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Hypertherm
Cutter
HT4400
Hypertherm HT4400 User Manual
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WIRING DIAGRAMS
7-2
HT4400
Instruction Manual
Battery
Cap, polarized
Cap, non-polarized
Cap, feed-thru
Circuit breaker
Coax shield
Current Sensor
Current sensor
Diode
Door interlock
Fan
Feedthru LC
Filter
, AC
DC supply
Fuse
Ground Clamp
Ground, Chassis
Ground, Earth
IGBT
Inductor
LED
Light
Pin
Plug
PNP
T
ransistor
Potentiometer
Push Button,
Normally Closed
MOV
Push Button,
Normally Open
Receptacle
Relay
, Coil
Relay
, Normally Closed
Relay
, Normally Open
Relay
, Solid State,
AC
Relay
, Solid State, DC
Relay
, Solid State, Dry
SCR
Shield
Shunt
Spark Gap
Switch, Flow
Resistor
144
146
Table of Contents
English
10
Electromagnetic Compatibility (EMC
8
Warranty
9
Table of Contents
10
Recognize Safety Information
15
Follow Safety Instructions
15
Cutting Can Cause Fire or Explosion
15
Electric Shock Can Kill
16
Cutting Can Produce Toxic Fumes
16
A Plasma Arc Can Cause Injury and Burns
17
Arc Rays Can Burn Eyes and Skin
17
Grounding Safety
17
Compressed Gas Equipment Safety
18
Gas Cylinders Can Explode if Damaged
18
Noise Can Damage Hearing
18
Pacemaker and Hearing Aid Operation
18
A Plasma Arc Can Damage Frozen Pipes
18
Additional Safety Information
18
Warning Label
19
Français
20
Default Chapter
20
Section 1A Sécurité
20
Danger Avertissement Précaution
21
Risque D'explosion Argon-Hydrogè N E Et Mé T Hane
21
Dé T Onation de L'hydrogè N E Lors du Coupage de L'aluminium
21
Les Chocs Électriques Peuvent Être Fatals
22
Identifier Les Consignes de Sé C Urité
21
Suivre Les Instructions de Sécurité
21
Identifier Les Consignes de Sécurité
21
Suivre Les Instructions de Sé C Urité
21
Le Coupage Peut Provoquer un Incendie Ou Une Explosion
21
Les Chocs É L Ectriques Peuvent Ê T Re Fatals
22
Le Coupage Peut Produire des Vapeurs Toxiques
22
Prévention des Chocs Électriques
22
L'arc Plasma Peut Provoquer des Blessures Ou des Brûlures
23
L'arc Plasma Peut Provoquer des Blessures Ou des Brû L Ures
23
Mise À la Masse Et À la Terre
23
Les Rayons de L'arc Peuvent Brûler Les Yeux Et la Peau
23
Les Rayons de L'arc Peuvent Brû L er Les Yeux Et la Peau
23
Torches À Allumage Instantané
23
Sécurité des Bouteilles de Gaz Comprimé
24
Le Bruit Peut Provoquer des Problè M es Auditifs
24
Pacemakers Et Prothéses Auditives
24
Pacemakers Et Prothèses Auditives
24
Sé C Urité des Bouteilles de Gaz Comprimé
24
Les Bouteilles de Gaz Comprimé Peuvent Exploser en Cas de Dommages
24
Le Bruit Peut Provoquer des Problèmes Auditifs
24
Un Arc Plasma Peut Endommager Les Tuyaux Gelé
24
Étiquette de Sécurité
25
É T Iquette de Sé C Urité
25
Specifications
26
Section 2 Specifications
26
System Components
27
Power Supply
27
Machine Torch
27
Valve Cluster
27
Gas Console
27
Ignition Console
27
Water Cooler
27
Remote Current Control Console - Optional
27
Command THC - Optional
27
Specifications
28
System Requirements
28
Power Supply
29
Machine Torch
30
Valve Cluster
30
Gas Console
31
Ignition Console
32
Water Cooler
33
Remote Current Control Console - Optional
34
Command THC - Optional
34
Installation
35
Section 3 Installation
35
Installation Requirements
36
Gas Requirements
36
Gas Supply Plumbing
36
Torch Coolant Requirements
37
Water Purity Requirements
38
Grounding Requirements
38
Fume Emissions
38
Noise Levels
39
Power Requirements
39
Connecting the Power
40
Torch Lifter Requirement
42
System Units Placement
42
HT4400 System Interconnections
45
Ignition Console Connections - 1 of 3
46
Ignition Console Connections - 2 of 3
47
Ignition Console Connections - 3 of 3
48
Gas Console Connections - 1 of 3
49
Gas Console Connections - 2 of 3
50
Gas Console Connections - 3 of 3
51
Water Cooler Connections - 1 of 2
52
Water Cooler Connections - 2 of 2
53
Remote Current Control Connection
54
Machine Interface Connections - 1 of 2
54
Machine Interface Connections - 2 of 2
55
Work Table Connection
56
Power Supply #2 Connection
56
Torch Connections
57
Torch Mounting and Alignment
58
Post-Installation
59
Operation
60
Section 4 Operation
60
Controls and Indicators
61
Gas Console
61
Gas Console Controls and Indicators
62
Status Display Messages on the Gas Console
63
Power Supply
63
Remote Current Control Console
64
Power Supply
64
Leak Tests
65
Daily Startup
67
Common Cutting Faults
71
Performance and Process Data
72
Cut Chart and Consumable Parts Index
73
Cutcharts
73
Changing Consumable Parts
82
Remove Consumables
82
Inspect Consumables
83
Inspect Torch
84
Inspect Electrode Pit Depth
85
Install Consumables
86
Replace Torch Water Tube
87
Cutting Techniques
88
How to Get Better Cut Quality
88
How to Get Longer Consumable Life
89
How to Get Better Pierces
91
How to Increase Cutting Speed
91
Maintenance
92
Section 5 Maintenance
92
Introduction
93
Routine Maintenance
93
Replacing the Water Cooler Filter
94
Pump Strainer Cleaning
94
Torch Coolant Draining
95
Water Cooler Draining
95
HT4400 Startup Sequence
96
HT4400 Plasma START Sequence
97
HT4400 Plasma RUN Sequence
98
Error Code Troubleshooting - 1 of 3
99
Error Code Troubleshooting - 2 of 3
100
Error Code Troubleshooting - 3 of 3
101
System Troubleshooting - 1 of 4
102
System Troubleshooting - 2 of 4
103
System Troubleshooting - 3 of 4
104
System Troubleshooting - 4 of 4
105
Initial Checks
106
Power Measurement Location - All Voltages
107
Power Distribution PCB1 - Status Indicators
108
Microprocessor Control Board PCB2 - Status Indicators
109
Analog Board PCB3 - Status Indicators
110
Current Sense Test
111
Relay Board PCB4 - Status Indicators
112
Serial I/O Board PCB5 - Status Indicators
115
Start Circuit Board PCB14 - Status Indicators and Operation
120
Pilot Arc Current Levels
120
Start Circuit Functional Schematic
121
Start Circuit Troubleshooting
121
Phase Loss Detection Board PCB21 - Status Indicators and Operation
122
Phase Loss Detection Board PCB21- Status Indicators and Operation
122
Chopper Module Test Procedure
123
Coolant Flow Test
125
Pressure Switch Settings
127
Gas Console Valve Select Switch Detail
128
Preventative Maintenance Schedule
129
Parts List
130
Section 6 Parts List
130
Power Supply
131
Front Panel Outside
131
Power Supply
132
Front Panel Inside
132
Power Supply
133
Front Bail (Wall)
133
Power Supply
134
Rear Bail (Wall)
134
Power Supply
135
Rear Panel Inside and Outside
135
Ignition Console
136
Gas Console
137
Water Cooler
138
HT4400 Torch
139
Consumable Configurations
140
Consumable Parts Kit
141
Counterclockwise Consumables
141
Valve Cluster Assembly
142
Recommended Spare Parts
142
Electrode Pit Depth Gauge Assembly
143
Wiring Diagrams
144
Introduction
144
Wiring Diagram Symbols
144
Appendix A System Grounding
160
System Grounding Requirements
160
Suggested Ground Cable Routing
160
Power Supply
160
Equipment Grounding
160
Work Table Grounding
161
Appendix B Propylene Glycol & Benzotriazole Safety Data
174
Appendix C Gas Regulators
174
Appendix D Noise Levels
176
5
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Hypertherm HT4400 Specifications
General
Brand
Hypertherm
Model
HT4400
Category
Cutter
Language
English
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