................4-1Front Panel Controls and Indicators .........................................................................................................................4-2

HT2000 Titan Gas Panel (Fig. 4-1) ..................................................................................................................4-2Daily Start-up ............................................................................................................................................................4-3

Check Torch ....................................................................................................................................................4-3Turn Gases On.................................................................................................................................................4-3Turn Power Supply On and Adjust Voltage/Current.........................................................................................4-4Adjust Preflow Gases.......................................................................................................................................4-4Adjust Cut Flow Gases and Prepare for Cutting ..............................................................................................4-4

Common Cutting Faults ............................................................................................................................................4-5Technical Questions .................................................................................................................................................4-5Cut Charts.................................................................................................................................................................4-5Conversions..............................................................................................................................................................4-5Mild Steel ..................................................................................................................................................................4-7

200 amps • Air Plasma / Air Shield ................................................................................................................4-7Mild Steel ..................................................................................................................................................................4-8

200 amps • O2 Plasma / Air Shield.................................................................................................................4-8Mild Steel ..................................................................................................................................................................4-9

200 amps • N2 Plasma / CO2 Shield...............................................................................................................4-9Mild Steel ................................................................................................................................................................4-10

100* amps • Air Plasma / Air Shield .............................................................................................................4-10Mild Steel ................................................................................................................................................................4-11

100 amps • O2 Plasma / Air Shield...............................................................................................................4-11Mild Steel ................................................................................................................................................................4-12

50 amps • O2 Plasma / O2 Shield .................................................................................................................4-12Stainless Steel ........................................................................................................................................................4-13

200 amps • Air Plasma / Air Shield ..............................................................................................................4-13Stainless Steel ........................................................................................................................................................4-14

200 amps • N2 Plasma / Air Shield...............................................................................................................4-14Stainless Steel ........................................................................................................................................................4-15

200 amps • N2 Plasma / CO2 Shield.............................................................................................................4-15Stainless Steel ........................................................................................................................................................4-16

200 amps • H35 Plasma / N2 Shield.............................................................................................................4-16Stainless Steel ........................................................................................................................................................4-17

100 amps • Air Plasma / Air Shield ..............................................................................................................4-17

TABLE OF CONTENTS

HT2000 with Titan Instruction Manual v

Stainless Steel ........................................................................................................................................................4-18100 amps • H35 Plasma / N2 Shield.............................................................................................................4-18

Stainless Steel ........................................................................................................................................................4-1940 amps • Air Plasma / Air Shield ................................................................................................................4-19

Aluminum................................................................................................................................................................4-20200 amps • Air Plasma / Air Shield ..............................................................................................................4-20

Aluminum................................................................................................................................................................4-21200 amps • N2 Plasma / Air Shield...............................................................................................................4-21

Aluminum................................................................................................................................................................4-22200 amps • N2 Plasma / CO2 Shield.............................................................................................................4-22

Aluminum................................................................................................................................................................4-23200 amps • H35 Plasma / N2 Shield.............................................................................................................4-23

Aluminum................................................................................................................................................................4-24100 amps • Air Plasma / Air Shield ..............................................................................................................4-24

Aluminum................................................................................................................................................................4-25100 amps • H35 Plasma / N2 Shield.............................................................................................................4-25

Aluminum................................................................................................................................................................4-2640 amps • Air Plasma / Air Shield ................................................................................................................4-26

Mild Steel - Beveling Consumables ........................................................................................................................4-27200 amps • O2 Plasma / Air Shield...............................................................................................................4-27

Stainless Steel or Aluminum Gouging ....................................................................................................................4-28200 amps • H35 Plasma / N2 Shield.............................................................................................................4-28

Mild Steel Gouging .................................................................................................................................................4-28200 amps • Air Plasma / Air Shield ..............................................................................................................4-28

Changing Consumable Parts..................................................................................................................................4-29Removal and Inspection – Refer to Figure 4-2 ..............................................................................................4-29Replacement ..................................................................................................................................................4-30Changing the Water Tube ..............................................................................................................................4-31

Section 5 PARTS LIST..........................................................................................................................................5-1Gas Panel – 073220 .................................................................................................................................................5-3RHF&MV Console – 073223 ....................................................................................................................................5-5HT2000 Standard Machine Torch Assembly with Valve,

2" (50 mm) Dia. Torch Sleeve, and 25' (7.6 m) Leads – 128383..........................................................................5-7HT2000 Stainless Steel Machine Torch Assembly with Valve,

2" (50 mm) Dia. Torch Sleeve, and 25' (7.6 m) Leads – 128368..........................................................................5-7Torch Mounting Bracket for 2" (50 mm) Dia. Torch Sleeve – 020046 ......................................................................5-7HT2000 Optional Machine Torch Assembly with Valve,

1-3/4" (44 mm) Dia. Torch Sleeve, and 25' (7.6 m) Leads – 128200....................................................................5-9Torch Mounting Bracket for 1-3/4” (44 mm) Dia. Torch Sleeve – 020522 ................................................................5-9Consumable Parts Kit – 028602 .............................................................................................................................5-10

Section 6 WIRING DIAGRAMS............................................................................................................................6-1Introduction ...............................................................................................................................................................6-1Wiring Diagram Symbols ..........................................................................................................................................6-1HT2000 System Wiring Diagrams ............................................................................................................................6-5

TABLE OF CONTENTS

vi HT2000 with Titan Instruction Manual

Hypertherm Plasma Systems 1-1

Section 1

SAFETY

In this section:

Recognize Safety Information .........................................................................................................................1-2Follow Safety Instructions ...............................................................................................................................1-2Cutting Can Cause Fire or Explosion..............................................................................................................1-2Electric Shock Can Kill ....................................................................................................................................1-3Cutting Can Produce Toxic Fumes..................................................................................................................1-3A Plasma Arc Can Cause Injury and Burns.....................................................................................................1-4Arc Rays Can Burn Eyes and Skin .................................................................................................................1-4Grounding Safety ............................................................................................................................................1-4Compressed Gas Equipment Safety...............................................................................................................1-5Gas Cylinders Can Explode If Damaged ........................................................................................................1-5Noise Can Damage Hearing ...........................................................................................................................1-5Pacemaker and Hearing Aid Operation...........................................................................................................1-5A Plasma Arc Can Damage Frozen Pipes ......................................................................................................1-5Additional Safety Information ..........................................................................................................................1-5Warning Label .................................................................................................................................................1-6

SAFETY

1-2 Hypertherm Plasma Systems11-98

SAFETY

RECOGNIZE SAFETY INFORMATION

The symbols shown in this section are used toidentify potential hazards. When you see a safetysymbol in this manual or on your machine, understandthe potential for personal injury, and follow the relatedinstructions to avoid the hazard.

FOLLOW SAFETY INSTRUCTIONS

Read carefully all safety messages in this manual andsafety labels on your machine.

• Keep the safety labels on your machine in goodcondition. Replace missing or damaged labelsimmediately.

• Learn how to operate the machine and how to use the controls properly. Do not let anyone operate itwithout instruction.

• Keep your machine in proper working condition.Unauthorized modifications to the machine mayaffect safety and machine service life.

DANGER WARNING CAUTION

A signal word DANGER or WARNING is used with asafety symbol. DANGER identifies the most serioushazards.

• DANGER and WARNING safety labels are locatedon your machine near specific hazards.

• WARNING safety messages precede relatedinstructions in this manual that may result in injuryor death if not followed correctly.

• CAUTION safety messages precede relatedinstructions in this manual that may result indamage to equipment if not followed correctly.

Fire Prevention• Be sure the area is safe before doing any cutting.

Keep a fire extinguisher nearby.• Remove all flammables within 35 feet (10 m) of the

cutting area.• Quench hot metal or allow it to cool before handling

or before letting it touch combustible materials.• Never cut containers with potentially flammable

materials inside – they must be emptied andproperly cleaned first.

• Ventilate potentially flammable atmospheres beforecutting.

• When cutting with oxygen as the plasma gas, anexhaust ventilation system is required.

Explosion Prevention• Do not use the plasma system if explosive dust or

vapors may be present.• Do not cut pressurized cylinders, pipes, or any

closed container.• Do not cut containers that have held combustible

materials.

CUTTING CAN CAUSE FIRE OR EXPLOSION

WARNING

Explosion HazardArgon-Hydrogen and Methane

Hydrogen and methane are flammable gases thatpresent an explosion hazard. Keep flames away fromcylinders and hoses that contain methane or hydrogenmixtures. Keep flames and sparks away from the torchwhen using methane or argon-hydrogen plasma.

WARNING

Hydrogen Detonation with Aluminum Cutting

• When cutting aluminum underwater, or with thewater touching the underside of the aluminum, freehydrogen gas may collect under the workpiece anddetonate during plasma cutting operations.

• Install an aeration manifold on the floor of the watertable to eliminate the possibility of hydrogendetonation. Refer to the Appendix section of thismanual for aeration manifold details.

Touching live electrical parts can cause a fatal shockor severe burn.

• Operating the plasma system completes anelectrical circuit between the torch and theworkpiece. The workpiece and anything touchingthe workpiece are part of the electrical circuit.

• Never touch the torch body, workpiece or the waterin a water table when the plasma system isoperating.

Electric Shock Prevention

All Hypertherm plasma systems use high voltagein the cutting process (200 to 400 VDC arecommon). Take the following precautions whenoperating this system:• Wear insulated gloves and boots, and keep your

body and clothing dry.• Do not stand, sit or lie on – or touch – any wet

surface when using the plasma system.• Insulate yourself from work and ground using dry

insulating mats or covers big enough to prevent anyphysical contact with the work or ground. If you mustwork in or near a damp area, use extreme caution.

• Provide a disconnect switch close to the powersupply with properly sized fuses. This switch allowsthe operator to turn off the power supply quickly inan emergency situation.

• When using a water table, be sure that it is correctlyconnected to earth ground.

ELECTRIC SHOCK CAN KILL

• Install and ground this equipment according to theinstruction manual and in accordance with nationaland local codes.

• Inspect the input power cord frequently for damageor cracking of the cover. Replace a damaged powercord immediately. Bare wiring can kill.

• Inspect and replace any worn or damaged torchleads.

• Do not pick up the workpiece, including the wastecutoff, while you cut. Leave the workpiece in placeor on the workbench with the work cable attachedduring the cutting process.

• Before checking, cleaning or changing torch parts,disconnect the main power or unplug the powersupply.

• Never bypass or shortcut the safety interlocks.• Before removing any power supply or system

enclosure cover, disconnect electrical input power.Wait 5 minutes after disconnecting the main powerto allow capacitors to discharge.

• Never operate the plasma system unless the powersupply covers are in place. Exposed power supplyconnections present a severe electrical hazard.

• When making input connections, attach propergrounding conductor first.

• Each Hypertherm plasma system is designed to beused only with specific Hypertherm torches. Do notsubstitute other torches which could overheat andpresent a safety hazard.

Cutting can produce toxic fumes and gases thatdeplete oxygen and cause injury or death.

• Keep the cutting area well ventilated or use anapproved air-supplied respirator.

• Do not cut in locations near degreasing, cleaning orspraying operations. The vapors from certainchlorinated solvents decompose to form phosgenegas when exposed to ultraviolet radiation.

• Do not cut metal coated or containing toxic materi-als, such as zinc (galvanized), lead, cadmium or

CUTTING CAN PRODUCE TOXIC FUMES

beryllium, unless the area is well ventilated and theoperator wears an air-supplied respirator. Thecoatings and any metals containing these elementscan produce toxic fumes when cut.

• Never cut containers with potentially toxic materialsinside – they must be emptied and properly cleanedfirst.

• This product, when used for welding or cutting,produces fumes or gases which contain chemicalsknown to the State of California to cause birthdefects and, in some cases, cancer.

Hypertherm Plasma Systems 1-38-99

SAFETY

SAFETY

1-4 Hypertherm Plasma Systems5/6/02

SAFETY

Instant-On TorchesPlasma arc comes on immediately when the torchswitch is activated.

A PLASMA ARC CAN CAUSE INJURY AND BURNS

The plasma arc will cut quickly through gloves andskin.• Keep away from the torch tip.• Do not hold metal near the cutting path.• Never point the torch toward yourself or others.

Eye Protection Plasma arc rays produce intensevisible and invisible (ultraviolet and infrared) rays thatcan burn eyes and skin.• Use eye protection in accordance with applicable

national or local codes.• Wear eye protection (safety glasses or goggles with

side shields, and a welding helmet) with appropriatelens shading to protect your eyes from the arc’sultraviolet and infrared rays.

Lens ShadeArc Current AWS (USA) ISO 4850

Up to 100 A No. 8 No. 11100-200 A No. 10 No. 11-12200-400 A No. 12 No. 13Over 400 A No. 14 No. 14

ARC RAYS CAN BURN EYES AND SKIN

Skin Protection Wear protective clothing to protectagainst burns caused by ultraviolet light, sparks andhot metal.• Gauntlet gloves, safety shoes and hat.• Flame-retardant clothing to cover all exposed areas.• Cuffless trousers to prevent entry of sparks and

slag.• Remove any combustibles, such as a butane lighter

or matches, from your pockets before cutting.

Cutting Area Prepare the cutting area to reducereflection and transmission of ultraviolet light:• Paint walls and other surfaces with dark colors to

reduce reflection. • Use protective screens or barriers to protect others

from flash and glare.• Warn others not to watch the arc. Use placards or

signs.

Work Cable Attach the work cable securely to theworkpiece or the work table with good metal-to-metalcontact. Do not connect it to the piece that will fallaway when the cut is complete.

Work Table Connect the work table to an earthground, in accordance with appropriate national orlocal electrical codes.

GROUNDING SAFETY Input Power• Be sure to connect the power cord ground wire to

the ground in the disconnect box.• If installation of the plasma system involves

connecting the power cord to the power supply, besure to connect the power cord ground wireproperly.

• Place the power cord's ground wire on the stud first,then place any other ground wires on top of thepower cord ground. Fasten the retaining nut tightly.

• Tighten all electrical connections to avoid excessiveheating.

SAFETY

Hypertherm Plasma Systems 1-511-98

SAFETY

• Never lubricate cylinder valves or regulators with oilor grease.

• Use only correct gas cylinders, regulators, hosesand fittings designed for the specific application.

• Maintain all compressed gas equipment andassociated parts in good condition.

• Label and color-code all gas hoses to identify thetype of gas in each hose. Consult applicablenational or local codes.

GAS CYLINDERS CANEXPLODE IF DAMAGED

COMPRESSED GAS EQUIPMENT SAFETY

Gas cylinders contain gas under high pressure. Ifdamaged, a cylinder can explode.• Handle and use compressed gas cylinders in

accordance with applicable national or local codes.• Never use a cylinder that is not upright and secured

in place.• Keep the protective cap in place over valve except

when the cylinder is in use or connected for use.• Never allow electrical contact between the plasma

arc and a cylinder.• Never expose cylinders to excessive heat, sparks,

slag or open flame.• Never use a hammer, wrench or other tool to open

a stuck cylinder valve.

Prolonged exposure to noise from cutting or gougingcan damage hearing.• Use approved ear protection when using plasma

system.• Warn others nearby about the noise hazard.

NOISE CAN DAMAGE HEARING

Pacemaker and hearing aid operation can be affectedby magnetic fields from high currents.Pacemaker and hearing aid wearers should consult adoctor before going near any plasma arc cutting andgouging operations.

To reduce magnetic field hazards:• Keep both the work cable and the torch lead to one

side, away from your body.• Route the torch leads as close as possible to the

work cable.• Do not wrap or drape the torch lead or work cable

around your body.• Keep as far away from the power supply as

possible.

PACEMAKER AND HEARINGAID OPERATION

ADDITIONAL SAFETY INFORMATION

1. ANSI Standard Z49.1, Safety in Welding and Cutting, AmericanWelding Society, 550 LeJeune RoadP.O. Box 351020, Miami, FL 33135

2. ANSI Standard Z49.2, Fire Prevention in the Use of Cutting andWelding Processes, American National Standards Institute1430 Broadway, New York, NY 10018

3. ANSI Standard Z87.1, Safe Practices for Occupation andEducational Eye and Face Protection, American NationalStandards Institute, 1430 Broadway, New York, NY 10018

4. AWS F4.1, Recommended Safe Practices for the Preparation forWelding and Cutting of Containers and Piping That Have HeldHazardous Substances, American Welding Society550 LeJeune Road, P.O. Box 351040, Miami, FL 33135

5. AWS F5.2, Recommended Safe Practices for Plasma Arc Cutting, American Welding Society550 LeJeune Road, P.O. Box 351040, Miami, FL 33135

6. CGA Pamphlet P-1, Safe Handling of Compressed Gases inCylinders, Compressed Gas Association1235 Jefferson Davis Highway, Arlington, VA 22202

7. CSA Standard W117.2, Code for Safety in Welding and Cutting,Canadian Standards Association Standard Sales178 Rexdale Boulevard, Rexdale, Ontario M9W 1R3, Canada

8. NFPA Standard 51B, Cutting and Welding Processes, NationalFire Protection Association470 Atlantic Avenue, Boston, MA 02210

9. NFPA Standard 70–1978, National Electrical Code, National FireProtection Association, 470 Atlantic Avenue, Boston, MA 02210

10. OSHA, Safety and Health Standards, 29FR 1910U.S. Government Printing Office, Washington, D.C. 20402

A PLASMA ARC CAN DAMAGE FROZEN PIPES

Frozen pipes may be damaged or can burst if youattempt to thaw them with a plasma torch.

SAFETY

1-6 Hypertherm Plasma Systems8-99

SAFETY

WARNING LABELThis warning label is affixed to some power supplies. It isimportant that the operator and maintenance technicianunderstand the intent of these warning symbols as described.The numbered text corresponds to the numbered boxes onthe label.

1. Cutting sparks can cause explosion or fire.

1.1 Keep flammables away from cutting.

1.2 Keep a fire extinguisher nearby, and havea watchperson ready to use it.

1.3 Do not cut on any closed containers.

2. The plasma arc can cause injury andburns.

2.1 Turn off power before disassembling torch.

2.2 Do not hold the material near cutting path.

2.3 Wear complete body protection.

3. Electric shock from torch or wiring can kill.Protect yourself from electric shock.

3.1 Wear insulating gloves. Do not wear wet ordamaged gloves.

3.2 Insulate yourself from work and ground.

3.3 Disconnect input plug or power beforeworking on machine.

4. Breathing cutting fumes can be hazardousto your health.

4.1 Keep your head out of the fumes.

4.2 Use forced ventilation or local exhaust toremove the fumes.

4.3 Use ventilating fan to remove the fumes.

5. Arc rays can burn eyes and injure skin.

5.1 Wear hat and safety glasses. Use earprotection and button shirt collar. Usewelding helmet with correct shade of filter.Wear complete body protection.

6. Become trained and read the instructionsbefore working on the machine or cutting.

7. Do not remove or paint over (cover)warning labels.

Hypertherm Systèmes plasma 1a-12/12/01

Section 1a

SÉCURITÉ

Dans cette section :

Identifier les consignes de sécurité.........................................................................................................................1a-2Suivre les instructions de sécurité ..........................................................................................................................1a-2Danger Avertissement Précaution ........................................................................................................................1a-2Le coupage peut provoquer un incendie ou une explosion ....................................................................................1a-2

Prévention des incendies, Prévention des explosions ...................................................................................1a-2Risque d’explosion argon-hydrogène et méthane..........................................................................................1a-2Détonation de l’hydrogène lors du coupage de l’aluminium...........................................................................1a-2

Les chocs électriques peuvent être fatals...............................................................................................................1a-3Prévention des chocs électriques ..................................................................................................................1a-3

Le coupage peut produire des vapeurs toxiques....................................................................................................1a-3L’arc plasma peut provoquer des blessures ou des brûlures .................................................................................1a-4

Torches à allumage instantané ......................................................................................................................1a-4Les rayons de l’arc peuvent brûler les yeux et la peau...........................................................................................1a-4

Protection des yeux, Protection de la peau, Zone de coupage ....................................................................1a-4Mise à la masse et à la terre...................................................................................................................................1a-4

Câble de retour, Table de travail, Alimentation...............................................................................................1a-4Sécurité des bouteilles de gaz comprimé ...............................................................................................................1a-5Les bouteilles de gaz comprimé peuvent exploser en cas de dommages .............................................................1a-5Le bruit peut provoquer des problèmes auditifs......................................................................................................1a-5Pacemakers et prothèses auditives........................................................................................................................1a-5Un arc plasma peut endommager les tuyaux gelés................................................................................................1a-5Étiquette de sécurité ...............................................................................................................................................1a-6

SÉCURITÉ

1a-2 Hypertherm Systèmes plasma2/12/01

IDENTIFIER LES CONSIGNES DE SÉCURITÉ

Les symboles indiqués dans cette section sont utilisés pouridentifier les risques éventuels. Si vous trouvez un symbolede sécurité, que ce soit dans ce manuel ou surl’équipement, soyez conscient des risques de blessures etsuivez les instructions correspondantes afin d’éviter cesrisques.

SUIVRE LES INSTRUCTIONS DE SÉCURITÉ

Lire attentivement toutes les consignes de sécurité dans leprésent manuel et sur les étiquettes de sécurité se trouvantsur la machine.

• Les étiquettes de sécurité doivent rester lisibles.Remplacer immédiatement les étiquettes manquantes ouabîmées.

• Apprendre à faire fonctionner la machine et à utilisercorrectement les commandes. Ne laisser personne utiliserla machine sans connaître son fonctionnement.

• Garder la machine en bon état. Des modifications nonautorisées sur la machine peuvent engendrer desproblèmes de sécurité et raccourcir la durée d’utilisationde l’équipement.

DANGER AVERTISSEMENT PRÉCAUTION

Les signaux DANGER ou AVERTISSEMENT sont utilisésavec un symbole de sécurité, DANGER correspondant auxrisques les plus sérieux.

• Les étiquettes de sécurité DANGER et AVERTISSEMENTsont situées sur la machine pour signaler certainsdangers spécifiques.

• Les messages d’AVERTISSEMENT précèdent lesinstructions d’utilisation expliquées dans ce manuel etsignalent les risques de blessures ou de mort au cas oùces instructions ne seraient pas suivies correctement.

• Les messages de PRÉCAUTION précèdent lesinstructions d’utilisation contenues dans ce manuel etsignalent que le matériel risque d’être endommagé si lesinstructions ne sont pas suivies correctement.

Prévention des incendies• Avant de commencer, s’assurer que la zone de coupage

ne présente aucun danger. Conserver un extincteur àproximité.

• Éloigner toute matière inflammable à une distance d’aumoins 10 m du poste de coupage.

• Tremper le métal chaud ou le laisser refroidir avant de le manipuler ou avant de le mettre en contact avec desmatériaux combustibles.

• Ne jamais couper des récipients pouvant contenir desmatières inflammables avant de les avoir vidés etnettoyés correctement.

• Aérer toute atmosphère potentiellement inflammableavant d’utiliser un système plasma.

• Lors de l’utilisation d’oxygène comme gaz plasma, unsystème de ventilation par aspiration est nécessaire.

Prévention des explosions• Ne pas couper en présence de poussière ou de vapeurs.• Ne pas couper de bouteilles, de tuyaux ou autres

récipients fermés et pressurisés.• Ne pas couper de récipients contenant des matières

combustibles.

LE COUPAGE PEUT PROVOQUER UN INCENDIEOU UNE EXPLOSION

AVERTISSEMENTRisque d’explosion

argon-hydrogène et méthane

L’hydrogène et le méthane sont des gaz inflammables etpotentiellement explosifs. Conserver à l’écart de touteflamme les bouteilles et tuyaux contenant des mélanges àbase d’hydrogène ou de méthane. Maintenir toute flammeet étincelle à l’écart de la torche lors de l’utilisation d’unplasma d’argon-hydrogène ou de méthane.

AVERTISSEMENTDétonation de l’hydrogène lors du

coupage de l’aluminium

• Lors du coupage de l’aluminium sous l’eau, ou si l’eautouche la partie inférieure de la pièce d’aluminium, del’hydrogène libre peut s’accumuler sous la pièce à couperet détonner lors du coupage plasma.

• Installer un collecteur d’aération au fond de la table à eauafin d’éliminer les risques de détonation de l’hydrogène.Se référer à l’annexe du manuel pour plus derenseignements sur les collecteurs d’aération.

SÉCURITÉ


Toucher une pièce électrique sous tension peut provoquerun choc électrique fatal ou des brûlures graves.

• La mise en fonctionnement du système plasma ferme uncircuit électrique entre la torche et la pièce à couper. Lapièce à couper et tout autre élément en contact avec cettepièce font partie du circuit électrique.

• Ne jamais toucher le corps de la torche, la pièce à couperou l’eau de la table à eau pendant le fonctionnement dusystème plasma.

Prévention des chocs électriques

Tous les systèmes plasma Hypertherm utilisent des hautestensions pour le coupage (souvent de 200 à 400 V). On doit prendre les précautions suivantes quand on utilise lesystème plasma :• Porter des bottes et des gants isolants et garder le corps

et les vêtements au sec.• Ne pas se tenir, s’asseoir ou se coucher sur une surface

mouillée, ni la toucher quand on utilise le système plasma.• S’isoler de la surface de travail et du sol en utilisant des

tapis isolants secs ou des couvertures assez grandespour éviter tout contact physique avec le travail ou le sol.S’il s’avère nécessaire de travailler dans ou près d’unendroit humide, procéder avec une extrême prudence.

• Installer un sectionneur avec fusibles appropriés, àproximité de la source de courant. Ce dispositif permet àl’opérateur d’arrêter rapidement la source de courant encas d’urgence.

• En cas d’utilisation d’une table à eau, s’assurer que cettedernière est correctement mise à la terre.

LES CHOCS ÉLECTRIQUES PEUVENT ÊTRE FATALS

• Installer et mettre à la terre l’équipement selon lesinstructions du présent manuel et conformément auxcodes électriques locaux et nationaux.

• Inspecter fréquemment le cordon d’alimentation primairepour s’assurer qu’il n’est ni endommagé, ni fendu.Remplacer immédiatement un cordon endommagé. Un câble dénudé peut tuer.

• Inspecter et remplacer les câbles de la torche qui sontusés ou endommagés.

• Ne pas saisir la pièce à couper ni les chutes lors ducoupage. Laisser la pièce à couper en place ou sur latable de travail, le câble de retour connecté lors ducoupage.

• Avant de vérifier, de nettoyer ou de remplacer les piècesde la torche, couper l’alimentation ou débrancher la prisede courant.

• Ne jamais contourner ou court-circuiter les verrouillagesde sécurité.

• Avant d’enlever le capot du système ou de la source decourant, couper l’alimentation électrique. Attendre ensuite5 minutes pour que les condensateurs se déchargent.

• Ne jamais faire fonctionner le système plasma sans queles capots de la source de courant ne soient en place.Les raccords exposés de la source de courant sontextrêmement dangereux.

• Lors de l’installation des connexions, attacher tout d’abordla prise de terre appropriée.

• Chaque système plasma Hypertherm est conçu pour êtreutilisé uniquement avec des torches Hyperthermspécifiques. Ne pas utiliser des torches inappropriées quipourraient surchauffer et présenter des risques pour lasécurité.

Le coupage peut produire des vapeurs et des gaz toxiquesqui réduisent le niveau d’oxygène dans l’air et peuventprovoquer des blessures, voire la mort.• Conserver le poste de coupage bien aéré ou utiliser un

masque respiratoire homologué.• Ne pas procéder au coupage près d’endroits où

s’effectuent le dégraissage, le nettoyage ou la vapori-sation. Certains solvants chlorés se décomposent sousl’effet des rayons ultraviolets et forment du phosgène.

• Ne pas couper des métaux peints ou contenant desmatières toxiques comme le zinc (galvanisé), le plomb, lecadmium ou le béryllium, à moins que la zone de travail

LE COUPAGE PEUT PRODUIRE DES VAPEURS TOXIQUES

soit très bien ventilée et que l’opérateur porte un masquerespiratoire. Les revêtements et métaux contenant cesmatières peuvent produire des vapeurs toxiques lors ducoupage.

• Ne jamais couper de récipients pouvant contenir desmatières inflammables avant de les avoir vidés etnettoyés correctement.

• Quand on utilise ce produit pour le soudage ou lecoupage, il dégage des fumées et des gaz quicontiennent des produits chimiques qui, selon l’État deCalifornie, provoquent des anomalies congénitales et,dans certains cas, le cancer.

SÉCURITÉ


Torches à allumage instantané

L’arc plasma s’allume immédiatement après que la torchesoit mise en marche.

L’ARC PLASMA PEUT PROVOQUER DES BLESSURES OU DES BRÛLURES

L’arc plasma coupe facilement les gants et la peau.• Rester éloigné de l’extrémité de la torche.• Ne pas tenir de métal près de la trajectoire de coupe.• Ne jamais pointer la torche vers soi ou d’autres

personnes.

Protection des yeux Les rayons de l’arc plasmaproduisent de puissants rayons visibles ou invisibles(ultraviolets et infrarouges) qui peuvent brûler les yeux et lapeau.• Utiliser des lunettes de sécurité conformément aux codes

locaux ou nationaux en vigueur.• Porter des lunettes de protection (lunettes ou masque

muni d’écrans latéraux et encore masque de soudure)avec des verres teintés appropriés pour protéger les yeuxdes rayons ultraviolets et infrarouges de l’arc.

Puissance des verres teintésCourant de l’arc AWS (É.-U.) ISO 4850Jusqu’à 100 A No 8 No 11100-200 A No 10 No 11-12200-400 A No 12 No 13Plus de 400 A No 14 No 14

Protection de la peau Porter des vêtements de sécuritépour se protéger contre les brûlures que peuvent causer lesrayons ultraviolets, les étincelles et le métal brûlant :

LES RAYONS DE L’ARC PEUVENT BRÛLER LES YEUX ET LA PEAU

• Gants à crispin, chaussures et casque de sécurité.• Vêtements ignifuges couvrant toutes les parties exposées

du corps.• Pantalon sans revers pour éviter que des étincelles ou

des scories puissent s’y loger.• Avant le coupage, retirer de ses poches tout objet

combustible comme les briquets au butane ou lesallumettes.

Zone de coupage Préparer la zone de coupage afin deréduire la réverbération et la transmission de la lumièreultraviolette :• Peindre les murs et autres surfaces de couleur sombre

pour réduire la réflexion de la lumière.• Utiliser des écrans et autres dispositifs de protection afin

de protéger les autres personnes de la lumière et de laréverbération.

• Prévenir les autres personnes de ne pas regarder l’arc.Utiliser des affiches ou des panneaux.

Câble de retour Bien fixer le câble de retour (ou demasse) à la pièce à couper ou à la table de travail de façonà assurer un bon contact métal-métal. Ne pas fixer le câblede retour à la partie de la pièce qui doit se détacher.

Table de travail Raccorder la table de travail à la terre,conformément aux codes de sécurité locaux ou nationauxappropriés.

MISE À LA MASSE ET À LA TERRE Alimentation• S’assurer que le fil de terre du cordon d’alimentation est

connecté à la terre dans le coffret du sectionneur.• S’il est nécessaire de brancher le cordon d’alimentation à

la source de courant lors de l’installation du système,s’assurer que le fil de terre est correctement branché.

• Placer tout d’abord le fil de terre du cordon d’alimentationsur le plot de mise à la terre puis placer les autres fils deterre par-dessus. Bien serrer l’écrou de retenue.

• S’assurer que toutes les connexions sont bien serréespour éviter la surchauffe.

SÉCURITÉ


• Ne jamais lubrifier les robinets des bouteilles ou lesrégulateurs avec de l’huile ou de la graisse.

• Utiliser uniquement les bouteilles, régulateurs, tuyaux etaccessoires appropriés et conçus pour chaque applicationspécifique.

• Entretenir l’équipement et les pièces d’équipement à gazcomprimé afin de les garder en bon état.

• Étiqueter et coder avec des couleurs tous les tuyaux degaz afin d’identifier le type de gaz contenu dans chaquetuyau. Se référer aux codes locaux ou nationaux envigueur.

LES BOUTEILLES DE GAZCOMPRIMÉ PEUVENT EXPLOSEREN CAS DE DOMMAGES

SÉCURITÉ DES BOUTEILLES DE GAZ COMPRIMÉ

Les bouteilles de gaz contiennent du gaz à haute pression.Si une bouteille est endommagée, elle peut exploser.• Manipuler et utiliser les bouteilles de gaz comprimé

conformément aux codes locaux ou nationaux.• Ne jamais utiliser une bouteille qui n’est pas placée à la

verticale et bien assujettie.• Le capuchon de protection doit être placé sur le robinet

sauf si la bouteille est en cours d’utilisation ou connectéepour utilisation.

• Éviter à tout prix le contact électrique entre l’arc plasma etune bouteille.

• Ne jamais exposer des bouteilles à une chaleurexcessive, aux étincelles, aux scories ou aux flammesnues.

• Ne jamais utiliser des marteaux, des clés ou d’autresoutils pour débloquer le robinet des bouteilles.

Une exposition prolongée au bruit du coupage ou dugougeage peut provoquer des problèmes auditifs.• Utiliser un casque de protection homologué lors de

l’utilisation du système plasma.• Prévenir les personnes aux alentours des risques

encourus en cas d’exposition au bruit.

LE BRUIT PEUT PROVOQUER DESPROBLÈMES AUDITIFS

Les champs magnétiques produits par les courants à hautetension peuvent affecter le fonctionnement des prothèsesauditives et des pacemakers. Les personnes portant cetype d’appareil doivent consulter un médecin avant des’approcher d’un lieu où s’effectue le coupage ou legougeage plasma.

Pour réduire les risques associés aux champs magnétiques :• Garder loin de soi et du même côté du corps le câble de

retour et le faisceau de la torche.• Faire passer le faisceau de la torche le plus près possible

du câble de retour.• Ne pas s’enrouler le faisceau de la torche ou le câble de

retour autour du corps.• Se tenir le plus loin possible de la source de courant.

PACEMAKERS ET PROTHÈSES AUDITIVES

Les tuyaux gelés peuvent être endommagés ou éclatersi l'on essaie de les dégeler avec une torche plasma.

UN ARC PLASMAPEUT ENDOMMAGERLES TUYAUX GELÉS

SÉCURITÉ


Étiquette de sécuritéCette étiquette est affichée sur la source de courant. Il est importantque l’utilisateur et le technicien de maintenance comprennent lasignification des symboles de sécurité. Les numéros de la listecorrespondent aux numéros des images.

1. Les étincelles produites par le coupagepeuvent provoquer une explosion ou unincendie.

1.1 Pendant le coupage, éloigner toute matièreinflammable.

1.2 Conserver un extincteur à proximité ets’assurer qu’une personne soit prête àl’utiliser.

1.3 Ne jamais couper de récipients fermés.

2. L’arc plasma peut provoquer des blessureset des brûlures.

2.1 Couper l’alimentation avant de démonter latorche.

2.2 Ne pas tenir la surface à couper près de latrajectoire de coupe.

2.3 Porter des vêtements de protectioncouvrant tout le corps.

3. Un choc électrique causé par la torche oules câbles peut être fatal. Se protégercontre les risques de chocs électriques.

3.1 Porter des gants isolants. Ne pas porter degants mouillés ou abîmés.

3.2 S’isoler de la surface de travail et du sol.

3.3 Débrancher la prise ou la source decourant avant de manipuler l’équipement.

4. L’inhalation des vapeurs produites par lecoupage peut être dangereuse pour lasanté.

4.1 Garder le visage à l’écart des vapeurs.

4.2 Utiliser un système de ventilation paraspiration ou d’échappement localisé pourdissiper les vapeurs.

4.3 Utiliser un ventilateur pour dissiper lesvapeurs.

5. Les rayons de l’arc peuvent brûler les yeuxet provoquer des lésions de la peau.

5.1 Porter un casque et des lunettes desécurité. Se protéger les oreilles et porterune chemise dont le col peut êtredéboutonné. Porter un casque de souduredont la protection filtrante est suffisante.Porter des vêtements protecteurs couvrantla totalité du corps.

6. Se former à la technique du coupage et lireles instructions avant de manipulerl’équipement ou de procéder au coupage.

7. Ne pas retirer ou peindre (recouvrir) lesétiquettes de sécurité.

HT2000 with Titan Instruction Manual 2-11-99

Section 2

SPECIFICATIONS

System Components

See Figure 3-1 in Section 3 for details of the system interconnections.

Power Supply

The power supply houses two 100-amp, 15kHz choppers and an optional Torch Height Control (THC).

HT2000 Machine Torch

The HT2000 machine torch is liquid-cooled and capable of cutting most metals from gauge to 2-inch (50 mm)thickness and from gauge to 1" (25 mm) thickness for production cutting. To achieve consumable long life, allcuts must begin and end on the plate surface.

Remote High Frequency and Motor Valve Console (also called “High Frequency Console”)

The remote high frequency and motor valve console houses the high frequency starting circuit, a shield gas valve,a motorized metering valve and a solenoid valve that switches to allow plasma gas flow for both preflow andoperation modes. Note: This console is mounted approximately 25 feet (7.6 m) from the torch.

Gas Panel

The gas panel holds metering and solenoid valves for shield and plasma gases, flow meters, pressure gauges forplasma gases, and a pressure gauge for the shield gas supply.

Timer/Counter – Optional

The timer/counter allows the operator to monitor the number of arc starts and the cumulative time that the arc is onin hours. The arc starts can be reset.

Water Muffler – Optional

The water muffler for the HT2000 with Titan system is an option which greatly improves cutting safety and pollutioncontrol capabilities. The water muffler can be used to cut above, below and at the water line. Refer to the WaterMuffler instruction manual for more detailed information. The water muffler cannot be used with the stainless steeltorch.

SPECIFICATIONS

2-2 HT2000 with Titan Instruction Manual

Specifications

System Requirements

Power Requirements:Refer to HT2000 power supply specifications below:

Gas Requirements:Plasma Gas Types .........................................Oxygen, Nitrogen, Air,

Argon-Hydrogen (H35 = 35% Hydrogen/ 65% Argon) Shield Gas Types.............................................Air, Nitrogen, Carbon Dioxide

Gas Quality:Oxygen.............................................................99.5% pure (liquid gas recommended)Nitrogen ...........................................................99.995% pure (liquid gas recommended)Air.....................................................................Clean, dry, oil-free (compressed or liquid gas recommended)Carbon Dioxide ................................................99.5% pure (compressed or liquid gas recommended)

Plasma Gas Inlet Pressures and Flowrates:Air.....................................................................90 psi +/- 10 psi (6.2 bar +/- 0.7 bar) at 82 scfh (2322 l/h)Oxygen.............................................................120 psi +/- 10 psi (8.3 bar +/- 0.7 bar) at 80 scfh (2265 l/h)Nitrogen ...........................................................120 psi +/- 10 psi (8.3 bar +/- 0.7 bar) at 80 scfh (2265 l/h)Argon-Hydrogen...............................................120 psi +/- 10 psi (8.3 bar +/- 0.7 bar) at 105 scfh (2973 l/h)

Shield Gas Inlet Pressures and Flowrates:Air.....................................................................90 psi +/- 10 psi (6.2 bar +/- 0.7 bar) at 280 scfh (7929 l/h)Carbon Dioxide ................................................90 psi +/- 10 psi (6.2 bar +/- 0.7 bar) at 220 scfh (6230 l/h)Nitrogen ...........................................................90 psi +/- 10 psi (6.2 bar +/- 0.7 bar) at 275 scfh (7787 l/h)

HT2000 Power Supply

Maximum OCV (U0) .........................................280 VDCOutput Current (I2) ...........................................40 to 200 ampsOutput Voltage (U2) .........................................150 VDCDuty Cycle Rating (X) .....................................100% up to 30kW. Beyond 30kW, Duty Cycle (X) =

(30kW/Actual Power)2 Eg: If Actual Power = 32kW, thenDuty Cycle (X)= (30kW/32kW)2 = 88%

Ambient Temperatures/Duty Cycle ..................Power supplies will operate between +14° and 104°F (-10° and +40°C). Power supplies operated in an ambienttemperature above 86°F (30°C) may show some decrease induty cycle.

Power Factor (cosϕ) ........................................0.86

Input Power (Input Voltage (U1) x Input Current ( I1)):#073063 with THC/ #073104 without THC ......200 VAC, 3PH, 50 Hz, 108 amps#073064 with THC/ #073105 without THC ......208 VAC, 3PH, 60 Hz, 104 amps#073065 with THC/ #073107 without THC ......220/380/415 VAC, 3PH, 50 Hz, 98/57/52 amps#073054 with THC/ #073106 without THC ......240/480 VAC, 3PH, 60 Hz, 90/45 amps #073066 with THC/ #073108 without THC ......600 VAC, 3PH, 60 Hz, 36 amps

Dimensions and Weight:Width................................................................28-1/4" (710 mm)Height...............................................................35-1/2" (900 mm)Depth ...............................................................41-1/4" (1045 mm)Weight..............................................................780 lbs (351 kg)Cooling.............................................................Forced Air (Class F)Coolant Tank Capacity.....................................2.9 gallons (11 liters)

SPECIFICATIONS


HT2000 Machine Torch

17.75 (450.85)

11.75 (298.45)3.62 (91.92)

2" (50 mm) or1.75" (44 mm)See Section 9

2.38(60.48)

45°Figure 2-1 HT2000 Machine Torch (shown without off-valve assembly)

2.38"(60 mm)

2.0" (50 mm) or 1.75" (44 mm) see Section 5

3.62" (91 mm)

17.75" (450 mm)

11.75" (300 mm)

Maximum cutting thickness..............................2 inch (50 mm)Maximum current at 100% duty cycle ..............200 amps

Plasma and Shield Gas Flow...........................Refer to the Cut Charts in the Operation section for specificgas requirements.

Water coolant flow rate ....................................0.8 gpm (3.0 l/min)Weight..............................................................2-1/2 lbs (1.13 kg)

Remote High Frequency and Motor Valve (RHF&MV) Console

Dimensions and Weight:Width................................................................20" (508 mm)Height...............................................................16" (406 mm)Depth ...............................................................8.8" (223 mm)Weight..............................................................60 lbs (27 kg)

21.6" (549 mm)20" (508 mm)

18.5" (470 mm)

16"(406 mm)

14.5"(368 mm)

0.5"dia. (4)

Figure 2-2 Mounting Dimensions – RHF&MV Console

0.37

5" (

9.5

mm

)

SPECIFICATIONS

2-4 HT2000 with Titan Instruction Manual1-99

0.375" (9.5 mm)

34" (864 mm)

8.62

5" (

219

mm

)

9" (

229

mm

)

33.595" (853 mm)

26.975" (685 mm)

20.325" (516 mm)

13.675" (347 mm)

7.025" (178 mm)

Gas Panel

Dimensions and Weight:Width.................................................9" (228 mm)Height ...............................................34" (864 mm)Depth ................................................6" (150 mm)Weight...............................................20 lbs (9 kg)

Figure 2-3 Mounting Dimensions – Gas Panel

0.203 ø (5 mm) – 12 places

Figure 2-4 Mounting Dimensions –Timer/Counter

6.50" (165 mm)

5/32" ø (4 mm) – 4 places

1.17" (30 mm)

0.50" (13 mm)

3.38" (86 mm)

6.25" (159 mm)8.5" (216 mm)

Water Muffler – Optional

Refer to the Water Muffler Instruction Manual. The water muffler cannot be used with the stainless steel torch.

Timer/Counter – Optional

Dimensions and Weight:Width.................................................6-1/2" (165 mm)Height ...............................................2-1/2" (64 mm)Depth ................................................8-5/8" (219 mm)Weight...............................................3 lbs (1 kg)

HT2000 with Titan Instruction Manual 3-1

Section 3

INSTALLATION

Gas or water Torque Specification

hose size lbf-in lbf-ft kgf-cm

up to 3/8" (10 mm) 75-85 6.25-7 86-98

1/2" (12 mm) 360-480 30-40 415-550

Pre-installation

See the HT2000 instruction manual 802070 Pre-installation section for system requirements.

System Units Placement

• Position all required units prior to making electrical, gas and interface connections.

• Ground all external modules in the HT2000 with Titan system to earth.

• To prevent leaks in the system, tighten all gas and water connections to the following specifications:

Use 2 wrenches when tightening to prevent damage to the mating component.

Use the diagram on the following 2 pages to make system interconnections. Follow the number guide on thediagram to find out specific information on each cable, hose or connection. The numbered items are detailed on thepages following the interconnection diagram.

Machine ComputerInterface


To Water MufflerPump

Red

Green

Timer/Counter

HT2000 Power Supply Work Table

11X1

To SecondHT2000 Power Supply

12

11

9

8

10

2

5

1

3

7

6A

6B

4


Gas HoseCoolant Hose

BlueGray GreenRed

Figure 3-1 HT2000 with Titan Interconnection Diagram

Abbreviations used in this section:HT2000 Power supply = PSRemote High Frequency and Motor Valve Console = RHF&MVHigh Frequency = HFVoltage, Current = V/CWater Muffler = WM

ShieldIN***

N2, Air, H35 PlasmaIN**

O2PlasmaIN*

Red

Green

RHF&MV Console – HF Panel

RHF&MV Console – Internal

HT2000 TitanRemote HighFrequency andMotor Valve(RHF&MV)Console

HT2000 TitanGas Panel

To TorchSee page 3-9.

Hardware connectionssupplied by customer.

* 1/4 NPT male adapter provided for plasma supply hose** 1/4 NPT female adapter provided for plasma supply hose*** 1/8 NPT male adapter provided for shield supply hose

5

13

7

1416

15

6A

6B

1

3

1

3

17

18

19

4

INSTALLATION


Power Supply Connections

Note: All leads between the power supply and the RHF&MV console can be ordered as a package under onenumber – 128201.

Part No. Length

123041 60 ft (18.3 m)

Negative Lead – Power Supply (PS) to RHF&MV Console1 1

Part No. Length

123043 60 ft (18.3 m)

Pilot Arc lead – PS to RHF&MV Console3 3

Part No. Length

023755 4 ft (1.2 m)023920 8 ft (2.4 m)023508 10 ft (3 m)023403 15 ft (4.6 m)023404 25 ft (7.6 m)023968 30 ft (9.2 m)023986 35 ft (10.7 m)023405 50 ft (15 m)123041 60 ft (18.3 m)

Positive Lead – PS to Work Table2 2

Part No. Length

123042 60 ft (18.3 m)

RHF Cable – PS to RHF&MV Console4 4

1X1 2X1

From 1X1 To 2X1 Signal

34 1 RHF Door Intrlck35 4 RHF Door Intrlck36 3 Shield4 2 PS3 / Shield Gas8 5 PS3 / Shield Gas9 6 Cable Shield23 7 SV6 / Shield ON24 8 SV6 / Shield ON25 11 Shield


10 10 SV7 / Cap OFF11 13 SV7 / Cap OFF12 14 Shield1 12 T1 / HV Xfrmer2 15 T1 / HV Xfrmer3 16 Shield14 Unused15 Unused21 Shield

INSTALLATION


Part No. Length

123292 60 ft (18.3 m)

MV Cable – PS to RHF&MV Console5 5

1X3 4X1


16 16 SV4A/ Cuflow17 17 SV4A/ Cutflow10 10 Shield23 23 SV4B/ Preflow24 24 SV4B/ Preflow25 25 Shield29 29 SV5 / Plasma OFF


30 30 SV5 / Plasma OFF34 34 Shield12 12 MV2 Decrease11 11 MV2 Decrease18 18 Shield14 14 MV2 Motor Increase21 21 Shield

Part No. Length

128052 60 ft (18.3 m)

Cooling Hoses – PS to RHF&MV Console6 6

This part number includes bothhoses.

6b

6a

RED

GRNGRN

RED

Part No. Length

023989 10 ft (3 m)023549 15 ft (4.6 m)023605 25 ft (7.6 m)023757 38 ft (11.6 m)023606 50 ft (15 m)123044 60 ft (18.3 m)023607 75 ft (23 m)123077 85 ft (25.9 m)023608 100 ft (30.5)023963 115 ft (35.1 m)123147 120 ft (36.6 m)023743 125 ft (38.1 m)023609 150 ft (46 m)023953 200 ft (62 m)

Gas Panel Cable – PS to Gas Panel7 7

1X2 3X1


29 29 S3 / MV2 Increase30 30 Spare34 34 Shield5 5 S3 / MV2 Decrease6 6 S3 / MV2 Common1 1 Shield2 2 LT1 / DC ON3 3 LT1 / DC ON7 7 Shield8 8 SV1A / O2 / N29 9 SV1A / O2 / N24 4 Shield16 16 SV2 / O2 / N217 17 SV2 / O2 / N210 10 Shield27 27 SV1B / O2 / N228 28 SV1B / O2 / N222 22 Shield


11 11 SV3 / Preflow Trap12 12 SV3 / Preflow Trap18 18 Shield19 19 S1 / N2 / O220 20 S1 / N2 / O213 13 Shield14 14 S2 / Test / Preflow15 15 S2 / Test / Common21 21 Shield35 35 S2 / Test / Operate36 36 S2 / Test / Common31 31 Shield32 32 PS1&PS233 33 PS1&PS237 37 Shield

INSTALLATION


1X7

1X6

Machine V/C Interface Cable – PS to Machine Interface

From 1x6 Color Signal

2 Yellow Initial Height Sig. (OFF=Closed)6 Black Initial Height Com.11 Shield4 Orange Auto Height Sig. (OFF=Closed)8 Black Auto Height Com.13 Shield34 Red *†Lifter DOWN Load (DOWN=Closed)29 Black Lifter DOWN Line23 Shield35 Green *†Lifter UP Load (UP=Closed)30 Black Lifter UP Line24 Shield36 Red Upper Limit Switch ( OFF=Closed)31 Blue Upper Limit Switch25 Shield


33 Red Arc Voltage (1/50 Arc Voltage)28 Yellow Arc Voltage27 Shield9 Blue Plasma START (START=Closed)15 Black Plasma START14 Shield37 Red †Arc Transfer (TRANSFER=Closed)32 Green †Arc Transfer26 Shield1 White Hold Ignition Sig. (HOLD=Closed)5 Black Hold Ignition Com.10 Shield3 Brown Ramp Down Error7 Black Ramp Down Error12 Shield


2 White Current 103 Red Current 204 Green Current 405 Orange Current 806 Blue Current 1007 White/Black Current 20010 Shld Shield11 Blue/Black Current Common


16 Black/Red Voltage V517 White/Red Voltage V1018 Orange/Red Voltage V2019 Blue/Red Voltage V4020 Red/Green Voltage V8021 Orange/Green Voltage V10022 Black/White/Red Voltage V20023 White/Black/Red Voltage VCommon

Part No. Length

023841 6 ft (1.8 m)023842 15 ft (4.6 m)023843 25 ft (7.6 m)023844 35 ft (10.7 m)023845 50 ft (15 m)123047 60 ft (18.3 m)023846 75 ft (23 m)

Part No. Length

123080 85 ft (25.9 m)023847 100 ft (30.5)023962 115 ft (35.1 m)123148 120 ft (36.6 m)023848 125 ft (38.1 m)023849 150 ft (46 m)023850 200 ft (62 m)

8 8

9 9

* Signals are AC relays. DC relays are available as an option from Hypertherm by ordering kit: 128404

Machine I/O Interface Cable – PS to Machine Interface

Part No. Length

023902 6 ft (1.8 m)023851 15 ft (4.6 m)023852 25 ft (7.6 m)023853 35 ft (10.7 m)023854 50 ft (15 m)

Part No. Length

023855 75 ft (23 m)023856 100 ft (30.5)023903 125 ft (38.1 m)023857 150 ft (46 m)023858 200 ft (62 m)

WARNING

When installing or servicing the HT2000 Titan, AC or DC line voltages may be present on the UP,DOWN and TRANSFER signals even if the power supply line disconnect switch is OFF. Make certainthat all line disconnect switches relating to the HT2000 Titan system are OFF during installation andwhen servicing.

1X10

INSTALLATION


Water Muffler Pump Cable – Power Supply to Water Muffler Pump

See water muffler instruction manual 802050 to connect cable to pumpmotor, and to make remaining water muffler connections. The water mufflercannot be used with the stainless steel torch.

1010 Part No. Length

023866 50 ft (15 m)023867 75 ft (23 m)023868 100 ft (30.5)

From 1X10 Color To WM Pump Contactor

2 Black Coil4 White AC Neut.3 Green Ground

11X1

Hold Cable – Power Supply 1 to Power Supply 2

Wire HT2000Color TB3 Function

Black 13 Hold SignalRed 14 Hold CommonShield 15 Hold Shield

Part No. Length

023340 15 ft (4.6 m)023341 25 ft (7.6 m)023342 50 ft (15 m)023343 100 ft (30.5)023344 150 ft (46 m)

12

Shield Gas Hose – Gas Panel to RHF&MV Console13

12

Timer/Counter Cable – Power Supply to Timer/Counter11

11 Part No. Length

023687 10 ft (3 m)023692 25 ft (7.6 m)023758 38 ft (11.6 m)023693 50 ft (15 m)123046 60 ft (18.3 m)023694 75 ft (23 m)123079 85 ft (25.9 m)023695 100 ft (30.5)023993 115 ft (35.1 m)123189 120 ft (36.6 m)023696 150 ft (46 m)023954 200 ft (62 m)

From To HT200011x1 TB3 Color Function

1 2 White Starts and Arc time (CON1 Closed)2 1 Black Starts and Arc time (CON1 Closed)3 3 Drain Drain15 5 Red Error Counter (Ramp Down Error)16 4 Black Error Counter (Ramp Down Error)12 6 Drain Drain

Gas Panel Connections

See page 3-3 for gas panel connection to power supply.Hoses from supply gases to gas panel provided by the customer.

Note: The following 20 ft length hoses can be ordered as a package withone number – 128202.

Part No. Length

024349 20 ft (6.1 m)

13

Note: Turn counterclockwise to tighten

INSTALLATION


Part No. Length

024067 20 ft (6.1 m)

Shield Gas Sense Hose – Gas Panel to RHF&MV Console14 14

Part No. Length

024017 20 ft (6.1 m)

Plasma Preflow Gas Hose – Gas Panel to RHF&MV Console15 15

Part No. Length

024308 20 ft (6.1 m)

Plasma Cut Flow Gas Hose – Gas Panel to RHF&MV Console16 16

Note: Turn counterclockwise to tighten

INSTALLATION


RHF&MV Console to Torch Connections

See pages 3-2 and 3-3 for RHF&MV console connections to the power supply and gas panel.

Routing the Torch Leads

Caution: Before routing the leads, make sure the torch is removed from the torch leads.

Route the torch leads from the RHF&MV console to the torch through a festoon or a power track.

Connecting the Torch Leads to the Torch

Note: The following torch leads, hose, cable and torch with off-valve assembly can be orderedwith one number – 128200.

See page 3-3 for torch lead connections to the RHF&MV Console.

See page 3-1 for torque specifications.

Leads HT2000 Torch – RHF&MV Console to Torch17

17

Part 1Pilot/ShieldGas (Blue)

Green

Red

Gray

Green

Red

Gray

Part 4

Part 3

Part 2

Shielded TorchLeads Part No. Part 1 Part 2 Part 3 Part 4 Length

028994 023326 024192 023013 023013 25 ft (7.6 m)

See Figure 3-2 to make connections to torch.

1. Remove the 12" off-valve hose from the off-valve subassembly (if connected). Note that the fitting is left-handthreaded and turns in a clockwise direction to remove.

2. Slide the torch sleeve over the RHF torch leads and out of the way.

3. With the red and green torch leads, use a 3/8" open-end wrench to hold the torch body fittings and a 1/2" open-end wrench to turn the torch lead fittings. Attach the leads to the red and green tubes of the torch main body.

INSTALLATION


4. Attach the lead with the teflon tube (pilot/shield gas (blue)) to the shortest tube (point 3) on the torch main body.Use a 5/16" open-end wrench to hold the torch body fitting and a 7/16" open-end wrench to turn the torch leadfitting.

5. Finally, connect the gray torch lead hose to point 4. Again, use a 5/16" open-end wrench to hold the torch bodyfitting and a 7/16" open-end wrench to turn the torch lead fitting.

Note: If the 12" off-valve hose is not connected to the torch, make the connection to point 5 (left-hand threaded connection) at this time. Use the same wrenches as in steps 4&5.

6. Slide the torch sleeve over the torch main body and screw them together.

7. Connect the 12" hose that extends beyond the end of the sleeve to the off-valve elbow connected to point 2(left-hand threaded connection).

Part No. Length

024283 25 ft, 5" (7.7 m)

Hose – RHF&MV Console to Torch Off-Valve18 18

• Connect the plasma hose from point 1 of the off-valve subassembly to the plasma flow connector on theRHF&MV console.Note that the fitting is left-hand threaded and is turned in a counterclockwise direction to tighten.

Part No. Length

123293 25 ft (7.6 m)

Cable – RHF&MV Console to Torch Off-Valve19 19

From 4X2 To Off Valve Signal

1 1 Plasma Off & Vent2 24 Ground3 No Conn. Drain

3

4

2

1

• Connect the torch off-valve cable from the off-valve subassembly to the 4X2 connector on the RHF&MVconsole.

INSTALLATION


Figure 3-2 HT2000 Machine Torch Connections

Torch Off-Valve Cable

Plasma Hose

Off-valve subassembly

Point 2(left-handthreaded)

Off-valveconnector


Torchsleeve

12" Off-valve hose


Point 4

Red and Greentubes

Point 3

12" Off-valve hose

Torch main body

18

19

INSTALLATION


Torch mounting bracket

90°0°

Securing screws

Figure 3-3 Torch Alignment

Torch sleeve

Torch Alignment

Prior to cutting with the machine torch, ensure that the torch is at right angles to the workpiece to get a clean,vertical cut. Use a square to align the torch. The torch should be aligned at 0° and 90°. See Figure 3-3.

Mounting the Machine Torch

1. Loosen the securing screw(s) and install the machine torch (with torch leads attached) in the torch mountingbracket. See Figure 3-3.

2. Position the torch until the torch body extends all the way through the bracket, so that the bracket is now aroundthe plastic torch sleeve and not touching the stainless steel torch body. Position the torch approximately 0.25" (6 mm) from the work surface.

3. Tighten the securing screws.


Section 4

OPERATION

Refer to HT2000 Instruction manual 802070 for explanation of power supply and timer/counter front panel controlsand indicators.

OPERATION


DesignationsFM1-FM2 –– FlowmeterLT1 –– Indicator LampMV2-MV4 –– Motor ValvePG1-PG3 –– Pressure GaugeS1-S3 –– Toggle Switch

N2 –– NitrogenO2 –– OxygenH35 –– Argon-Hydrogen

TestCut Flow

TestPreflow

Run

With Cut Gas Switch at N2/AIR/H35, Set Valve to Desired Gas.With Switch at O2, Set Valve to N2.

N2

H35 Air

AirCO2

N2 O2

O2N2 / Air / H35

O2N2AirH35

Cut FlowRateCut Gas

S2TEST PREFLOW – Sets the plasmapreflow flow rate on the flowmeter. Inthis position the contactor is disabled.TEST CUT FLOW – Allows the selectedplasma gas flow rate to be adjusted onthe flowmeter for cutting conditions. Inthis position the contactor is disabled.RUN – Enables the contactor and thesubsequent firing of the arc after the gasrates have been set in the Test Preflowand Test Cut Flow positions.

MV2Adjusts N2, air or H35 plasma gas flow rate % while in TEST PREFLOW mode.Preflow plasma gas flow rate percentagesare specified in the Cut Charts.

PG3Indicates shield gas pressure at the torch.

PLASMA SELECT SwitchSupplied by Messer

SHIELD SELECTPLASMA SELECT

MV4Adjusts shield gas pressure to the torch.

SHIELD SELECT SwitchSupplied by Messer

SHIELD GAS FLOW RATE

MV3Adjusts O2 plasma gas flow rate % whilein TEST PREFLOW mode. Preflowplasma gas flow rate percentages arespecified in the Cut Charts.

PREFLOWRATE ADJUST

S1Selects the use of either N2, air, H35 orO2 as the plasma cutting gas.

S3Adjusts N2, air or O2 plasma gas flow rate% while in TEST CUT FLOW mode.Plasma gas flow rate percentages arespecified in the Cut Charts.

PG2Indicates the O2 plasma inlet pressure.Gas inlet pressures are specified in theCut Charts.

PG1Indicates the N2, air or H35 plasma inletpressure. Gas inlet pressures arespecified in the Cut Charts

FM2Indicates the flow rate % of O2 plasmagas flow. Percentages are specified in theCut Charts.

FM1Indicates the flow rate % of N2, air orH35 plasma gas. Percentages arespecified in the Cut Charts.

LT1Illuminates when main contactor closes,indicating that DC power is beingsupplied to the torch

PLASMA GAS FLOW RATE

Figure 4-1 HT2000 Titan Gas Panel Controls and Indicators

Front Panel Controls and Indicators

HT2000 Titan Gas Panel (Fig. 4-1)

OPERATION


Daily Start-up

Prior to start-up, ensure that your cutting environment and that your clothing meet the safety requirements outlinedin the Safety section of this manual. If problems occur during start-up, refer to Section 3 for installationrequirements.

Check Torch

1. Remove the consumables from the torch and check for worn or damaged parts. Always place theconsumables on a clean, dry, oil free surface after removing. Dirty consumables can cause the torch tomalfunction.

• Check the pit depth of the electrode using the electrode gauge assembly. A standard electrode should bereplaced when the depth exceeds .044 inch (1.1 mm). The SilverPlus electrode may be replaced when thepit depth exceeds approximately double the recommended depth of a standard electrode.

• Wipe the current ring in the torch with a clean paper towel or Q-tip. (See Fig. 4-2)

• Refer to the Cut Charts to choose the correct consumables for your cutting needs.

2. Replace consumable parts. Refer to Changing Consumable Parts later in this section for detailed information onreplacing consumables.

3. Ensure that the torch is squared to the material. Refer to Section 3: Installation for the torch alignmentprocedure.

Turn Gases On

4. Set S2 toggle switch on the gas panel to RUN.

5. Set S1 on the gas panel to N2/Air/H35 (for nitrogen, air or argon-hydrogen as plasma gas), or O2 (for oxygen as plasma gas).

6. Select the proper plasma and shield gases with the customersupplied interface. Note: When selecting O2 as the plasma gas, setPlasma Select switch to the N2 position.

7. Turn the required supply gases On.

• When using oxygen, nitrogen, or argon-hydrogen as theplasma gas, adjust supply regulator to read 120 psi +/- 10 psi(8.2 bar +/- 0.7 bar).

When using air as the plasma gas, adjust supply regulator toread 90 psi +/- 10 psi (6.2 bar +/- 0.7 bar).

• Adjust supply regulator for shield gas to read 90 psi +/- 10 psi(6.2 bar +/- 0.7 bar).

WARNING

Before operating this system, you must read the Safety section thoroughly! Turn main disconnectswitch to the HT2000 power supply OFF before proceeding with the following steps.

ShieldSelect

S1S2

PlasmaSelect

OPERATION


Turn Power Supply On and Adjust Voltage/Current

8. Turn main disconnect switch ON.

9. Turn on the power supply by depressing the POWER ON (I) button (PB1) on the HT2000 power supply.Ensure that the green POWER ON indicator lights. If the POWER ON light fails to come on, see Section 3 forproper setup.

10. Set the voltage and current. Select the arc current and arc voltage from the Cut Charts for the type andthickness of metal to be cut.

Adjust Preflow Gases

11. Set S2 on the gas panel to TEST PREFLOW. Verify the plasmagas pressure reading on the plasma pressure gauges (PG1,PG2). Refer to the Cut Charts for the proper pressure setting.

12. Look at the oxygen (FM2) and/or nitrogen/air/argon-hydrogen(FM1) flowmeters on the gas panel and adjust the preflow plasmagas flow rate % by referring to the Cut Charts and turning theoxygen (MV3) and/or nitrogen/air/argon-hydrogen (MV2) preflowrate adjust metering valves.

13. Look at the shield gas pressure gauge (PG3) on the gas panel,and set to the Cut Chart specifications by turning the shield gasadjust metering valve (MV4).

Note: If the power supply has been off for more than 1 hour, or if you have changed consumable parts orhave changed gases, purge gas lines by leavingsystem in TEST PREFLOW for 1 minute.

Adjust Cut Flow Gases and Prepare for Cutting

14. Set S2 on the gas panel to TEST CUT FLOW.

15. Look at the oxygen (FM2) and/or nitrogen/air/argon-hydrogen(FM1) flowmeters on the gas panel and set the CUT FLOWplasma gas flow rate % by referring to the Cut Charts and togglingthe CUT FLOW RATE switch (S3) up or down.

Note: If the power supply has been off for more than 1 hour, or if you have changed consumable parts orhave changed gases, purge gas lines by leavingsystem in TEST PREFLOW for 1 minute.

16. Set S2 to RUN after the test preflow and test operate flow rateshave been set.

The system is now ready for operation.

PG1 PG2

MV2 MV3

PG3 MV4

FM1 FM2

S2

S2

S3

FM1 FM2

OPERATION


Common Cutting Faults• Torch pilot arc will initiate, but will not transfer. Causes can be:

1. Work cable connection on cutting table not making good contact.2. Torch too far from workpiece (check Cut Chart information).

• The workpiece is not totally penetrated, and there is excessive sparking on top of the workpiece. Causescan be:1. Current is set too low (check Cut Chart information).2. Cut speed is too high (check Cut Chart information).3. Torch parts are worn (see Changing Consumable Parts).4. Metal being cut is too thick.

• Dross forms on the bottom of the cut. Causes can be:1. Cutting speed is too slow or too fast (check Cut Chart information).2. Arc current set too low (check Cut Chart information).3. Torch parts are worn (see Changing Consumable Parts).

• Cut angle not square. Causes can be:1. Wrong direction of machine travel. High quality side is on the right with respect to the forward motion of

the torch.2. Torch-to-work distance is not correct (check Cut Chart information).3. Cutting speed is not correct (check Cut Chart information).4. Arc current is not correct (check Cut Chart information).5. Damaged consumable parts (see Changing Consumable Parts ).

• Short consumable life. Causes can be:1. Arc current, arc voltage, travel speed, motion delay, gas flow rates, or initial torch height not set as

specified in Cut Charts.2. Attempting to cut highly magnetic metal plate (some metals such as armor plate with a high nickel

content) will shorten consumable life. Long consumable life is difficult to achieve when cutting plate thatis magnetized or becomes magnetized easily.

3. Not beginning or ending the cut on the plate surface. To achieve consumable long life, all cuts mustbegin and end on the plate surface.

Technical Questions

If your system does not function correctly:

1. Recheck all pre-installation and installation requirements and connections.2. If you are unable to solve the problem, call your distributor. He will be able to help you, or refer you to an

authorized Hypertherm repair facility.3. If you need assistance, call Hypertherm's Technical Service department listed in the front of this manual.

Cut Charts

The Cut Charts on the following pages provide the necessary information for the operator using the HT2000 Titansystem to be successful in plasma arc cutting. The HT2000 provides a wide travel speed operating window: usually± 10 ipm (± 254 mm/min) on most materials. The data listed in the charts are for making drop cuts with minimaldross.

Caution: Before cutting, check all settings and adjustments and check for damaged torchparts and worn consumable parts.

Conversions1 inch = 25.4 mm; 1 scfh = 28.316 liter/hour; 1 psi = .0689 bar = 6.895 KPa

OPERATION

4-6 HT2000 with Titan Instruction Manual2

CUT CHART AND CONSUMABLE PARTS INDEXPlasma Gas/ Retaining Swirl

Metal Amps Shield Gas Shield Cap Nozzle Ring Electrode Page

MildSteel

MildSteel

MildSteel

StainlessSteel

StainlessSteel

Aluminum

Aluminum

200 Air / Air 020424 120837 020608 020679 120667 4-7200 O2 / Air 020424 120837 020605 120833 120667 4-8200 N2 / CO2 020424 120837 020608 020607 020415 4-9100 Air / Air 020448 120837 020611 020607 120547 4-10100 O2 / Air 020424 120837 020690 020613 120547 4-1150 O2 / O2 120186 120185 120182 120179 120178 4-12

200 Air / Air 020424 120837 020608 020679 120667 4-13200 N2 / Air 020424 120837 020608 020607 020415 4-14200 N2 / CO2 020424 120837 020608 020607 020415 4-15200 H35 / N2* 020602 120837 020608 020607 020415 4-16100 Air / Air 020448 120837 020611 020607 120547 4-17100 H35 / N2* 020448 120837 020611 020607 020415 4-1840 Air / Air 020688 020423 020689 020613 120667 4-19

200 Air / Air 020424 120837 020608 020679 120667 4-20200 N2 / Air 020424 120837 020608 020607 020415 4-21200 N2 / CO2 020424 120837 020608 020607 020415 4-22200 H35 / N2* 020602 120837 020608 020607 020415 4-23100 Air / Air 020448 120837 020611 020607 120547 4-24100 H35 / N2* 020448 120837 020611 020607 020415 4-2540 Air / Air 020688 020423 020689 020613 120667 4-26

200 O2/Air 120260 120837 120259 120833 120258 4-27

200 Air / Air 020485 120837 020615 020607 120667 4-28

200 H35 / N2* 020485 120837 020615 020607 020415 4-28

200 H35 / N2* 020485 120837 020615 020607 020415 4-28

BEVELCUTTING

200 Air / Air 020566 120837 020608 020679 120667100 Air / Air 020618 120837 020611 020607 120547

200 O2 / Air 020566 120837 020605 120833 120667100 O2 / Air 020566 120837 020690 020613 120547

200 N2 / CO2 020566 120837 020608 020607 020415

200 N2 / Air 020566 120837 020608 020607 020415

Consumablesused withHT2000

Water Muffler*

** Do not use the water muffler when cutting with argon-hydrogen (H35)!

Note: If using the Command THC or other ohmic contact sensing device, use retaining caps with an IHS tab: 120837 clockwise;120838 counterclockwise for all cutting currents except 50A; 120185 for 50A cutting only.

OPERATION


Shield Arc Approx.Material Plasma Gas Flow Rate % Gas (Air) Torch-to-work Initial Torch Voltage Motion

Thickness Preflow Cutflow Pressure Distance Piercing Height Setting Travel Speed Delay Time(inches) (mm) (Air %) (Air %) (psi) (inches) (mm) (inches) (mm) (volts) (ipm) (mm/min.) (sec)



3/16 5 54 65 60 1/8 3 1/4 6 130 200 50801/4 6 (62.3 (75.0 (270 1/8 3 1/4 6 130 135 3400 0.5

.315 8 SCFH) SCFH) SCFH) 1/8 3 1/4 6 135 115 2900 0.53/8 10 1/8 3 1/4 6 135 100 2540 1.01/2 12 .157 4 .314 8 140 80 2030 2.05/8 15 .157 4 .314 8 145 60 1520 2.03/4 20 3/16 5 3/8 10 150 45 1140 2.57/8 22 1/4 6 1/2 12 155 30 760 2.5

1 25 1/4 6 1/2 12 160 25 635 2.51-1/4 32 1/4 6 165 15 3801-1/2 38 1/4 6 170 10 2501-3/4 44 5/16 8 180 7 180

2 50 5/16 8 185 5 130

Mild Steel200 amps • Air Plasma / Air Shield

This gas combination gives good cut speed, low dross levels and is very economical. Some surface nitriding canoccur.

Notes: Set plasma gas inlet pressure to 90 psi (6.2 bar)Set shield gas inlet pressure to 90 psi (6.2 bar)Production cutting above 1" (25 mm) not recommendedDrop cutting above 1-1/2" (38 mm) not recommended

Above Water

1/4 6 54 65 70 1/8 3 1/4 6 130 130 3300 0.5.315 8 (62.3 (75.0 (280 1/8 3 1/4 6 135 110 2700 0.53/8 10 SCFH) SCFH) SCFH) 1/8 3 1/4 6 135 95 2400 1.01/2 12 1/8 3 1/4 6 140 75 1900 2.05/8 15 .157 4 .314 8 145 50 1200 2.03/4 20 3/16 5 3/8 10 150 35 850 2.57/8 22 1/4 6 1/2 12 155 20 530 3.0

1 25 1/4 6 1/2 12 165 15 400 3.0

3" Under Water

020424Shield

120837Retaining cap

020608Nozzle

020679Swirl ring

120667Electrode

OPERATION



Thickness Preflow Cutflow Pressure Distance Piercing Height Setting Travel Speed Delay Time(inches) (mm) (O2 % N2 %) (O2 % N2 %) (psi) (inches) (mm) (inches) (mm) (volts) (ipm) (mm/min.) (sec)



1/4 6 12 38 64 0 60 1/8 3 1/4 6 120 160 4060 0.5.315 8 (14.9 / 50.4 (79.6 / 0 (270 1/8 3 1/4 6 125 120 3000 0.53/8 10 SCFH) SCFH) SCFH) 1/8 3 1/4 6 125 100 2540 1.01/2 12 .157 4 .314 8 125 80 2030 2.05/8 15 .157 4 .314 8 130 70 1780 2.03/4 20 3/16 5 3/8 10 135 55 1400 2.57/8 22 1/4 6 1/2 12 135 45 1140 2.5

1 25 1/4 6 1/2 12 140 35 890 2.51 1/4 32 1/4 6 150 22 5601-1/2 38 1/4 6 155 15 3801-3/4 44 5/16 8 165 10 250

2 50 5/16 8 170 7 180

Mild Steel200 amps • O2 Plasma / Air Shield

This gas combination gives superior cut speed, minimum dross, minimum surface nitriding and excellentweldability.

Notes: Set oxygen plasma gas inlet pressure to 120 psi (8.3 bar). Set nitrogen plasma gas inlet pressure to 120 psi (8.3 bar)Set shield gas inlet pressure to 90 psi (6.2 bar)Production cutting above 1" (25 mm) not recommended. Drop cutting above 1-1/2" (38 mm) not recommended* Use 020679 swirl ring in place of 120833 swirl ring to obtain smoother cut edges on material

1/4" to 3/8" thick, but expect a 30-40% decrease in electrode life+ SilverPlus provides increased life to high duty cycle users in most applications. The hafnium wears to

approximately twice the depth of an all copper electrode (120667). Arc voltage may need to be increased by 5-10 volts throughout the electrode life to maintain proper cut height parameters.

Above Water

1/4 6 12 38 64 0 70 1/8 3 1/4 6 125 145 3700 0.5.315 8 (14.9 / 50.4 (79.6 / 0 (270 1/8 3 1/4 6 125 110 2800 0.53/8 10 SCFH) SCFH) SCFH) 1/8 3 1/4 6 130 80 2000 1.01/2 12 1/8 3 1/4 6 130 70 1800 2.05/8 15 .157 4 .314 8 135 60 1500 2.03/4 20 3/16 5 3/8 10 140 48 1200 2.57/8 22 1/4 6 1/2 12 140 38 950 3.0

1 25 1/4 6 1/2 12 145 25 680 3.0

3" Under Water

120833* (cw)120834 (ccw)Swirl ring

120667 (standard)Electrode 220084 (optional)SilverPlus electrode+

020605Nozzle

120837 (cw)120838 (ccw)Retaining cap

020424Shield

OPERATION


Shield Arc Approx.Material Plasma Gas Flow Rate % Gas (CO2) Torch-to-work Initial Torch Voltage Motion

Thickness Preflow Cutflow Pressure Distance Piercing Height Setting Travel Speed Delay Time(inches) (mm) (N2 %) (N2 %) (psi) (inches) (mm) (inches) (mm) (volts) (ipm) (mm/min.) (sec)

3/16 5 50 60 60 1/8 3 1/4 6 120 130 3300 0.51/4 6 (62.3 (75.0 (270 1/8 3 1/4 6 125 110 2800 1.03/8 10 (SCFH) SCFH) SCFH) 1/8 3 1/4 6 130 85 2160 1.51/2 12 1/8 3 1/4 6 130 55 1400 2.05/8 15 .157 4 .314 8 135 45 1140 2.03/4 20 3/16 5 3/8 10 145 25 635 2.57/8 22 1/4 6 1/2 12 150 20 510 3.0

1 25 1/4 6 1/2 12 160 15 380 3.01-1/4 32 1/4 6 165 10 2501-1/2 38 1/4 6 175 5 130

Mild Steel200 amps • N2 Plasma / CO2 Shield

This gas combination may be used when cut edge quality and surface nitriding are less important. Electrode life isextended when using this combination.

Notes: Set plasma gas inlet pressure to 120 psi (8.3 bar)Set shield gas inlet pressure to 90 psi (6.2 bar)Production cutting above 1" (25 mm) not recommended

Above Water Only

020424Shield

120837Retaining cap

020608Nozzle

020607Swirl ring

020415Electrode

OPERATION






.075* 2 48 39 60 3/32 2.5 3/16 5 120 235 60501/8 3 (55.3 (44.9 (270 3/32 2.5 3/16 5 125 185 4700 0.5

3/16 5 SCFH) SCFH) SCFH) 1/8 3 1/4 6 125 175 4450 0.51/4 6 1/8 3 1/4 6 130 125 3175 0.53/8 10 1/8 3 1/4 6 135 50 1270 1.01/2 12 1/8 3 140 35 8905/8 15 .157 4 145 25 6353/4 20 3/16 5 150 20 510

Mild Steel100* amps • Air Plasma / Air Shield

This gas combination gives good cut speed, low dross levels and is very economical. Some surface nitriding canoccur. While this process may be used on thicker materials, optimal recommended range is to 3/8" (10mm).

* Set arc current to 80 amps when cutting .075" (2 mm) thick mild steel

Notes: Set plasma gas inlet pressure to 90 psi (6.2 bar)Set shield gas inlet pressure to 90 psi (6.2 bar)Production cutting above 3/8" (10 mm) not recommended

Above Water

1/8 3 48 39 70 5/64 2 5/32 4 130 120 30503/16 5 (55.3 (44.9 (270 1/8 3 1/4 6 135 90 2300 0.51/4 6 SCFH) SCFH) SCFH) 1/8 3 1/4 6 140 70 1730 0.53/8 10 1/8 3 1/4 6 145 42 1050 0.51/2 12 1/8 145 28 700

3" Under Water

020448Shield

120837Retaining cap

020611Nozzle

020607Swirl ring

120547Electrode

OPERATION






1/8 3 7 28 36 0 60 3/32 2.5 3/16 5 125 240 61003/16 5 (9 / 37 (45 / 0 (270 1/8 3 1/4 6 125 180 45701/4 6 SCFH) SCFH) SCFH) 1/8 3 1/4 6 125 120 3050 0.53/8 10 1/8 3 1/4 6 130 90 2280 0.51/2 12 1/8 3 130 60 15205/8 15 .157 4 140 45 11403/4 20 3/16 5 145 30 760

Mild Steel100 amps • O2 Plasma / Air Shield

This gas combination gives good cut speed, low dross and is very economical. Some surface nitriding can occur.While this process may be used on thicker materials, optimal recommended range is to 3/8" (10mm).

Notes: Set oxygen plasma gas inlet pressure to 120 psi (8.3 bar)Set nitrogen plasma gas inlet pressure to 120 psi (8.3 bar)Set shield gas inlet pressure to 90 psi (6.2 bar)Production cutting above 3/8" (10 mm) not recommended* To maximize consumable life, modify the part lead-in and lead-out to reduce ramp-down errors.

For strip cutting or other applications where proper ramp-down is difficult to achieve, use electrode P/N 120667 inplace of electrode P/N120547.

Above Water

1/8 3 7 28 36 0 60 5/64 2 5/32 4 125 220 55803/16 5 (9 / 37 (45 / 0 (270 1/8 3 1/4 6 125 160 4060 0.51/4 6 SCFH) SCFH) SCFH) 1/8 3 1/4 6 125 110 2790 0.53/8 10 1/8 3 1/4 6 130 85 2160 0.51/2 12 1/8 3 135 60 1520

3" Under Water

020613 (cw)120252 (ccw)Swirl ring

120547*Electrode

020690Nozzle

120837 (cw)120838 (ccw)Retaining cap

020424Shield

OPERATION


Shield Arc Approx.Material Plasma Gas Flow Rate % Gas (O2) Torch-to-work Initial Torch Voltage Motion


.048 (18 GA.) 3 27 30 0 18 .060 1.50 .120 3.0 108 160 4060 0

.074 (14 GA.) 2 / 17 18 / 0 17 .060 1.50 .120 3.0 108 120 3050 0.3

.100 (12 GA.) l/min l/min l/min .070 1.75 .140 3.5 113 100 2540 0.3

.125 (10 GA.) .080 2.00 .160 4.0 118 60 1520 0.5

Mild Steel50 amps • O2 Plasma / O2 Shield

Notes: Set oxygen plasma gas inlet pressure to 120 psi (8.3 bar)Set nitrogen plasma gas inlet pressure to 120 psi (8.3 bar)Set shield gas inlet pressure to 120 psi (8.3 bar)The oxygen shield gas must be supplied from a regulator separate from the oxygen plasma gas regulator.If using the Digital Remote (DR) or Programmable Remote (PR), set current to 60 amps.If using a torch height control system capable of achieving the arc voltage setting on this chart, set accordingly.If using a less sensitive torch height control system, round off the arc voltage numbers to the nearest achievablesetting.Torch-to-work Distance tolerances are ± .010 inch (± .25 mm). When using a THC the tolerances are ± 1 volt.Stay within travel speed ranges to produce dross-free cuts.Due to the low gas flow rates associated with the 50 amp process, initial cut quality may be degraded while nitrogen isbeing purged from the gas line when changing from preflow to cut flow (up to 2 seconds). To compensate, eitherincrease machine motion delay or increase the lead-in distance at the start of the cut.Note that some height control systems may need to be locked out to prevent the torch from diving into the plate if themachine motion delay option is used.

Above Water Only

120185Retaining cap

120186Shield

120182Nozzle

120179Swirl ring

120178Electrode

OPERATION






3/16 5 54 65 60 1/8 3 1/4 5 125 220 56001/4 6 (62.3 (75.0 (270 1/8 3 1/4 6 130 195 5000 0.53/8 10 SCFH) SCFH) SCFH) 1/8 3 1/4 6 130 145 3700 1.01/2 12 1/8 3 1/4 6 135 105 2700 2.05/8 15 .157 4 .314 8 140 75 1900 2.03/4 20 3/16 5 3/8 10 140 55 1400 2.57/8 22 1/4 6 1/2 12 145 40 1000 3.0

1 25 1/4 6 150 30 7601-1/4 32 ` 1/4 6 160 15 3801-1/2 38 1/4 6 170 10 250

Stainless Steel200 amps • Air Plasma / Air Shield

This gas combination gives good cut speed, low dross and is very economical. Some surface nitriding and surfaceoxidation of alloying elements can occur.

Notes: Set air plasma gas inlet pressure to 90 psi (6.2 bar)Set air shield gas inlet pressure to 90 psi (6.2 bar)Production cutting above 7/8" (22 mm) not recommended

Above Water

3/16 5 54 65 70 1/8 3 1/4 6 125 210 53201/4 6 (62.3 (75.0 (280 1/8 3 1/4 6 130 180 4500 0.53/8 10 SCFH) SCFH) SCFH) 1/8 3 1/4 6 135 125 3150 1.01/2 12 1/8 3 1/4 6 140 90 2300 2.05/8 15 .157 4 .314 8 145 60 1520 2.03/4 20 3/16 5 3/8 10 145 45 1150 2.57/8 22 1/4 6 1/2 12 150 30 750 3.0

1 25 1/4 6 155 22 570

3" Under Water

020424Shield

120837Retaining cap

020608Nozzle

020679Swirl ring

120667Electrode

OPERATION






3/16 5 50 60 60 1/8 3 1/4 5 125 135 34301/4 6 (66.4 (79.6 (270 1/8 3 1/4 6 130 120 3050 0.53/8 10 SCFH) SCFH) SCFH) 1/8 3 1/4 6 130 100 2540 1.01/2 12 1/8 3 1/4 6 135 75 1900 2.05/8 15 .157 4 .314 8 140 60 1520 2.03/4 20 3/16 5 3/8 10 140 45 1140 2.57/8 22 1/4 6 1/2 12 145 35 890 2.5

1 25 1/4 6 150 20 5101-1/4 32 ` 1/4 6 160 15 3801-1/2 38 1/4 6 160 10 250

Stainless Steel200 amps • N2 Plasma / Air Shield

This gas combination is used when cut edge quality, surface nitriding and surface oxidation of alloying elementsare less important. Electrode life is extended when this combination is used.

Notes: Set nitrogen plasma gas inlet pressure to 120 psi (8.3 bar)Set air shield gas inlet pressure to 90 psi (6.2 bar)Production cutting above 7/8" (22 mm) not recommended

Above Water

3/16 5 50 60 70 1/8 3 1/4 6 125 130 32501/4 6 (66.4 (79.6 (280 1/8 3 1/4 6 130 110 2750 0.53/8 10 SCFH) SCFH) SCFH) 1/8 3 1/4 6 135 85 2160 1.01/2 12 1/8 3 1/4 6 140 60 1520 2.05/8 15 .157 4 .314 8 145 45 1140 2.03/4 20 3/16 5 3/8 10 145 30 800 2.5

3" Under Water

020424Shield

120837Retaining cap

020608Nozzle

020607Swirl ring

020415Electrode

OPERATION






3/16 5 50 60 60 1/8 3 1/4 6 125 190 4800 0.51/4 6 (66.4 (79.6 (210 1/8 3 1/4 6 130 170 4300 1.03/8 10 SCFH) SCFH) SCFH) 1/8 3 1/4 6 130 125 3200 1.51/2 12 1/8 3 1/4 6 135 95 2400 2.05/8 15 .157 4 .314 8 140 70 1800 2.03/4 20 3/16 5 3/8 10 140 50 1250 2.57/8 22 1/4 6 1/2 12 145 40 1000 3.0

1 25 1/4 6 150 30 7601-1/4 32 ` 1/4 6 160 15 3801-1/2 38 1/4 6 170 10 250

Stainless Steel200 amps • N2 Plasma / CO2 Shield

This gas combination is used when surface nitriding and surface oxidation of alloying elements is less important.Electrode life is extended when using this gas combination.

Notes: Set nitrogen plasma gas inlet pressure to 120 psi (8.3 bar)Set carbon dioxide shield gas inlet pressure to 90 psi (6.2 bar)Production cutting above 7/8" (22 mm) not recommended

Above Water

3/16 5 50 60 60 1/8 3 1/4 6 125 180 4550 0.51/4 6 (66.4 (79.6 (210 1/8 3 1/4 6 130 150 3850 1.03/8 10 SCFH) SCFH) SCFH) 1/8 3 1/4 6 135 110 2700 1.51/2 12 1/8 3 1/4 6 140 75 1920 2.05/8 15 .157 4 .314 8 145 50 1350 2.03/4 20 3/16 5 3/8 10 145 38 950 2.57/8 22 1/4 6 1/2 12 150 28 700 3.0

3" Under Water

020424Shield

120837Retaining cap

020608Nozzle

020607Swirl ring

020415Electrode

OPERATION


Shield Arc Approx.Material Plasma Gas Flow Rate % Gas (N2) Torch-to-work Initial Torch Voltage Motion

Thickness Preflow Cutflow Pressure Distance Piercing Height Setting Travel Speed Delay Time(inches) (mm) (H35 %) (H35 %) (psi) (inches) (mm) (inches) (mm) (volts) (ipm) (mm/min.) (sec)

1/4 6 25 25 60 3/16 5 3/8 10 135 62 1600 1.03/8 10 (89.9 (89.9 (275 3/16 5 3/8 10 140 52 1300 1.01/2 12 SCFH) SCFH) SCFH) 3/16 5 3/8 10 140 42 1100 2.05/8 15 S 1/4 6 1/2 12 145 37 940 2.03/4 20 1/4 6 1/2 12 150 32 810 2.57/8 22 5/16 8 5/8 16 155 27 690 2.5

1 25 5/16 8 155 22 5601-1/4 32 ` 5/16 8 165 16 4001-1/2 38 5/16 8 170 11 2801-3/4 44 5/16 8 180 8 200

2 50 5/16 8 185 6 150

Stainless Steel200 amps • H35 Plasma / N2 Shield

This gas combination (Hypertherm recommends a mixture of 35% hydrogen and 65% argon for the plasma gas)gives maximum thickness cutting capability, minimum dross levels, minimum amount of surface contamination,excellent weldability and excellent cut quality on thicknesses greater than 1/2". On thicknesses less than 1/2",excessive dross levels may be experienced. Electrode life is extended when this combination is used.

Notes: Set argon-hydrogen plasma gas inlet pressure to 120 psi (8.3 bar)Set nitrogen shield gas inlet pressure to 90 psi (6.2 bar)Drop cutting above 1-1/2" (38 mm) not recommended.Production cutting above 7/8" (22 mm) not recommended

Above Water Only

WARNING

Do not use water mufflerwhen cutting with argon-hydrogen

020602Shield

120837Retaining cap

020608Nozzle

020607Swirl ring

020415Electrode

OPERATION






1/8 3 48 39 60 3/32 2.5 3/16 5 125 140 35603/16 5 (53.3 (44.9 (270 1/8 3 1/4 6 130 110 2800 0.51/4 6 SCFH) SCFH) SCFH) 1/8 3 1/4 6 130 80 2030 0.53/8 10 1/8 3 1/4 6 135 55 1400 0.51/2 12 1/8 3 140 35 8905/8 15 .157 4 145 25 6353/4 20 3/16 5 150 20 510


This gas combination gives good cut speed, low dross and is very economical. Some surface nitriding and surfaceoxidation of alloying elements can occur.


Above Water

1/8 3 48 39 60 5/64 2 5/32 4 125 135 34003/16 5 (53.3 (44.9 (270 1/8 3 1/4 6 130 100 2520 0.51/4 6 SCFH) SCFH) SCFH) 1/8 3 1/4 6 135 65 1720 0.53/8 10 1/8 3 1/4 6 140 45 1120 0.51/2 12 1/8 3 145 25 670

3" Under Water

020448Shield

120837Retaining cap

020611Nozzle

020607Swirl ring

120547Electrode

OPERATION




1/8 3 13 13 60 3/32 2.5 3/16 5 130 50 12603/16 5 (46.7 (46.7 (270 1/8 3 1/4 6 135 40 1060 0.51/4 6 SCFH) SCFH) SCFH) 3/16 5 3/8 10 140 35 890 0.53/8 10 3/16 5 3/8 10 140 30 750 0.51/2 12 3/16 5 3/8 10 145 25 630 1.0

Stainless Steel100 amps • H35 Plasma / N2 Shield

This gas combination (Hypertherm recommends a mixture of 35% hydrogen and 65% argon for the plasma gas)gives good cut speed, but may result in excessive dross. Some surface nitriding and surface oxidation of alloyingelements can occur.

Notes: Set argon-hydrogen plasma gas inlet pressure to 120 psi (8.3 bar)Set nitrogen shield gas inlet pressure to 90 psi (6.2 bar)Production cutting above 3/8" (10 mm) not recommended

Above Water Only

020448Shield

120837Retaining cap

020611Nozzle

020607Swirl ring

020415Electrode

WARNING


OPERATION




.050 (18 GA.) 40 20 60 3/32 2.5 3/16 5 120 145 37001/16 1.5 (46.0 (23.1 (275 3/32 2.5 3/16 5 120 120 30501/8 3 SCFH) SCFH) SCFH) 3/32 2.5 3/16 5 125 75 1900 0.51/4 6 1/8 3 135 24 6103/8 10 1/8 3 140 12 300


This gas combination gives good cut speed, low dross level and is very economical. Some surface nitriding andsurface oxidation of alloying elements can occur.


Above Water Only

020688Shield

020423Retaining cap

020689Nozzle

020613Swirl ring

120667Electrode

OPERATION






3/16 5 54 65 60 1/8 3 1/4 6 130 220 5600 0.51/4 6 (62.3 (75.0 (270 1/8 3 1/4 6 140 190 4800 1.03/8 10 SCFH) SCFH) SCFH) 1/8 3 1/4 6 140 145 3700 2.01/2 12 1/8 3 1/4 6 145 110 2800 2.55/8 15 .157 4 .314 8 150 85 2200 2.53/4 20 3/16 5 3/8 10 155 65 1650 2.57/8 22 1/4 6 1/2 12 160 50 1300 2.5

1 25 1/4 6 165 35 9001-1/4 32 ` 1/4 6 170 20 5001-1/2 38 1/4 6 175 12 300

Aluminum200 amps • Air Plasma / Air Shield

This gas combination gives good cut speed, low dross levels and is very economical.


Above Water

3/16 5 54 65 70 1/8 3 1/4 6 135 210 5300 0.51/4 6 (62.3 (75.0 (280 1/8 3 1/4 6 140 170 4300 1.03/8 10 SCFH) SCFH) SCFH) 1/8 3 1/4 6 145 125 3150 2.01/2 12 1/8 3 1/4 6 150 90 2240 2.55/8 15 .157 4 .314 8 155 65 1650 3.03/4 20 3/16 5 3/8 10 160 45 1150 3.0

3" Under Water

020424Shield

120837Retaining cap

020608Nozzle

020679Swirl ring

120667Electrode

OPERATION






3/16 5 50 60 60 1/8 3 1/4 6 130 180 4570 0.51/4 6 (66.4 (79.6 (270 1/8 3 1/4 6 135 160 4060 1.03/8 10 SCFH) SCFH) SCFH) 1/8 3 1/4 6 135 120 3050 1.51/2 12 1/8 3 1/4 6 140 80 2030 2.05/8 15 .157 4 .314 8 140 70 1780 2.03/4 20 3/16 5 3/8 10 150 50 1270 2.57/8 22 1/4 6 1/2 12 160 35 890 2.5

1 25 1/4 6 165 25 6351-1/4 32 ` 1/4 6 175 20 5101-1/2 38 1/4 6 185 10 250

Aluminum200 amps • N2 Plasma / Air Shield

This gas combination is used when cut edge quality is less important. Electrode life is extended when thiscombination is used.


Above Water

3/16 5 50 60 70 1/8 3 1/4 6 135 170 4350 0.51/4 6 (66.4 (79.6 (280 1/8 3 1/4 6 140 140 3650 1.03/8 10 SCFH) SCFH) SCFH) 1/8 3 1/4 6 140 100 2600 1.51/2 12 1/8 3 1/4 6 145 65 1620 2.05/8 15 .157 4 .314 8 145 55 1350 2.53/4 20 3/16 5 3/8 10 155 35 890 3.07/8 22 1/4 6 1/2 12 165 25 620 3.0

3" Under Water

020424Shield

120837Retaining cap

020608Nozzle

020607Swirl ring

020415Electrode

OPERATION






3/16 5 50 60 60 1/8 3 1/4 6 130 185 4700 0.51/4 6 (66.4 (79.6 (210 1/8 3 1/4 6 135 160 4050 1.03/8 10 SCFH) SCFH) SCFH) 1/8 3 1/4 6 135 120 3050 2.01/2 12 1/8 3 1/4 6 140 95 2400 2.55/8 15 .157 4 .314 8 140 70 1800 2.53/4 20 3/16 5 3/8 10 150 55 1400 3.07/8 22 1/4 6 1/2 12 160 42 1050 3.0

1 25 1/4 6 165 33 8401-1/4 32 ` 1/4 6 175 20 5101-1/2 38 5/16 8 185 11 280

Aluminum200 amps • N2 Plasma / CO2 Shield

This gas combination is used when cut edge quality is less important. Electrode life is extended when thiscombination is used.


Above Water

3/16 5 50 60 60 1/8 3 1/4 6 130 175 4450 0.51/4 6 (66.4 (79.6 (220 1/8 3 1/4 6 135 145 3650 1.03/8 10 SCFH) SCFH) SCFH) 1/8 3 1/4 6 140 100 2600 2.01/2 12 1/8 3 1/4 6 145 75 1820 2.55/8 15 .157 4 .314 8 145 55 1350 2.53/4 20 3/16 5 3/8 10 155 40 980 3.07/8 22 1/4 6 1/2 12 165 30 750 3.0

3" Under Water

020424Shield

120837Retaining cap

020608Nozzle

020607Swirl ring

020415Electrode

OPERATION




3/16 5 25 25 60 3/16 5 3/8 10 130 170 4300 0.51/4 6 (89.9 (89.9 (275 3/16 5 3/8 10 130 155 4000 1.03/8 10 SCFH) SCFH) SCFH) 1/4 6 1/2 12 135 120 3000 2.01/2 12 1/4 6 1/2 12 140 100 2550 2.05/8 15 1/4 6 1/2 12 145 80 2000 2.53/4 20 5/16 8 5/8 16 150 60 1500 2.57/8 22 5/16 8 5/8 16 155 50 1250 2.5

1 25 5/16 8 155 40 10001-1/4 32 ` 5/16 8 165 26 6601-1/2 38 5/16 8 170 18 4601-3/4 44 5/16 8 180 12 300

2 50 5/16 8 185 7 180

Aluminum200 amps • H35 Plasma / N2 Shield

This gas combination (Hypertherm recommends a mixture of 35% hydrogen and 65% argon for the plasma gas)gives maximum thickness cutting capability, excellent cut quality and excellent weldability. Electrode life isextended when this combination is used.


Above Water Only

020602Shield

120837Retaining cap

020608Nozzle

020607Swirl ring

020415Electrode

WARNING


OPERATION






1/8 3 48 39 60 3/32 2.5 3/16 5 135 110 28003/16 5 (55.3 (44.9 (270 1/8 3 1/4 6 140 90 2290 0.51/4 6 SCFH) SCFH) SCFH) 1/8 3 1/4 6 145 70 1780 0.53/8 10 1/8 3 1/4 6 145 50 1270 0.51/2 12 1/8 3 150 40 10105/8 15 .157 4 155 30 7603/4 20 3/16 5 160 25 635




Above Water

1/8 3 48 39 70 5/64 2 5/32 4 135 100 26503/16 5 (55.3 (44.9 (280 1/8 3 1/4 6 140 80 2050 0.51/4 6 SCFH) SCFH) SCFH) 1/8 3 1/4 6 145 60 1510 0.53/8 10 1/8 3 1/4 6 150 40 1000 0.51/2 12 1/8 3 155 30 750

3" Under Water

020448Shield

120837Retaining cap

020611Nozzle

020607Swirl ring

120547Electrode

OPERATION




1/8 3 13 13 60 3/32 2.5 3/16 5 135 95 24403/16 5 (46.7 (46.7 (270 1/8 3 1/4 6 140 85 2200 0.51/4 6 SCFH) SCFH) SCFH) 1/8 3 1/4 6 145 80 1980 0.53/8 10 1/8 3 1/4 6 145 60 1530 0.51/2 12 1/8 3 150 50 1280

Aluminum100 amps • H35 Plasma / N2 Shield

This gas combination (Hypertherm recommends a mixture of 35% hydrogen and 65% argon for the plasma gas)gives good cut speed, low dross levels and is very economical.


Above Water Only

020448Shield

120837Retaining cap

020611Nozzle

020607Swirl ring

020415Electrode

WARNING


OPERATION




3/32 2.5 40 20 60 3/32 2.5 3/16 5 120 140 35501/8 3 (46.0 (23.1 (275 3/32 2.5 3/16 5 130 100 2550 0.51/4 6 SCFH) SCFH) SCFH) 1/8 3 140 35 9003/8 10 1/8 3 150 15 350




Above Water Only

020613Swirl ring

120667Electrode

020689Nozzle

020423Retaining cap

020688Shield

OPERATION




1/4 6 12 38 64 0 60 1/8 3 1/4 6 115 160 4060 0.5.315 8 (14.9 / 50.4 (79.6 / 0 (270 1/8 3 1/4 6 120 120 3000 0.53/8 10 SCFH) SCFH) SCFH) 1/8 3 1/4 6 120 100 2540 1.01/2 12 .157 4 .314 8 120 80 2030 2.05/8 15 .157 4 .314 8 125 70 1780 2.03/4 20 3/16 5 3/8 10 130 55 1400 2.57/8 22 1/4 6 1/2 12 135 45 1140 2.5

1 25 1/4 6 1/2 12 135 35 890 2.51 1/4 32 1/4 6 140 22 5601-1/2 38 1/4 6 150 15 3801-3/4 44 5/16 8 160 10 250

2 50 5/16 8 170 7 180

Mild Steel - Beveling Consumables200 amps • O2 Plasma / Air Shield

Notes: Set oxygen plasma gas inlet pressure to 120 psi (8.3 bar).Set nitrogen plasma gas inlet pressure to 120 psi (8.3 bar).Set shield gas inlet pressure to 90 psi (6.2 bar).Production cutting above 1" (25 mm) not recommended

Beveling cuts should be made between 45° and 90° to the work surface.

Above Water Only

120833 (cw)

120834 (ccw)

Swirl ring

120258Electrode

120257Water Tube

120259Nozzle

120837 (cw)

120838 (ccw)

Retaining cap120260Shield

OPERATION


Shield Arc Plasma Gas Shield GasPlasma Gas Flow Rate %

Gas (N2) Current (H35) Inlet (N2) InletPreflow Cut Flow Pressure Setting Pressure Pressure(H35 %) (H35 %) (psi) (amps) (psi) (psi)

Shield Arc Plasma Gas Shield GasPlasma Gas Flow Rate %

Gas (Air) Current (Air) Inlet (Air) InletPreflow Cut Flow Pressure Setting Pressure Pressure(Air %) (Air %) (psi) (amps) (psi) (psi)

71 71 50 200 90 90

(81.8 SCFH)

Mild Steel Gouging200 amps • Air Plasma / Air Shield

29 29 50 200 120 90

(81.8 SCFH)

Stainless Steel or Aluminum Gouging200 amps • H35 Plasma / N2 Shield

Hypertherm recommends a mixture of 35% hydrogen and 65% argon for the plasma gas.

020607Swirl ring

120667Electrode

020615Nozzle

120837Retaining cap

020485Shield

020607Swirl ring

020415Electrode

020615Nozzle

120837Retaining cap

020485Shield

OPERATION


Changing Consumable Parts

Check the consumable parts daily for wear before cutting. Before removing parts, bring the torch to the edge of themachine, with the lifter raised to its highest point. This prevents the danger of dropping the consumables into thewater of the water table.

Removal and Inspection – Refer to Figure 4-2

1. Remove the retaining cap and shield by unscrewing the retaining cap by hand.

2. Check the shield for external signs of wear. It should be clean and clear of metal debris. The gas holes alongthe edge of the shield should not be blocked with debris. The center hole should not have any nicks or gouges,and should show no signs of arcing activity.

3. Unscrew and remove the shield from the retaining cap. Inspect the gas holes from the inside. The holes shouldbe clear of metal or other debris. (Debris can cause arcing.)

4. Inspect the two O-rings on the torch body. They should be lubricated and undamaged. If they are dry, lubricatethem lightly with a very thin film of the lubricant provided in the spare parts kit. If they are damaged, replacethem.

5. Using the 3/4" side of the wrench supplied with the consumable parts kit, remove the nozzle. Inspect it fordamage or signs of wear. You can clean the inside of the nozzle with steel wool, but be sure to remove anyremnants of the steel wool afterward. The hole in the nozzle should not be worn or oval-shaped.

6. Using the 3/8" center hole in the wrench, remove the electrode and inspect it. If the center of the electrode has apit more than .044" (1.1 mm) deep, replace it. Use the electrode gauge assembly supplied in the spare parts kitto measure pit depth. If the electrode is still good, inspect its O-ring: it should be lubricated and undamaged. If itis dry, lubricate it lightly with a very thin film of the lubricant provided in the spare parts kit. If it is damaged,replace it.

7. Remove the swirl ring from the electrode and inspect it. It should be clean, and the holes on the top and sidesshould not be plugged. Inspect its O-ring. It should be lubricated and undamaged. If it is dry, lubricate it lightlywith a very thin film of the lubricant provided in the spare parts kit. If it is damaged, replace it.

8. Inspect the inside of the torch body by using a mirror, or by looking carefully inside. The current ring inside ofthe torch body should be clean and undamaged. Use a clean paper towel or Q-tip to remove dirt, grease, etc. Apreferred method to clean the current ring is with a clean paper towel or Q-tip dipped in water or 3% hydrogenperoxide. If the water tube is damaged at all, it may need to be replaced. See Changing the Water Tube .

WARNING

Always disconnect power to the power supply before inspecting or changing torch consumableparts.

OPERATION


Replacement

1. Before installing the electrode, be sure to lightly grease the O-ring with a small amount of silicon lubricant.Replace the electrode and tighten it with the wrench. Do not overtighten.

2. Before installing the swirl ring, be certain that the O-rings have been lubricated with a small amount of silicongrease. Install the swirl ring with the bottom O-ring facing the inside of the torch. Push it into place. Be sure tohold the swirl ring in place until the nozzle is installed to avoid dropping it into the water of the water table.

3. Install the nozzle and finger-tighten it. Finish tightening it with the wrench. Do not overtighten.

4. Screw on the shield to the retaining cap and tighten by hand. Screw on the retaining cap to the torch by hand.Make sure that it is tightened snugly; if it is loose, it can affect the shield gas flow.

Figure 4-2 Changing Consumable Parts

Shield Retaining cap Nozzle Swirl ring Electrode

Currentring Torch body (shown without off valve SA and sleeve)

Water tube

OPERATION


Changing the Water Tube

Problems and causes you may find with a defective or improperly installed water tube:

• Short electrode life: Water tube not screwed in tightly

• Flow switch interlock shutting down the system: Water flow restricted due to loose water tube.

• Humming or rattling sound coming from the torch: Water tube bent or loose

If you suspect a problem with the water tube, you may need to replace it.

1. Disconnect power supply from power source.

2. Remove all consumables from torch (see Changing Consumable Parts ).

3. Look for any damage or bends in the water tube.

4. Remove and replace the water tube by using the water tube wrench (027347) supplied by Hypertherm – Fig. 4-3. When installing water tube, do not over tighten! Snug down by hand only.

Figure 4-3 Changing the Water Tube

WARNING

Always disconnect the power supplyfrom the main power source before

inspecting or changing the torch parts.

OPERATION



Section 5

PARTS LIST

This section provides part numbers for the components in the HT2000 Titan Gas Panel, Remote HighFrequency&Motor Valve Console (also called “High Frequency Console”), and the HT2000 machine torch andconsumables for the Titan Integrated Plasma System.

• See Installation in this manual for cable and hose part numbers.

• See HT2000 Instruction manual 802070 for power supply information.

PARTS LIST


23, 24

15

Figure 5-1 HT2000 Titan Gas Panel

19

21

20

18

1716

14

13

16

22

20

18

3

12

11

109

8

76

34, 52

1

PARTS LIST


Gas Panel – 073220

PartItem Number Description Designator Qty.

1 001623 Panel:HT2000 Titan Gas Panel 12 011053 Flowmeter:0-10 SC/BP-8 Float Cal. 2% FM1 1

011058 Flowtube/BP-8 Float:0-10 SC Cal. 2%011008 Shield:Flowmeter Plastic011081 Flowmeter Float Stop

3 011053 Flowmeter:0-10 SC/BP-8 Float Cal. 2% FM2 1011058 Flowtube/BP-8 Float:0-10 SC Cal. 2%011008 Shield:Flowmeter Plastic011081 Flowmeter Float Stop

4 005149 Light bulb:120VAC LT1 15 005089 Lens:White 16 022027 Pressure Gauge:160# 1.5" PG1 17 022027 Pressure Gauge:160# 1.5" PG2 18 005180 Toggle Switch:SP3T ON/OFF/ON S2 19 005181 Toggle Switch:DPDT ON/NONE/ON S1 110 005042 Toggle Switch:SP Momentary ON/OFF/ON S3 111 004117 Cap:Needle Valve 312 022008 Pressure Gauge:100#/BAR 2.5" PG3 113 006109 Solenoid Valve:1/8FPT120V2W NC Manifold SV1B 114 006109 Solenoid Valve:1/8FPT120V2W NC Manifold SV1A 115 004718 Manifold:Motor Valve 116 005243 Pressure Switch:80 Psi 1/8 NPT PS2 117 005243 Pressure Switch:80 Psi 1/8 NPT PS1 118 006064 Meter Valve:1/8 FPT .125 Orifice MV3 119 006064 Meter Valve:1/8 FPT .125 Orifice MV2 120 006106 Solenoid Valve:1/8FPT 120V TFE Plunger SV3 121 006106 Solenoid Valve:1/8FPT 120V TFE Plunger SV2 122 006064 Meter Valve:1/8 FPT .125 Orifice MV4 1

129173 Harness:HT2000 Titan Gas Panel23 008176 Pin:24-20 AWG Type III 2124 008447 Receptacle Shell:CPC 23-37 Standard Sex 3X1 1

PARTS LIST


23

22

21

24

20

19

18

17 1415 16

12 11

101113

8

9

7

5

64 32

1

Figure 5-2 HT2000 Titan RHF&MV Console

PARTS LIST


RHF&MV Console – 073223


1 002279 Box:HT2000 Titan RHF 12 073221 High Frequency Panel Assembly 13 001626 Panel:HT2000 Titan RHF HF 14 005227 Pressure Switch:12 Psi PS3 15 006032 Solenoid Valve:150# 1/4 FPT 120V NC SV6 16 006106 Solenoid Valve:1/8FPT 120V SV7 17 006063 Motor-Valve:Electric 1/8FPT .125 Orifice MV1 18 006109 Solenoid Valve:1/8FPT120V2W NC SV4A 19 006109 Solenoid Valve:1/8FPT120V2W NC SV4B 110 029317 High Voltage Transformer SA:200/2000 T1 111 129188 HF/I0 PCB SA:HT2000 Titan RHF 112 001624 Bracket:HT2000 Titan RHF 113 004314 Block:200 Cathode 114 009350 Spark Gap Assembly:40-200/2000/HD SG1 115 004061 Electrode:Spark Gap 1/8 X 1.6 316 004140 Base:40/0/100/200/HD Spark Gap 117 004144 Bar:009350 Spark Gap Cap Mounting 118 009280 Cap:.002UF 15KV C3,C4 219 109074 Coil Assembly:HT2000 Titan High Freq. T2 120 041312 PCB Assembly:2000 I/O 121 129189 Panel SA:HT2000 Titan RHF 122 001625 Panel:HT2000 Titan RHF Side 123 129192 Harness:HT2000 Titan RHF 4X1,4X2,2X1 124 005100 Switch:Door Interlock S1 1

PARTS LIST


14 (Only used with the128383 torch)

13

3b

2

3a

3

5

6

4

1

10

10 12

7

11

9

8

Figure 5-3 HT2000 Torch Assembly with Valve, 25' (7.6 m) Leads and 2" (50 mm) Diameter Sleeve

PARTS LIST


HT2000 Standard Machine Torch Assembly with Valve, 2" (50 mm) Dia. TorchSleeve, and 25' (7.6 m) Leads – 128383


128383 HT2000 Standard Torch Assy w/Valve and 25' Leads1 120837 Nozzle Retaining Cap, with IHS tab 12 020424 Shield, MAX200/HT2000 200A 13 120584 HT2000 Torch Main Body 13a 020963 Water Tube:PAC200T/2000 Electd Cool 13b 044027 O-Ring:Buna 70Duro 1.301X.070 24 020605 Nozzle, MAX200 200A .082 O2 15 120667 Electrode: HT2000 200A O2, LL 16 120833 Swirl Ring: HT2000 O2 1

129470 Off-Valve SA: HT2000 Mch Tch 17 006100 Solenoid Valve:150# 1/8 FPT SV5 18 020041 Tch Mtg Sleeve:2" 19 120832 Bracket:2" Dia Torch Off-Valve II 110 024355 Hose Assy:3/16Blu LH'A' 1' 1 ft11 123293 Cable, Torch Off-Valve 4X2 112 024283 Hose SA, 3/16 Blu LH 'A' 113 028994 Leads:HT2000 Torch Power with sleeve 25' 114 020407 Adapter:1-3/4"-2" Torch Mounting Sleeve 1

HT2000 Stainless Steel Machine Torch Assembly with Valve, 2" (50 mm) Dia.Torch sleeve, and 25' (7.6 m) Leads – 128368


128368 HT2000 Stainless Steel Torch Assy w/Valve and 25' Leads1 120837 Nozzle Retaining Cap, with IHS tab 12 020424 Shield, MAX200/HT2000 200A 13 120356 HT2000 SS Torch Main Body 13a 020963 Water Tube:PAC200T/2000 Electd Cool 13b 044027 O-Ring:Buna 70Duro 1.301X.070 24 020605 Nozzle, MAX200 200A .082 O2 15 120667 Electrode: HT2000 200A O2, LL 16 120833 Swirl Ring: HT2000 O2 1

129470 Off-Valve SA: HT2000 Mch Tch 17 006100 Solenoid Valve:150# 1/8 FPT SV5 18 020041 Tch Mtg Sleeve:2" 19 120832 Bracket:2" Dia Torch Off-Valve II 110 024355 Hose Assy:3/16Blu LH'A' 1' 1 ft11 123293 Cable, Torch Off-Valve 4X2 112 024283 Hose SA, 3/16 Blu LH 'A' 113 028994 Leads:HT2000 Torch Power with sleeve 25' 1

Torch Mounting Bracket for 2" (50 mm) Dia. sleeve – 020046

PARTS LIST


13

3b

2

3a

3

5

6

4

1

10

10 12

7

11

9

8

Figure 5-4 HT2000 Torch Assembly with Valve, 25' (7.6 m) Leads and 1-3/4" (44 mm) Diameter Sleeve

PARTS LIST


HT2000 Optional Machine Torch Assembly with Valve, 1-3/4" (44 mm) Dia.Torch sleeve, and 25' (7.6 m) Leads – 128200


128200 HT2000 Optional Machine Torch Assy w/Valve and 25' Leads1 120837 Nozzle Retaining Cap, with IHS tab 12 020424 Shield, MAX200/HT2000 200A 13 120584 HT2000 Torch Main Body 13a 020963 Water Tube:PAC200T/2000 Electd Cool 13b 044027 O-Ring:Buna 70Duro 1.301X.070 24 020605 Nozzle, MAX200 200A .082 O2 15 120667 Electrode: HT2000 200A O2, LL 16 120833 Swirl Ring: HT2000 O2 1

129168 Off-Valve SA: HT2000 Mch Tch 17 006100 Solenoid Valve:150# 1/8 FPT SV5 18 020431 Tch Mtg Sleeve:1-3/4" GNRC 19 120492 Bracket:1-3/4" Dia Torch Off-Valve II 110 024355 Hose Assy:3/16Blu LH'A' 1' 1 ft11 123293 Cable, Torch Off-Valve 4X2 112 024283 Hose SA, 3/16 Blu LH 'A' 113 028994 Leads:HT2000 Torch Power with sleeve 25' 1

Torch Mounting Bracket for 1-3/4" (44 mm) Dia. sleeve – 020522

PARTS LIST


Figure 5-5 Consumable Parts

7

4

3 5

6

8

1 2

Consumable Parts Kit – 028602

PartItem Number Description Qty.

028602 Kit: HT2000 Spare Parts001067 Box: Gray Plastic 1

1 020424 Shield, 200A 11 020448 Shield, 100A 12 120837 Nozzle Retaining Cap, with IHS tab 13 020605 Nozzle, 200A .082 O2 53 020690 Nozzle, 100A .055 O2 34 020608 Nozzle, 200A .086 Air/N2/H35 54 020611 Nozzle, 100A .059 Air 35 120833 Swirl Ring: HT2000 O2 16 020607 Swirl Ring, Air/N2/H35 16 020613 Swirl Ring, Air 16 020679 Swirl Ring, Air/N2 17 120667 Electrode:HT2000 200A Oxy, LL 57 020415 Electrode, N2/H35 57 120547 Electrode, HT2000 100A Hylife 38 020963 Water Tube:PAC200T/2000 Electd Cool 1

027055 Lubricant, Silicon, 1/4 Oz Tube 1027194 Wrench, Nozzle, 3/4" 1027524 Wrench, Nozzle, 1" 1044027 O-Ring, Buna-N 2027347 Tool: Water Tube Removal 1004147 Electrode Gauge Assy 1


Section 6

WIRING DIAGRAMS

Introduction

This section contains the wiring diagrams for the HT2000 with Titan system. When tracing a signal path or referencing with the Parts List or Troubleshooting sections, please be aware of the following format to assist youin understanding the wiring diagrams' organization:

• Sheet numbers are located in the lower right-hand corner.• Page-to-page referencing is done in the following manner:

C SHEET4-D3

CSHEET4-D3

Destination and Source Coordinates refer to letters A-D on the Y-axis of each sheet and numbers 1-4 on the X-axis of each sheet. Lining up the coordinates will bring you to the source or destination blocks (similar to a roadmap).

Wiring Diagram Symbols

Wiring diagram symbols and their identification precede the system wiring diagrams in this section.

Source Connection Source Reference Block Destination Sheet # DestinationCoordinates

Source Sheet # Source Coordinates Source Reference Block DestinationCoordinates

WIRING DIAGRAMS


Bat

tery

Cap

, po

lari

zed

Cap

, no

n-p

ola

rize

d

Cap

, fee

d-t

hru

Cir

cuit

bre

aker

Co

ax s

hie

ld

Cu

rren

t S

enso

r

Cu

rren

t se

nso

r

Dio

de

Do

or

inte

rlo

ck

Fan

Fee

dth

ru L

C

Filt

er, A

C

DC

su

pp

ly

Fu

se

Gro

un

d C

lam

p

Gro

un

d, C

has

sis

Gro

un

d, E

arth

IGB

T

Ind

uct

or

LE

D

Lig

ht

Pin

Plu

g

PN

PTr

ansi

sto

r

Po

ten

tio

met

er

Pu

sh B

utt

on

,N

orm

ally

Clo

sed

MO

V

Pu

sh B

utt

on

,N

orm

ally

Op

en

Rec

epta

cle

Rel

ay, C

oil

Rel

ay, N

orm

ally

Clo

sed

Rel

ay, N

orm

ally

Op

en

Rel

ay, S

olid

Sta

te, A

C

Rel

ay, S

olid

Sta

te, D

C

Rel

ay, S

olid

Sta

te, D

ry

SC

R

Sh

ield

Sh

un

t

Sp

ark

Gap

Sw

itch

, Flo

w

Res

isto

r

WIRING DIAGRAMS


Sw

itch

, Lev

el,

No

rmal

ly C

lose

dTi

me

Del

ay C

lose

d,

NO

/Off

Tran

sfo

rmer

Ele

ctro

de

Torc

h S

ymb

ols

No

zzle

Sh

ield

Torc

h

Tran

sfo

rmer

, Air

Co

re

Tran

sfo

rmer

Co

il

Val

ve, S

ole

no

id

Volt

age

So

urc

e

Zen

er D

iod

e

VAC

So

urc

e

Tria

c

Sw

itch

, Pre

ssu

re,

No

rmal

ly C

lose

d

Sw

itch

, Pre

ssu

re,

No

rmal

ly O

pen

Sw

itch

, 1 P

ole

, 1 T

hro

w

Sw

itch

, 1 P

ole

, 2 T

hro

w

Sw

itch

, 1 P

ole

, 1 T

hro

w,

Cen

ter

Off

Sw

itch

, Tem

per

atu

re,

No

rmal

ly C

lose

d

Sw

itch

, Tem

per

atu

re,

No

rmal

ly O

pen

Tim

e D

elay

Clo

sed

,N

C/O

ff

Tim

e D

elay

Op

en,

NO

/Off

Tim

e D

elay

Op

en,

NC

/On

Term

inal

Blo

ck

Torc

h, H

yDef

init

ion

™

WIRING DIAGRAMS


D

TWK10-27-00LMB10-23-0011684DDJR4-7-98BC4-7-989419CDJR12-22-97BC12-17-979071BDJR10-30-97BC10-15-978829A

REVISIONSREV ECN DATE DRAWN DATE APPROVED

10-30-97DJR

10-30-97AD

9-5-97AD

1 OF 4N/A

ELEC SCHEM:HT2000-TITAN

013312B1013-2-312013312

MATERIAL

PURPOSES WITHOUT PERMISSION

THIS DRAWING AND ALL INFORMATION

PROPRIETARY AND MAY NOT BE USEDCONTAINED THEREON IS CONSIDERED

FOR MANUFACTURING OR FABRICATION

FROM HYPERTHERM, INC.

DRAWN BY

CHECKED BY

APP. BY

FILE NAME

MODEL

DESCRIPTION

DRAWING NO.

SCALE

STOCK NO.

SHEET

UNLESS OTHERWISE SPECIFIEDDIMENSIONS ARE IN INCHES.TOLERANCES ON:2 PL DECIMALS Å}.0153 PL DECIMALS Å}.005FRACTIONS Å}1/64BREAK SHARP CORNERS WITHCHAMFER OR RADIUS .015 MAX.

DATE

DATE

DATE Hypertherm, IncorporatedBox-5010 Hanover, NH 03755-5010 603/643-3441

HYPERTHERM, INC.

44 33 22

BB

CC

DD

11223344

DD

CC

BB

AA

11

AA

128200

OFF Valve

W-MWater

VoltageDependant

Power3 Phase

Supply

SupplyWater

Water Hose 128141

Workpiece

Torch

4X2

4X1

HF & MVPilot Arc 123043 (60')

Motor Valve Cable 123292 (60')

Cooling Water 128052 (60')

073223

2X1

128202

073220

3X1

Air

OxygenGas Panel

Plasm

a Cut F

low 024308 (20')

Shield S

ense 024067 (20')

Plasm

a Preflow

024017 (20')

Shield G

as 024349 (20')

128201

HF Cable 123042 (60')

Negative Lead 123041 (60')

Gas Cable 023606 (50')

Nitrogen

w/ Ground

3 PhasePower

HT2000

W/ THC

073054 240-480/60

Power Supply200 Amp

1X2

1X1

1X3

11X1

2nd HT2000 System

Customer Supplied

073194

OptionalExt. Counter/Time

Interface

ComputerI/O Interface Cable 023845 (50')

W-M Pump Cable 023866 (50')

Positive Lead 023041 (60')

Hold Cable 023340 (15')

Timer Cable 023687 (10")

V&C Interface Cable 023854 (50')

(Optional control w/Machine I/O Cable)

W/O THC

073106 240-480/60073104 200/50-60

073108 600/60

073105 208/60073107 380-415/50

073066 600/60

073064 208/60073065 380-415/50

1X7

1X6

1X10

073063 200/50-60 Ar-H

Plasma Gas (25')

Shielded Torch Leads 028994 (25')

MotV/Torch OFF-V Cable (25')

D

1234

D

C

B

A

1

10-30-97DJR

10-30-97AD

9-5-97AD

2 OF 4N/A


013312B2013-2-312013312

MATERIAL






DRAWN BY

CHECKED BY

APP. BY

FILE NAME

MODEL

DESCRIPTION

DRAWING NO.

SCALE

STOCK NO.

SHEET


DATE

DATE


HYPERTHERM, INC.

234

D

C

B

A

TIMING DIAGRAM SEE 013224 (IM 802070)POWER SUPPLY, ELECTRICAL SCHEMATIC SEE 013224

D

1

2

47

C4

C3

SG1

28

28

1

4

2

3

5

6

7

8

11

T1

4X2

1

4

3

2

1

SV4A

2

10

13

14

12

2X1

15

16

SV4B

17

10

23

24

30

34

29

25

16

T2

27

27

3

2

4

1

11

18

15

14

4X1

21

S3

LT1DC

29

30

34

5

6

1

2

3

SV1B

SV1A

SV2

7

8

4

9

28

22

16

17

27

SV3

S2

10

11

12

18

20

13

14

15

19

19

20

21

35

36

31

3X1

33

37

32

12

123041

34

35

36

4

5

6

11

8

9

24

2394

95

12

123043

123041

10

11

12

1

96

97

99

2

3

1X1

101

98

10

17

23

24

100

171

172

29

25

34

30102

103

16

25

SHEET

3-D3013224

SHEET

CABLE: 023606

11

14

15

18

21

1X3

157

158

29

34

5

30

6

1

2

3

40R/B

110

111

7

8

4

9

113

112

173

28

22

16

17

115

114

17427

10

11

18

12

117

62

116

20

13

14

15

61

63

64

19

013224

3-A2SHEET

013224

SHEET

7-B2013224

4-D2013224

4-A3

21

35

36

31

66

13

65

33

37

1X2

14

32

414-D2 12

C

B

A

12

10-30-97DJR

10-30-97AD

9-5-97AD

3 OF 4N/A


013312B3013-2-312013312

MATERIAL






DRAWN BY

CHECKED BY

APP. BY

FILE NAME

MODEL

DESCRIPTION

DRAWING NO.

SCALE

STOCK NO.

SHEET


DATE

DATE


HYPERTHERM, INC.

34

D

C

B

A

D

1234

SV5

Torch

CABLE: 128200

C2

C1

S1

HF & ValvePanel

PS3

SV6

SV7

MV1

Gas Panel

Decrease

Increase

Increase

Decrease

OFF

S1B O2

N2

O2S1A

N2

Preflow

O2

PS1

N2

Cut Flow

PS2

Run

HT2000Power Supply (+) Work Cable (Anode)

CABLE: 123042

CABLE: 123292

Door Interlock

F

(-) Torch Lead (Cathode)

(+) Pilot Arc (Anode)

G

BB

O

P

N RED WHT

RED

BLK

GRN

D

RHF CONSOLE

MGI SUPPLIEDMGI OPTIONAL PANEL

MV1

B

SV4

A

SV5

PLASMA FLOW

CAP ON SENSE

BLOCK

PS3SV7

CATHODE

TORCH

SHIELD GAS

COOLING SUPPLY

COOLING RETURN

COOLING RETURN

COOLING SUPPLY

MV3

SV3

MV2

FM1

B

A

FM2SV1

SV2

PG3

SV9MV4

PREFLOW GAS

SHIELD GAS

SHIELD SENSE

CUT FLOW GAS

SV10

CV1

2

CV3

CV2

Ar-H

N

AIR

GAS PANEL

O2

2

CV5

CO

CV4

PG2

PS2

PG1

PS1

SV6

CO1

SOLENOID VALVE PREFLOWSV4BSV4A SOLENOID VALVE CUTFLOW

CRITICAL ORIFICE, CAP OFFC01

2CUTFLOW

2

SV1ASV1B SOLENOID VALVE, N CUTFLOW

SOLENOID VALVE, O

2

SOLENOID VALVE, CAP OFF

SOLENOID VALVE, SHIELD ON

SOLENOID VALVE, PLASMA OFF

2SOLENOID VALVE, O PREFLOW

SOLENOID VALVE, N PREFLOW

2

2

METERING VALVE, SHIELD

METERING VALVE, O PREFLOW

METERING VALVE, N PREFLOW

METERING VALVE, PLASMA MOTOR

PRESSURE SWITCH, SHIELD/CAP OFF

PRESSURE SWITCH OXYGEN INLET

PRESSURE SWITCH, NITROGEN INLET

PRESSURE GAUGE, SHIELD

PRESSURE GAUGE, OXYGEN INLET

PRESSURE GAUGE, NITROGEN INLET

FLOW METER, OXYGEN

FLOW METER, NITROGEN

SV7SV6SV5

SV3SV2

MV4MV3MV2MV1

PS3PS2PS1

PG3PG2PG1

FM2FM1

C

B

A

12

10-30-97DJR

10-30-97AD

9-5-97AD

4 OF 4N/A


013312B4013-2-312013312

MATERIAL






DRAWN BY

CHECKED BY

APP. BY

FILE NAME

MODEL

DESCRIPTION

DRAWING NO.

SCALE

STOCK NO.

SHEET


DATE

DATE


HYPERTHERM, INC.

34

D

C

B

A

D

1234

NOTES:1. FOR ELECTRICAL DIAGRAM SEE DWG. NO.013312 SHEET 3

Documents

High Frequency Console