HySpeed ®

®
HT2000LHF
200 Volt
Plasma Arc
Cutting System
Instruction Manual
803040 – Revision 7
Changed Page Description Rev 5 to 6 8/31/03

6.2 Item # 7 changed from 041560 to 041764. Item # 8 081031 (firmware)

was removed.
Section 7 Wiring diagram revision changed from H to K (all pages)

Changed Page Description IM304 Rev 4 to 5 9/27/99

0.01 Uprevved because of ECNs 10483, 10484, 10639m, 10145, 10670

0.02 Added plumbing and electrical codes statement to warranty
1.0-1a.06 New safety sections
3.18 New graphic of valve cluster
3.19 Modified graphic of torch
5.17 Changed graphic of coolant reservoir
5.18 New graphic of coolant reservoir
6.08 New coolant reservoir #, new level switch SA #
6.15 New Torch mounting sleeve #
6.18 Added new level switch SA # to recommended spare parts
7.05-7.13 Uprevved wiring diagrams to G

Begin w/serial # 2LHF-000300

Changed Page Description IM304 Rev 3 to 4 5/26/99

0.01 Uprevved because of request to add cut quality info and ECNs 10228, 10308, 10344, 10417
0.03-.08 Updated TOC
2.03 Added 440V power supplies
3.03 Changed spec. on coolant
3.04 Added power specs for 440V
3.11 Added note referencing DC relay kit part number
4.10 Added line referencing cutting techniques
4.33-4.36 Adding cutting techniques
6.04 Added 440V control xfrmr
6.05 Added 440V power xfrmr
6.09 Changed p/n of items 6 and 7 for new pressure switch
6.13 Added 015049 to parts list
6.16 Changed figure title to HT2000 Consumable Parts
6.17 Added HT2000 Beveling Consumable Parts Kit
6.18 Bumped page - also changed p/n for pressure switch in gas console recommended spare parts
7.01-7.13 Wiring diagram change to reflect new 440V power supply rev E to rev F
a.01-a.14 Added argon-hydrogen cutting and installation
i.01-i.06 Updated index

Begin w/serial # 2LHF-000199

Changed Page Description IM304 Rev 2 to 3 1/18/99

0.01 Uprevved because of ECNs 10078, 10079, 10070, 9753, 10012, 9864, 10020, 9926
0.06 Changed TOC to reference HT2000LHF Torches
0.08 Changed TOC to reference HT2000LHF Torches
2.01 Added line in spec description to specify recommended production cutting thickness
2.02 Added note to Water Muffler description stating that it cannot be used with the stainless torch
2.03 Added dimension on torch diameter and referenced an additional drawing in Section 6
2.06 Added note to Water Muffler description stating that it cannot be used with the stainless torch
3.07 Added note to Water Muffler description stating that it cannot be used with the stainless torch
3.11 Updated signal labels for I/O cable
3.13 Added note to Water Muffler cable stating that it cannot be used with the stainless torch
4.11 Changed index to cut chart and consumables to include new electrode and swirl ring
4.12-4.29 Updated cut charts with new electrode, swirl ring, and clearer cutting capacities
5.02 Removed old style pump clamp from drawing
6.05 New part number for valve SV7
6.08 Added kits for pump and motor replacement
6.09 New part number for valves SV1-3
6.15 Added new stainless steel torch
6.16 Added new electrode to parts kit
6.17 New part numbers for valves, pump

Begin w/serial # 2LHF-000199

Changed Page Description IM304 Rev 1 to 2 8/21/98

0.01 Uprevved because of ECNs 9763, 9758, 9803

0.08 Added figure of coolant flow diagram to TOC
3.08 New graphic of rear panel
5.17 Added figure of coolant flow diagram
6.08 New graphic of rear panel, new p/ns for valve assembly, water pump assembly
7.04 Added coolant flow diagram to wiring diagrams
Begin w/serial # 2LHF-000150
Changed Page Description IM304 Rev 0 to 1 7/24/98

0.01 Uprevved because of ECNs 9523, 9483, grounding appendix, serial # jump to 2LHF-000150
0.07 Added System Grounding to TOC
0.08 Added System Grounding to TOC
3.03 Referenced new grounding appendix
4.15 Added a sentence to Mild Steel 100A cutting cut chart
4.16 Added a sentence to Mild Steel 100A cutting cut chart
5.05 New power distribution PCB graphic, added fuse
5.14 Added error code for phase loss
6.02 New firmware rev
6.06 New graphic of chopper with phase loss board, new phase loss board #
6.16 Changed some quantities in consumable parts kit
7.01 Uprevved wiring diagrams to E
i.02 Added j1 to grounding requirements in index
i.04 Added phase loss to index
j.01 New system grounding appendix
j.02 New system grounding appendix
j.03 New system grounding appendix
j.04 New system grounding appendix
j.05 New system grounding appendix

Begin w/serial # 2LHF-000150

 200 Volt
HySpeed HT2000LHF

Instruction Manual

(P/N 803040)

Revision 7 – November, 2013

Hypertherm, Inc.
Hanover, NH USA
www.hypertherm.com

© Copyright 2013 Hypertherm, Inc.

All Rights Reserved

Hypertherm, HT, HyLife, HySpeed and LongLife are trademarks of Hypertherm, Inc.
and may be registered in the United States and/or other countries
 Hypertherm, Inc.
Etna Road, P.O. Box 5010
Hanover, NH 03755 USA
603-643-3441 Tel (Main Office)
603-643-5352 Fax (All Departments)
info@hypertherm.com (Main Office Email)
800-643-9878 Tel (Technical Service)
service@hypertherm.com (Technical Service Email)
800-737-2978 Tel (Customer Service)
customer.service@hypertherm.com (Customer Service Email)
Hypertherm Automation, LLC
5 Technology Drive, Suite 300
West Lebanon, NH 03755 USA
603-298-7970 Tel
603-298-7977 Fax
Hypertherm Plasmatechnik, GmbH
Technologiepark Hanau
Rodenbacher Chaussee 6
63457 Hanau-Wolfgang, Deutschland
49 6181 58 2100 Tel
49 6181 58 2134 Fax
49 6181 58 2123 (Technical Service)
Hypertherm (S) Pte Ltd.
No. 19 Kaki Bukit Road 2
K.B. Warehouse Complex
Singapore 417847, Republic of Singapore
65 6 841 2489 Tel
65 6 841 2490 Fax
65 6 841 2489 (Technical Service)
Hypertherm UK, Ltd.
9 Berkeley Court, Manor Park
Runcorn, Cheshire, England WA7 1TQ
44 1928 579 074 Tel
44 1928 579 604 Fax
France
15 Impasse des Rosiers
95610 Eragny, France
00 800 3324 9737 Tel
00 800 4973 7329 Fax
Hypertherm S.r.l.
Via Torino 2
20123 Milano, Italia
39 02 725 46 312 Tel
39 02 725 46 400 Fax
39 02 725 46 314 (Technical Service)
Hypertherm Europe B.V.
Vaartveld 9
4704 SE Roosendaal, Nederland
31 165 596907 Tel
31 165 596901 Fax
31 165 596908 Tel (Marketing)
31 165 596900 Tel (ETSO – Technical Service)
00 800 49 73 7843 Tel (ETSO – Technical Service
toll-free in Europe)
Japan
1952-14 Yata-Natsumegi
Mishima City, Shizuoka Pref.
411-0801 Japan
81 0 559 75 7387 Tel
81 0 559 75 7376 Fax
Hypertherm Brasil Ltda.
Rua Visconde de Santa Isabel, 20 – Sala 611
Vila Isabel, RJ
Brasil CEP 20560-120
55 21 2278 6162 Tel
5/23/03
55 21 2578 0947 Fax
 ELECTROMAGNETIC COMPATIBILITY (EMC)

EMC INTRODUCTION The size of the surrounding area to be Earthing of Workpiece

considered will depend on the structure of
Hypertherm's CE-marked equipment is built Where the workpiece is not bonded to earth
the building and other activities that are tak-
in compliance with standard EN50199. The for electrical safety , nor connected to earth
ing place. The surrounding area may extend
equipment should be installed and used in because of its size and position, for example,
beyond the boundaries of the premises.
accordance with the information below to ship's hull or building steelwork, a connection
achieve electromagnetic compatibility. bonding the workpiece to earth may reduce
METHODS OF REDUCING EMISSIONS
emissions in some, but not all instances.
The limits required by EN50199 may not be Care should be taken to prevent the earthing
adequate to completely eliminate interfer- Mains Supply
of the workpiece increasing the risk of injury
ence when the af fected equipment is in Cutting equipment must be connected to the to users, or damage to other electrical equip-
close proximity or has a high degree of mains supply according to the manufactur- ment. Where necessary , the connection of
sensitivity. In such cases it may be neces- er's recommendations. If interference the workpiece to earth should be made by a
sary to use other measures to further occurs, it may be necessary to take direct connection to the workpiece, but in
reduce interference. additional precautions such as filtering of some countries where direct connection is
This plasma equipment is designed for use the mains supply. Consideration should be not permitted, the bonding should be
only in an industrial environment. given to shielding the supply cable of per- achieved by suitable capacitances selected
manently installed cutting equipment, in according to national regulations.
INSTALLATION AND USE metallic conduit or equivalent. Shielding
Note. The cutting circuit may or may not be
should be electrically continuous throughout
The user is responsible for installing and earthed for safety reasons. Changing the
its length. The shielding should be connect-
using the plasma equipment according to earthing arrangements should only be au-
ed to the cutting mains supply so that good
the manufacturer's instructions. If electro- thorized by a person who is competent to
electrical contact is maintained between the
magnetic disturbances are detected then it assess whether the changes will increase
conduit and the cutting power source
shall be the responsibility of the user to re- the risk of injury , for example, by allowing
enclosure
solve the situation with the technical assis- parallel cutting current return paths which
tance of the manufacturer . In some cases may damage the earth circuits of other
Maintenance of Cutting Equipment
this remedial action may be as simple as equipment. Further guidance is given in IEC
earthing the cutting circuit, see Earthing of The cutting equipment must be routinely TC26 (sec)94 and IEC TC26/108A/CD Arc
Workpiece. In other cases it could involve maintained according to the manufacturer's Welding Equipment Installation and Use.
constructing an electromagnetic screen recommendations. All access and service
enclosing the power source and the work doors and covers should be closed and Screening and Shielding
complete with associated input filters. In all properly fastened when the cutting
Selective screening and shielding of other
cases electromagnetic disturbances must equipment is in operation. The cutting
cables and equipment in the surrounding
be reduced to the point where they are no equipment should not be modified in any
area may alleviate problems of interference.
longer troublesome. way except for those changes and adjust-
Screening of the entire plasma cutting
ments covered in the manufacturer's
installation may be considered for special
ASSESSMENT OF AREA instructions. In particular, the spark gaps of
applications
arc striking and stabilizing devices should
Before installing the equipment the user be adjusted and maintained according to
shall make an assessment of potential elec- the manufacturer's recommendations.
tromagnetic problems in the surrounding
area. The following shall be taken into Cutting Cables
account:
a. Other supply cables, control cables, The cutting cables should be kept as short
signalling and telephone cables; above, as possible and should be positioned close
below and adjacent to the cutting equip- together, running at or close to the floor
ment. level.
b. Radio and television transmitters and
receivers. Equipotential Bonding
c. Computer and other control equipment. Bonding of all metallic components in the
d. Safety critical equipment, for example cutting installation and adjacent to it should
guarding of industrial equipment. be considered. However , metallic compo-
e. Health of the people around, for nents bonded to the workpiece will increase
example the use of pacemakers and hear- the risk that the operator could receive a
ing aids. shock by touching these metallic
f. Equipment used for calibration or mea- components and the electrode at the same
surement. time. The operator should be insulated from
g. Immunity of other equipment in the en- all such bonded metallic components.
vironment. User shall ensure that other
equipment being used in the environment is
compatible. This may require additional
protection measures.
h. Time of day that cutting or other activities
are to be carried out.

Hypertherm Plasma Systems i

WARRANTY

WARNING Hypertherm, infringes any patent of any third party . You shall
Genuine Hypertherm parts are the factory-recommended notify Hypertherm promptly upon learning of any action or
replacement parts for your Hypertherm system. Any damage threatened action in connection with any such alleged
caused by the use of other than genuine Hypertherm parts may infringement, and Hypertherm’s obligation to indemnify shall be
not be covered by the Hypertherm warranty. conditioned upon Hypertherm’ s sole control of, and the
indemnified party’s cooperation and assistance in, the defense
WARNING of the claim.
You are responsible for the safe use of the Product.
Hypertherm does not and cannot make any guarantee or
LIMITATION OF LIABILITY
warranty regarding the safe use of the Product in your In no event shall Hypertherm be liable to any person or
environment. entity for any incidental, consequential, indirect, or
punitive damages (including but not limited to lost profits)
GENERAL regardless of whether such liability is based on breach of
Hypertherm, Inc. warrants that its Products shall be free from contract, tort, strict liability, breach of warranties, failure of
defects in materials and workmanship, if Hypertherm is notified essential purpose or otherwise and even if advised of the
of a defect (i) with respect to the power supply within a period possibility of such damages.
of two (2) years from the date of its delivery to you, with the
exception of G3 Series power supplies, which shall be within a
LIABILITY CAP
period of three (3) years from the date of delivery to you, and In no event shall Hypertherm’s liability, whether such
(ii) with respect to the torch and leads within a period of one (1) liability is based on breach of contract, tort, strict liability,
year from its date of delivery to you. This warranty shall not breach of warranties, failure of essential purpose or
apply to any Product which has been incorrectly installed, otherwise, for any claim action suit or proceeding arising
modified, or otherwise damaged. Hypertherm, at its sole out of or relating to the use of the Products exceed in the
option, shall repair , replace, or adjust, free of charge, any aggregate the amount paid for the Products that gave rise
defective Products covered by this warranty which shall be to such claim.
returned with Hypertherm’s prior authorization (which shall not
be unreasonably withheld), properly packed, to Hypertherm’ s INSURANCE
place of business in Hanover , New Hampshire, or to an At all times you will have and maintain insurance in such
authorized Hypertherm repair facility, all costs, insurance and quantities and types, and with coverage suf ficient and
freight prepaid. Hypertherm shall not be liable for any repairs, appropriate to defend and to hold Hypertherm harmless in
replacement, or adjustments of Products covered by this the event of any cause of action arising from the use of the
warranty, except those made pursuant to this paragraph or with Products.
Hypertherm’s prior written consent. The warranty above is
exclusive and is in lieu of all other warranties, express, NATIONAL AND LOCAL CODES
implied, statutory, or otherwise with respect to the National and Local codes governing plumbing and electrical
Products or as to the results which may be obtained installation shall take precedent over any instructions
therefrom, and all implied warranties or conditions of contained in this manual. In no event shall Hypertherm be
quality or of merchantability or fitness for a particular liable for injury to persons or property damage by reason of any
purpose or against infringement. The foregoing shall code violation or poor work practices.
constitute the sole and exclusive remedy for any breach
by Hypertherm of its warranty. Distributors/OEMs may offer TRANSFER OF RIGHTS
different or additional warranties, but Distributors/OEMs are You may transfer any remaining rights you may have
not authorized to give any additional warranty protection to you hereunder only in connection with the sale of all or substantially
or make any representation to you purporting to be binding all of your assets or capital stock to a successor in interest who
upon Hypertherm. agrees to be bound by all of the terms and conditions of this
Warranty.
PATENT INDEMNITY
Except only in cases of products not manufactured by
Hypertherm or manufactured by a person other than
Hypertherm not in strict conformity with Hypertherm’ s
specifications and in cases of designs, processes, formulae, or
combinations not developed or purported to be developed by
Hypertherm, Hypertherm will defend or settle, at its own
expense, any suit or proceeding brought against you alleging
that the use of the Hypertherm product, alone and not in
combination with any other product not supplied by

ii Hypertherm Plasma Systems

9-01
 TABLE OF CONTENTS

Electromagnetic Compatibility (EMC) .......................................................................................................................i

Warranty .....................................................................................................................................................................ii

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

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

Section 2 SPECIFICATIONS
HySpeed HT2000LHF System Components ............................................................................................................2-1
Power Supply ..................................................................................................................................................2-1
HySpeed LHF Machine Torch..........................................................................................................................2-1
Gas Console ....................................................................................................................................................2-1
Argon-Hydrogen Manifold – Optional...............................................................................................................2-1
Digital Remote Voltage & Current Control Console .........................................................................................2-1
Programmable Remote Voltage & Current Control Console............................................................................2-1
Remote Current Control Console.....................................................................................................................2-2
Initial Height Sensing - Optional.......................................................................................................................2-2
Timer/Counter – Optional.................................................................................................................................2-2

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TABLE OF CONTENTS

Water Muffler – Optional ..................................................................................................................................2-2

CommandTHC – Optional................................................................................................................................2-2
Specifications............................................................................................................................................................2-2
System Requirements .....................................................................................................................................2-2
Power Supply ...................................................................................................................................................2-3
HySpeed LHF Machine Torch..........................................................................................................................2-3
Gas Console ....................................................................................................................................................2-4
Argon-Hydrogen Manifold – Optional...............................................................................................................2-4
Digital Remote Voltage & Current Control Console .........................................................................................2-5
Programmable Remote Voltage & Current Control Console............................................................................2-5
Remote Current Control Console.....................................................................................................................2-5
Initial Height Sensing (IHS) – Optional.............................................................................................................2-6
Timer/Counter – Optional.................................................................................................................................2-6
Water Muffler – Optional ..................................................................................................................................2-6
CommandTHC – Optional................................................................................................................................2-6

Section 3 INSTALLATION
Upon Receipt ............................................................................................................................................................3-1
Claims .......................................................................................................................................................................3-1
Installation Requirements .........................................................................................................................................3-1
Gas Requirements ....................................................................................................................................................3-1
Gas Supply Plumbing.......................................................................................................................................3-2
Torch Coolant Requirements ....................................................................................................................................3-3
Grounding Requirements..........................................................................................................................................3-3
Noise Levels .............................................................................................................................................................3-4
Power Requirements ................................................................................................................................................3-4
Line Disconnect Switch ....................................................................................................................................3-4
Power Cable.....................................................................................................................................................3-5
Positioning the Power Supply ..........................................................................................................................3-5
Connecting the Power ..............................................................................................................................................3-5
Torch Lifter Requirement ..........................................................................................................................................3-7
Optional Equipment ..................................................................................................................................................3-7
Water Muffler....................................................................................................................................................3-7
System Units Placement...........................................................................................................................................3-7
Power Supply Connections.....................................................................................................................................3-10
Gas Console Connections ......................................................................................................................................3-14
Valve Cluster and Torch Connections ....................................................................................................................3-17
Routing the Torch Leads................................................................................................................................3-17
Connecting the Torch Leads to the Torch......................................................................................................3-17
Valve Cluster Connections.............................................................................................................................3-18
Mounting the Machine Torch ..................................................................................................................................3-20
Torch Alignment .............................................................................................................................................3-20

Section 4 OPERATION
Front Panel Controls and Indicators .........................................................................................................................4-1

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 TABLE OF CONTENTS

Status Indicators Before Startup ......................................................................................................................4-1

Power Supply ...................................................................................................................................................4-1
Gas Console ....................................................................................................................................................4-2
Digital Remote Voltage & Current Control Console .........................................................................................4-3
Programmable Remote Voltage & Current Control Console............................................................................4-3
Remote Current Control Console.....................................................................................................................4-3
Timer/Counter ..................................................................................................................................................4-4
System Checkout......................................................................................................................................................4-4
Set Switches and Check Torch ........................................................................................................................4-4
Turn Gases On.................................................................................................................................................4-4
Turn Power Supply On and Adjust Voltage/Current.........................................................................................4-5
Adjust Preflow Gases.......................................................................................................................................4-5
Adjust Cut Flow Gases and Check Initial Height Sensing (IHS) ......................................................................4-5
Final Torch Adjustment ....................................................................................................................................4-6
Check Torch Height Control (THC) and Digital Remote Voltage & Current Console ...............................................4-6
Noise Levels .............................................................................................................................................................4-7
Daily Startup .............................................................................................................................................................4-7
Check Torch.....................................................................................................................................................4-7
Turn Gases On.................................................................................................................................................4-8
Turn Power Supply On and Adjust Voltage & Current .....................................................................................4-8
Adjust Preflow Gases.......................................................................................................................................4-8
Adjust Cut Flow Gases and Prepare for Cutting ..............................................................................................4-9
Common Cutting Faults ............................................................................................................................................4-9
Technical Questions ...............................................................................................................................................4-10
Cut Charts...............................................................................................................................................................4-10
Concersions ............................................................................................................................................................4-10
Cut Chart and Consumable Parts Index .................................................................................................................4-11
Changing Consumable Parts ..................................................................................................................................4-31
Removal and Inspection.................................................................................................................................4-31
Replacement ..................................................................................................................................................4-32
Changing the Water Tube ..............................................................................................................................4-33
How to Optimize Cut Quality...................................................................................................................................4-34
Tips for Table and Torch ................................................................................................................................4-34
Plasma Set-up Tips........................................................................................................................................4-34
Maximize the Life of Consumable Parts.........................................................................................................4-34
Additional Factors of Cut Quality....................................................................................................................4-35
Additional Improvements................................................................................................................................4-36

Section 5 MAINTENANCE
Introduction ...............................................................................................................................................................5-1
Routine Maintenance ................................................................................................................................................5-1
Torch and Torch Leads ....................................................................................................................................5-1
Power Supply ...................................................................................................................................................5-2
Gas Console ....................................................................................................................................................5-3
Start Sequence .........................................................................................................................................................5-3
Initial Checks ............................................................................................................................................................5-4

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TABLE OF CONTENTS

Troubleshooting ........................................................................................................................................................5-6
Status Led Troubleshooting......................................................................................................................................5-9
Chopper Module Test Procedure............................................................................................................................5-12
Error Codes ............................................................................................................................................................5-14
Coolant Flow Test Procedure .................................................................................................................................5-15
Check Reservoir Coolant ...............................................................................................................................5-15
Verify Flow Rate Return from Torch...............................................................................................................5-15
Verify Flow Rate to Torch...............................................................................................................................5-16
Check Pump, Motor and Solenoid Valve (V1)................................................................................................5-16
Torch Coolant Draining ...........................................................................................................................................5-17
Preventive Maintenance Schedule .........................................................................................................................5-19

Section 6 PARTS LIST

Introduction ...............................................................................................................................................................6-1
Power Supply: Front Panel ..............................................................................................................................6-2
Power Supply: THC Assembly (optional) .........................................................................................................6-3
Power Supply: Control Panel ...........................................................................................................................6-3
Power Supply: Center Wall Right Side.............................................................................................................6-4
Power Supply: Center Wall Left Side ...............................................................................................................6-5
Power Supply: Front Wall Inside ......................................................................................................................6-6
Power Supply: Rear Wall Inside.......................................................................................................................6-7
Power Supply: Rear Wall Outside....................................................................................................................6-8
Gas Console ....................................................................................................................................................6-9
Digital Remote Voltage & Current Control Console .......................................................................................6-10
Programmable Remote Voltage & Current Control Console..........................................................................6-11
Initial Height Sensing Control Console...........................................................................................................6-12
Argon-Hydrogen Manifold ..............................................................................................................................6-13
Timer/Counter ................................................................................................................................................6-14
Remote Current Control Console...................................................................................................................6-14
Hyspeed HT2000LHF Torches ......................................................................................................................6-15
Consumable Parts Kits...................................................................................................................................6-16
Recommended Spare Parts ...................................................................................................................................6-20
Power Supply .................................................................................................................................................6-20
Gas Console ..................................................................................................................................................6-20

Section 7 WIRING DIAGRAMS ..........................................................................................................................10-1

Introduction .............................................................................................................................................................10-1
Wiring Diagram Symbols ........................................................................................................................................10-1
System Wiring Diagrams ........................................................................................................................................10-5

Appendix A ARGON-HYDROGEN CUTTING and GOUGING............................................................................a-1

Appendix B PROPYLENE GLYCOL SAFETY DATA .........................................................................................b-2

BENZOTRIAZOLE SAFETY DATA ...............................................................................................b-10

Appendix C INITIAL HEIGHT SENSING CONNECTIONS ..................................................................................c-1

vi Hyspeed HT2000LHF Instruction Manual

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 TABLE OF CONTENTS

Appendix D ELECTROMAGNETIC COMPATIBILITY ........................................................................................d-1

Appendix E AIR FILTERS ....................................................................................................................................e-1

Appendix F AERATION MANIFOLD FOR CUTTING ALUMINUM .....................................................................f-1

Appendix G IEC SYMBOLS.................................................................................................................................g-1

Appendix H SYSTEM GROUNDING ...................................................................................................................h-1

Hyspeed HT2000LHF Instruction Manual vii

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TABLE OF CONTENTS

viii Hyspeed HT2000LHF Instruction Manual

6
 Section 1

SAFETY

In this section:

Recognize Safety Information...................................................................................................................................1-2

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

Hypertherm Plasma Systems 1-1

SAFETY

RECOGNIZE SAFETY INFORMATION • Keep your machine in proper working condition.

Unauthorized modifications to the machine may
The symbols shown in this section are used to affect safety and machine service life.
identify potential hazards. When you see a safety
symbol in this manual or on your machine, understand
the potential for personal injury, and follow the related
instructions to avoid the hazard. DANGER WARNING CAUTION

A signal word DANGER or WARNING is used with a

FOLLOW SAFETY INSTRUCTIONS safety symbol. DANGER identifies the most serious
hazards.

Read carefully all safety messages in this manual and • DANGER and WARNING safety labels are located
safety labels on your machine. on your machine near specific hazards.
• WARNING safety messages precede related
• Keep the safety labels on your machine in good
instructions in this manual that may result in injury
condition. Replace missing or damaged labels
or death if not followed correctly.
immediately.
• CAUTION safety messages precede related
• Learn how to operate the machine and how to use
instructions in this manual that may result in
the controls properly. Do not let anyone operate it
damage to equipment if not followed correctly.
without instruction.

CUTTING CAN CAUSE FIRE OR EXPLOSION

Fire Prevention WARNING

• Be sure the area is safe before doing any cutting. Explosion Hazard
Keep a fire extinguisher nearby. Argon-Hydrogen and Methane
• Remove all flammables within 35 feet (10 m) of the
cutting area. Hydrogen and methane are flammable gases that
• Quench hot metal or allow it to cool before handling present an explosion hazard. Keep flames away from
or before letting it touch combustible materials. cylinders and hoses that contain methane or hydrogen
• Never cut containers with potentially flammable mixtures. Keep flames and sparks away from the torch
materials inside – they must be emptied and when using methane or argon-hydrogen plasma.
properly cleaned first.
• Ventilate potentially flammable atmospheres before
cutting. WARNING
• When cutting with oxygen as the plasma gas, an Hydrogen Detonation with Aluminum Cutting
exhaust ventilation system is required.
• When cutting aluminum underwater, or with the
Explosion Prevention water touching the underside of the aluminum, free
• Do not use the plasma system if explosive dust or hydrogen gas may collect under the workpiece and
vapors may be present. detonate during plasma cutting operations.
• Do not cut pressurized cylinders, pipes, or any • Install an aeration manifold on the floor of the water
closed container. table to eliminate the possibility of hydrogen
• Do not cut containers that have held combustible detonation. Refer to the Appendix section of this
materials. manual for aeration manifold details.

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 SAFETY

ELECTRIC SHOCK CAN KILL

Touching live electrical parts can cause a fatal shock • Install and ground this equipment according to the
or severe burn. instruction manual and in accordance with national
and local codes.
• Operating the plasma system completes an
• Inspect the input power cord frequently for damage
electrical circuit between the torch and the
or cracking of the cover. Replace a damaged power
workpiece. The workpiece and anything touching
cord immediately. Bare wiring can kill.
the workpiece are part of the electrical circuit.
• Inspect and replace any worn or damaged torch
• Never touch the torch body, workpiece or the water
leads.
in a water table when the plasma system is
• Do not pick up the workpiece, including the waste
operating.
cutoff, while you cut. Leave the workpiece in place
or on the workbench with the work cable attached
Electric Shock Prevention
during the cutting process.
All Hypertherm plasma systems use high voltage • Before checking, cleaning or changing torch parts,
in the cutting process (200 to 400 VDC are disconnect the main power or unplug the power
common). Take the following precautions when supply.
operating this system: • Never bypass or shortcut the safety interlocks.
• Wear insulated gloves and boots, and keep your • Before removing any power supply or system
body and clothing dry. enclosure cover, disconnect electrical input power.
• Do not stand, sit or lie on – or touch – any wet Wait 5 minutes after disconnecting the main power
surface when using the plasma system. to allow capacitors to discharge.
• Insulate yourself from work and ground using dry • Never operate the plasma system unless the power
insulating mats or covers big enough to prevent any supply covers are in place. Exposed power supply
physical contact with the work or ground. If you must connections present a severe electrical hazard.
work in or near a damp area, use extreme caution. • When making input connections, attach proper
• Provide a disconnect switch close to the power grounding conductor first.
supply with properly sized fuses. This switch allows • Each Hypertherm plasma system is designed to be
the operator to turn off the power supply quickly in used only with specific Hypertherm torches. Do not
an emergency situation. substitute other torches which could overheat and
• When using a water table, be sure that it is correctly present a safety hazard.
connected to earth ground.

CUTTING CAN PRODUCE TOXIC FUMES

Cutting can produce toxic fumes and gases that beryllium, unless the area is well ventilated and the
deplete oxygen and cause injury or death. operator wears an air-supplied respirator. The
coatings and any metals containing these elements
• Keep the cutting area well ventilated or use an can produce toxic fumes when cut.
approved air-supplied respirator. • Never cut containers with potentially toxic materials
• Do not cut in locations near degreasing, cleaning or inside – they must be emptied and properly cleaned
spraying operations. The vapors from certain first.
chlorinated solvents decompose to form phosgene • This product, when used for welding or cutting,
gas when exposed to ultraviolet radiation. produces fumes or gases which contain chemicals
• Do not cut metal coated or containing toxic materi- known to the State of California to cause birth
als, such as zinc (galvanized), lead, cadmium or defects and, in some cases, cancer.

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SAFETY

A PLASMA ARC CAN CAUSE INJURY AND BURNS

Instant-On Torches The plasma arc will cut quickly through gloves and
Plasma arc comes on immediately when the torch skin.
switch is activated. • Keep away from the torch tip.
• Do not hold metal near the cutting path.
• Never point the torch toward yourself or others.

ARC RAYS CAN BURN EYES AND SKIN

Eye Protection Plasma arc rays produce intense Skin Protection Wear protective clothing to protect
visible and invisible (ultraviolet and infrared) rays that against burns caused by ultraviolet light, sparks and
can burn eyes and skin. hot metal.
• Use eye protection in accordance with applicable • Gauntlet gloves, safety shoes and hat.
national or local codes. • Flame-retardant clothing to cover all exposed areas.
• Wear eye protection (safety glasses or goggles with • Cuffless trousers to prevent entry of sparks and
side shields, and a welding helmet) with appropriate slag.
lens shading to protect your eyes from the arc’s • Remove any combustibles, such as a butane lighter
ultraviolet and infrared rays. or matches, from your pockets before cutting.

Lens Shade Cutting Area Prepare the cutting area to reduce

Arc Current AWS (USA) ISO 4850 reflection and transmission of ultraviolet light:
Up to 100 A No. 8 No. 11 • Paint walls and other surfaces with dark colors to
100-200 A No. 10 No. 11-12 reduce reflection.
200-400 A No. 12 No. 13 • Use protective screens or barriers to protect others
Over 400 A No. 14 No. 14 from flash and glare.
• Warn others not to watch the arc. Use placards or
signs.

GROUNDING SAFETY Input Power

• Be sure to connect the power cord ground wire to
the ground in the disconnect box.
Work Cable Attach the work cable securely to the • If installation of the plasma system involves
workpiece or the work table with good metal-to-metal connecting the power cord to the power supply, be
contact. Do not connect it to the piece that will fall sure to connect the power cord ground wire
away when the cut is complete. properly.
• Place the power cord's ground wire on the stud first,
Work Table Connect the work table to an earth then place any other ground wires on top of the
ground, in accordance with appropriate national or power cord ground. Fasten the retaining nut tightly.
local electrical codes. • Tighten all electrical connections to avoid excessive
heating.

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 SAFETY

COMPRESSED GAS EQUIPMENT SAFETY GAS CYLINDERS CAN

EXPLODE IF DAMAGED
• Never lubricate cylinder valves or regulators with oil
or grease. Gas cylinders contain gas under high pressure. If
• Use only correct gas cylinders, regulators, hoses damaged, a cylinder can explode.
and fittings designed for the specific application. • Handle and use compressed gas cylinders in
• Maintain all compressed gas equipment and accordance with applicable national or local codes.
associated parts in good condition. • Never use a cylinder that is not upright and secured
• Label and color-code all gas hoses to identify the in place.
type of gas in each hose. Consult applicable • Keep the protective cap in place over valve except
national or local codes. 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.

NOISE CAN DAMAGE HEARING PACEMAKER AND HEARING

AID OPERATION

Pacemaker and hearing aid operation can be affected

Prolonged exposure to noise from cutting or gouging
by magnetic fields from high currents.
can damage hearing.
Pacemaker and hearing aid wearers should consult a
• Use approved ear protection when using plasma
doctor before going near any plasma arc cutting and
system.
gouging operations.
• Warn others nearby about the noise hazard.
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
A PLASMA ARC CAN work cable.
DAMAGE FROZEN PIPES • Do not wrap or drape the torch lead or work cable
around your body.
• Keep as far away from the power supply as
Frozen pipes may be damaged or can burst if you possible.
attempt to thaw them with a plasma torch.

ADDITIONAL SAFETY INFORMATION 5. AWS F5.2, Recommended Safe Practices for Plasma Arc
Cutting, American Welding Society
1. ANSI Standard Z49.1, Safety in Welding and Cutting, American 550 LeJeune Road, P.O. Box 351040, Miami, FL 33135
Welding Society, 550 LeJeune Road 6. CGA Pamphlet P-1, Safe Handling of Compressed Gases in
P.O. Box 351020, Miami, FL 33135 Cylinders, Compressed Gas Association
2. ANSI Standard Z49.2, Fire Prevention in the Use of Cutting and 1235 Jefferson Davis Highway, Arlington, VA 22202
Welding Processes, American National Standards Institute 7. CSA Standard W117.2, Code for Safety in Welding and Cutting,
1430 Broadway, New York, NY 10018 Canadian Standards Association Standard Sales
3. ANSI Standard Z87.1, Safe Practices for Occupation and 178 Rexdale Boulevard, Rexdale, Ontario M9W 1R3, Canada
Educational Eye and Face Protection, American National 8. NFPA Standard 51B, Cutting and Welding Processes, National
Standards Institute, 1430 Broadway, New York, NY 10018 Fire Protection Association
4. AWS F4.1, Recommended Safe Practices for the Preparation for 470 Atlantic Avenue, Boston, MA 02210
Welding and Cutting of Containers and Piping That Have Held 9. NFPA Standard 70–1978, National Electrical Code, National Fire
Hazardous Substances, American Welding Society Protection Association, 470 Atlantic Avenue, Boston, MA 02210
550 LeJeune Road, P.O. Box 351040, Miami, FL 33135 10. OSHA, Safety and Health Standards, 29FR 1910
U.S. Government Printing Office, Washington, D.C. 20402

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SAFETY

WARNING LABEL 1. Cutting sparks can cause explosion or fire.

This warning label is affixed to some power supplies. It is
1.1 Keep flammables away from cutting.
important that the operator and maintenance technician
understand the intent of these warning symbols as described.
1.2 Keep a fire extinguisher nearby, and have
The numbered text corresponds to the numbered boxes on a watchperson ready to use it.
the label.
1.3 Do not cut on any closed containers.

2. The plasma arc can cause injury and

burns.

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 or

damaged gloves.

3.2 Insulate yourself from work and ground.

3.3 Disconnect input plug or power before

working on machine.

4. Breathing cutting fumes can be hazardous

to your health.

4.1 Keep your head out of the fumes.

4.2 Use forced ventilation or local exhaust to

remove 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 ear

protection and button shirt collar. Use
welding helmet with correct shade of filter.
Wear complete body protection.

6. Become trained and read the instructions

before working on the machine or cutting.

7. Do not remove or paint over (cover)

warning labels.

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 Section 1a

SÉCURITÉ

Dans cette section :

Identifier les consignes de sécurité.........................................................................................................................1a-2

Suivre les instructions de sécurité ..........................................................................................................................1a-2
Danger Avertissement Précaution ........................................................................................................................1a-2
Le coupage peut provoquer un incendie ou une explosion ....................................................................................1a-2
Prévention des incendies, Prévention des explosions ...................................................................................1a-2
Risque d’explosion argon-hydrogène et méthane..........................................................................................1a-2
Détonation de l’hydrogène lors du coupage de l’aluminium...........................................................................1a-2
Les chocs électriques peuvent être fatals...............................................................................................................1a-3
Prévention des chocs électriques ..................................................................................................................1a-3
Le coupage peut produire des vapeurs toxiques....................................................................................................1a-3
L’arc plasma peut provoquer des blessures ou des brûlures .................................................................................1a-4
Torches à allumage instantané ......................................................................................................................1a-4
Les rayons de l’arc peuvent brûler les yeux et la peau...........................................................................................1a-4
Protection des yeux, Protection de la peau, Zone de coupage ....................................................................1a-4
Mise à la masse et à la terre...................................................................................................................................1a-4
Câble de retour, Table de travail, Alimentation ...............................................................................................1a-4
Sécurité des bouteilles de gaz comprimé ...............................................................................................................1a-5
Les bouteilles de gaz comprimé peuvent exploser en cas de dommages .............................................................1a-5
Le bruit peut provoquer des problèmes auditifs......................................................................................................1a-5
Pacemakers et prothèses auditives ........................................................................................................................1a-5
Un arc plasma peut endommager les tuyaux gelés................................................................................................1a-5
Étiquette de sécurité ...............................................................................................................................................1a-6

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SÉCURITÉ

IDENTIFIER LES CONSIGNES • Garder la machine en bon état. Des modifications non
DE SÉCURITÉ autorisées sur la machine peuvent engendrer des
problèmes de sécurité et raccourcir la durée d’utilisation
Les symboles indiqués dans cette section sont utilisés pour de l’équipement.
identifier les risques éventuels. Si vous trouvez un symbole
de sécurité, que ce soit dans ce manuel ou sur
l’équipement, soyez conscient des risques de blessures et
DANGER AVERTISSEMENT PRÉCAUTION
suivez les instructions correspondantes afin d’éviter ces
risques. Les signaux DANGER ou AVERTISSEMENT sont utilisés
avec un symbole de sécurité, DANGER correspondant aux
SUIVRE LES INSTRUCTIONS risques les plus sérieux.
DE SÉCURITÉ • Les étiquettes de sécurité DANGER et AVERTISSEMENT
Lire attentivement toutes les consignes de sécurité dans le sont situées sur la machine pour signaler certains
présent manuel et sur les étiquettes de sécurité se trouvant dangers spécifiques.
sur la machine. • Les messages d’AVERTISSEMENT précèdent les
instructions d’utilisation expliquées dans ce manuel et
• Les étiquettes de sécurité doivent rester lisibles. signalent les risques de blessures ou de mort au cas où
Remplacer immédiatement les étiquettes manquantes ou ces instructions ne seraient pas suivies correctement.
abîmées. • Les messages de PRÉCAUTION précèdent les
• Apprendre à faire fonctionner la machine et à utiliser instructions d’utilisation contenues dans ce manuel et
correctement les commandes. Ne laisser personne utiliser signalent que le matériel risque d’être endommagé si les
la machine sans connaître son fonctionnement. instructions ne sont pas suivies correctement.

LE COUPAGE PEUT PROVOQUER UN INCENDIE

OU UNE EXPLOSION

Prévention des incendies AVERTISSEMENT

• Avant de commencer, s’assurer que la zone de coupage Risque d’explosion
ne présente aucun danger. Conserver un extincteur à argon-hydrogène et méthane
proximité.
• Éloigner toute matière inflammable à une distance d’au L’hydrogène et le méthane sont des gaz inflammables et
moins 10 m du poste de coupage. potentiellement explosifs. Conserver à l’écart de toute
• Tremper le métal chaud ou le laisser refroidir avant de flamme les bouteilles et tuyaux contenant des mélanges à
le manipuler ou avant de le mettre en contact avec des base d’hydrogène ou de méthane. Maintenir toute flamme
matériaux combustibles. et étincelle à l’écart de la torche lors de l’utilisation d’un
• Ne jamais couper des récipients pouvant contenir des plasma d’argon-hydrogène ou de méthane.
matières inflammables avant de les avoir vidés et
nettoyés correctement. AVERTISSEMENT
• Aérer toute atmosphère potentiellement inflammable Détonation de l’hydrogène lors du
avant d’utiliser un système plasma. coupage de l’aluminium
• Lors de l’utilisation d’oxygène comme gaz plasma, un
système de ventilation par aspiration est nécessaire. • Lors du coupage de l’aluminium sous l’eau, ou si l’eau
touche la partie inférieure de la pièce d’aluminium, de
Prévention des explosions l’hydrogène libre peut s’accumuler sous la pièce à couper
• Ne pas couper en présence de poussière ou de vapeurs. et détonner lors du coupage plasma.
• Ne pas couper de bouteilles, de tuyaux ou autres • Installer un collecteur d’aération au fond de la table à eau
récipients fermés et pressurisés. afin d’éliminer les risques de détonation de l’hydrogène.
• Ne pas couper de récipients contenant des matières Se référer à l’annexe du manuel pour plus de
combustibles. renseignements sur les collecteurs d’aération.

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 SÉCURITÉ

LES CHOCS ÉLECTRIQUES PEUVENT ÊTRE FATALS

• Installer et mettre à la terre l’équipement selon les

Toucher une pièce électrique sous tension peut provoquer instructions du présent manuel et conformément aux
un choc électrique fatal ou des brûlures graves. codes électriques locaux et nationaux.
• Inspecter fréquemment le cordon d’alimentation primaire
• La mise en fonctionnement du système plasma ferme un pour s’assurer qu’il n’est ni endommagé, ni fendu.
circuit électrique entre la torche et la pièce à couper. La Remplacer immédiatement un cordon endommagé.
pièce à couper et tout autre élément en contact avec cette Un câble dénudé peut tuer.
pièce font partie du circuit électrique. • Inspecter et remplacer les câbles de la torche qui sont
• Ne jamais toucher le corps de la torche, la pièce à couper usés ou endommagés.
ou l’eau de la table à eau pendant le fonctionnement du • Ne pas saisir la pièce à couper ni les chutes lors du
système plasma. coupage. Laisser la pièce à couper en place ou sur la
table de travail, le câble de retour connecté lors du
Prévention des chocs électriques coupage.
Tous les systèmes plasma Hypertherm utilisent des hautes • Avant de vérifier, de nettoyer ou de remplacer les pièces
tensions pour le coupage (souvent de 200 à 400 V). On de la torche, couper l’alimentation ou débrancher la prise
doit prendre les précautions suivantes quand on utilise le de courant.
système plasma : • Ne jamais contourner ou court-circuiter les verrouillages
• Porter des bottes et des gants isolants et garder le corps de sécurité.
et les vêtements au sec. • Avant d’enlever le capot du système ou de la source de
• Ne pas se tenir, s’asseoir ou se coucher sur une surface courant, couper l’alimentation électrique. Attendre ensuite
mouillée, ni la toucher quand on utilise le système plasma. 5 minutes pour que les condensateurs se déchargent.
• S’isoler de la surface de travail et du sol en utilisant des • Ne jamais faire fonctionner le système plasma sans que
tapis isolants secs ou des couvertures assez grandes les capots de la source de courant ne soient en place.
pour éviter tout contact physique avec le travail ou le sol. Les raccords exposés de la source de courant sont
S’il s’avère nécessaire de travailler dans ou près d’un extrêmement dangereux.
endroit humide, procéder avec une extrême prudence. • Lors de l’installation des connexions, attacher tout d’abord
• Installer un sectionneur avec fusibles appropriés, à la prise de terre appropriée.
proximité de la source de courant. Ce dispositif permet à • Chaque système plasma Hypertherm est conçu pour être
l’opérateur d’arrêter rapidement la source de courant en utilisé uniquement avec des torches Hypertherm
cas d’urgence. spécifiques. Ne pas utiliser des torches inappropriées qui
• En cas d’utilisation d’une table à eau, s’assurer que cette pourraient surchauffer et présenter des risques pour la
dernière est correctement mise à la terre. sécurité.

LE COUPAGE PEUT PRODUIRE DES VAPEURS TOXIQUES

Le coupage peut produire des vapeurs et des gaz toxiques soit très bien ventilée et que l’opérateur porte un masque
qui réduisent le niveau d’oxygène dans l’air et peuvent respiratoire. Les revêtements et métaux contenant ces
provoquer des blessures, voire la mort. matières peuvent produire des vapeurs toxiques lors du
• Conserver le poste de coupage bien aéré ou utiliser un coupage.
masque respiratoire homologué. • Ne jamais couper de récipients pouvant contenir des
• Ne pas procéder au coupage près d’endroits où matières inflammables avant de les avoir vidés et
s’effectuent le dégraissage, le nettoyage ou la vapori- nettoyés correctement.
sation. Certains solvants chlorés se décomposent sous • Quand on utilise ce produit pour le soudage ou le
l’effet des rayons ultraviolets et forment du phosgène. coupage, il dégage des fumées et des gaz qui
• Ne pas couper des métaux peints ou contenant des contiennent des produits chimiques qui, selon l’État de
matières toxiques comme le zinc (galvanisé), le plomb, le Californie, provoquent des anomalies congénitales et,
cadmium ou le béryllium, à moins que la zone de travail dans certains cas, le cancer.

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SÉCURITÉ

L’ARC PLASMA PEUT PROVOQUER DES BLESSURES OU DES BRÛLURES

Torches à allumage instantané L’arc plasma coupe facilement les gants et la peau.
L’arc plasma s’allume immédiatement après que la torche • Rester éloigné de l’extrémité de la torche.
soit mise en marche. • Ne pas tenir de métal près de la trajectoire de coupe.
• Ne jamais pointer la torche vers soi ou d’autres
personnes.

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

Protection des yeux Les rayons de l’arc plasma • Gants à crispin, chaussures et casque de sécurité.
produisent de puissants rayons visibles ou invisibles • Vêtements ignifuges couvrant toutes les parties exposées
(ultraviolets et infrarouges) qui peuvent brûler les yeux et la du corps.
peau. • Pantalon sans revers pour éviter que des étincelles ou
• Utiliser des lunettes de sécurité conformément aux codes des scories puissent s’y loger.
locaux ou nationaux en vigueur. • Avant le coupage, retirer de ses poches tout objet
• Porter des lunettes de protection (lunettes ou masque combustible comme les briquets au butane ou les
muni d’écrans latéraux et encore masque de soudure) allumettes.
avec des verres teintés appropriés pour protéger les yeux
des rayons ultraviolets et infrarouges de l’arc. Zone de coupage Préparer la zone de coupage afin de
réduire la réverbération et la transmission de la lumière
Puissance des verres teintés ultraviolette :
Courant de l’arc AWS (É.-U.) ISO 4850 • Peindre les murs et autres surfaces de couleur sombre
Jusqu’à 100 A No 8 No 11 pour réduire la réflexion de la lumière.
100-200 A o
N 10 No 11-12 • Utiliser des écrans et autres dispositifs de protection afin
200-400 A o
N 12 No 13 de protéger les autres personnes de la lumière et de la
Plus de 400 A o
N 14 No 14 réverbération.
• Prévenir les autres personnes de ne pas regarder l’arc.
Protection de la peau Porter des vêtements de sécurité Utiliser des affiches ou des panneaux.
pour se protéger contre les brûlures que peuvent causer les
rayons ultraviolets, les étincelles et le métal brûlant :

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.
Câble de retour Bien fixer le câble de retour (ou de • S’il est nécessaire de brancher le cordon d’alimentation à
masse) à la pièce à couper ou à la table de travail de façon la source de courant lors de l’installation du système,
à assurer un bon contact métal-métal. Ne pas fixer le câble s’assurer que le fil de terre est correctement branché.
de retour à la partie de la pièce qui doit se détacher. • Placer tout d’abord le fil de terre du cordon d’alimentation
sur le plot de mise à la terre puis placer les autres fils de
Table de travail Raccorder la table de travail à la terre, terre par-dessus. Bien serrer l’écrou de retenue.
conformément aux codes de sécurité locaux ou nationaux • S’assurer que toutes les connexions sont bien serrées
appropriés. pour éviter la surchauffe.

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 SÉCURITÉ

SÉCURITÉ DES BOUTEILLES DE LES BOUTEILLES DE GAZ

GAZ COMPRIMÉ COMPRIMÉ PEUVENT EXPLOSER
EN CAS DE DOMMAGES
• Ne jamais lubrifier les robinets des bouteilles ou les
régulateurs avec de l’huile ou de la graisse. Les bouteilles de gaz contiennent du gaz à haute pression.
• Utiliser uniquement les bouteilles, régulateurs, tuyaux et Si une bouteille est endommagée, elle peut exploser.
accessoires appropriés et conçus pour chaque application • Manipuler et utiliser les bouteilles de gaz comprimé
spécifique. conformément aux codes locaux ou nationaux.
• Entretenir l’équipement et les pièces d’équipement à gaz • Ne jamais utiliser une bouteille qui n’est pas placée à la
comprimé afin de les garder en bon état. verticale et bien assujettie.
• Étiqueter et coder avec des couleurs tous les tuyaux de • Le capuchon de protection doit être placé sur le robinet
gaz afin d’identifier le type de gaz contenu dans chaque sauf si la bouteille est en cours d’utilisation ou connectée
tuyau. Se référer aux codes locaux ou nationaux en pour utilisation.
vigueur. • Éviter à tout prix le contact électrique entre l’arc plasma et
une bouteille.
• Ne jamais exposer des bouteilles à une chaleur
excessive, aux étincelles, aux scories ou aux flammes
nues.
• Ne jamais utiliser des marteaux, des clés ou d’autres
outils pour débloquer le robinet des bouteilles.

LE BRUIT PEUT PROVOQUER DES PACEMAKERS ET

PROBLÈMES AUDITIFS PROTHÈSES AUDITIVES

Les champs magnétiques produits par les courants à haute

Une exposition prolongée au bruit du coupage ou du
tension peuvent affecter le fonctionnement des prothèses
gougeage peut provoquer des problèmes auditifs.
auditives et des pacemakers. Les personnes portant ce
• Utiliser un casque de protection homologué lors de
type d’appareil doivent consulter un médecin avant de
l’utilisation du système plasma.
s’approcher d’un lieu où s’effectue le coupage ou le
• Prévenir les personnes aux alentours des risques
gougeage plasma.
encourus en cas d’exposition au bruit.
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
UN ARC PLASMA du câble de retour.
PEUT ENDOMMAGER • Ne pas s’enrouler le faisceau de la torche ou le câble de
LES TUYAUX GELÉS retour autour du corps.
• Se tenir le plus loin possible de la source de courant.

Les tuyaux gelés peuvent être endommagés ou éclater

si l'on essaie de les dégeler avec une torche plasma.

Hypertherm Systèmes plasma 1a-5

2/12/01
SÉCURITÉ

Étiquette de sécurité 1. Les étincelles produites par le coupage

Cette étiquette est affichée sur la source de courant. Il est important peuvent provoquer une explosion ou un
que l’utilisateur et le technicien de maintenance comprennent la incendie.
signification des symboles de sécurité. Les numéros de la liste 1.1 Pendant le coupage, éloigner toute matière
correspondent aux numéros des images. inflammable.
1.2 Conserver un extincteur à proximité et
s’assurer qu’une personne soit prête à
l’utiliser.
1.3 Ne jamais couper de récipients fermés.
2. L’arc plasma peut provoquer des blessures
et des brûlures.
2.1 Couper l’alimentation avant de démonter la
torche.
2.2 Ne pas tenir la surface à couper près de la
trajectoire de coupe.
2.3 Porter des vêtements de protection
couvrant tout le corps.
3. Un choc électrique causé par la torche ou
les câbles peut être fatal. Se protéger
contre les risques de chocs électriques.
3.1 Porter des gants isolants. Ne pas porter de
gants mouillés ou abîmés.
3.2 S’isoler de la surface de travail et du sol.
3.3 Débrancher la prise ou la source de
courant avant de manipuler l’équipement.
4. L’inhalation des vapeurs produites par le
coupage peut être dangereuse pour la
santé.
4.1 Garder le visage à l’écart des vapeurs.
4.2 Utiliser un système de ventilation par
aspiration ou d’échappement localisé pour
dissiper les vapeurs.
4.3 Utiliser un ventilateur pour dissiper les
vapeurs.
5. Les rayons de l’arc peuvent brûler les yeux
et provoquer des lésions de la peau.
5.1 Porter un casque et des lunettes de
sécurité. Se protéger les oreilles et porter
une chemise dont le col peut être
déboutonné. Porter un casque de soudure
dont la protection filtrante est suffisante.
Porter des vêtements protecteurs couvrant
la totalité du corps.
6. Se former à la technique du coupage et lire
les instructions avant de manipuler
l’équipement ou de procéder au coupage.
7. Ne pas retirer ou peindre (recouvrir) les
étiquettes de sécurité.

1a-6 Hypertherm Systèmes plasma

2/12/01
 Section 2

SPECIFICATIONS

HySpeed HT2000LHF System Components

See Figure 3-2 in Section 3 for details of the system interconnections.

Power Supply
The LHF power supply houses two 100-amp, 15 kHz choppers, the torch's high-frequency starting circuit and an
optional internal Torch Height Control (THC).

HySpeed LHF Machine Torch

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

Gas Console
This unit houses metering and solenoid valves for shield and plasma gases, flow meters, pressure gauges for
plasma gases, and a pressure gauge for the shield gas supply.

Argon-Hydrogen Manifold – Optional

This unit houses a flowmeter for argon-hydrogen, a metering valve, a plasma gas outlet switch and a plasma-off
valve.

Digital Remote Voltage & Current Control Console

This unit includes LED displays that indicate the setpoints for volts and amperes prior to starting the arc. The
displays then automatically display the actual values of the voltage and current while cutting. The digital remote has
potentiometers to set and adjust the voltage and current.

Programmable Remote Voltage & Current Control Console

This unit includes LED displays that indicate the setpoints for volts and amperes prior to starting the arc. The
displays then automatically display the actual values of the voltage and current while cutting. The programmable
remote functions are controlled by the CNC.

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7
SPECIFICATIONS

Remote Current Control Console

This unit contains a manually adjustable thumbwheel to set arc current only.

Initial Height Sensing - Optional

This unit, used with 2 inductive probes, is designed to automatically detect the workpiece surface and move the
torch to the pierce position. This system can be used for underwater cutting, cutting at the water line, or cutting
above water.

Timer/Counter – Optional
The timer/counter allows the operator to monitor the number of arc starts and the cumulative time that the arc is on
in hours. The arc starts can be reset.

Water Muffler – Optional

The water muffler for the LHF system is an option which greatly improves cutting safety and pollution control
capabilities. The water muffler can be used to cut above, below and at the water line. Refer to the Water Muffler
instruction manual 802050 for more detailed information. The water muffler cannot be used with the stainless steel
torch.

CommandTHC – Optional
The CommandTHC is an external torch height control and initial height sensing system designed for plasma cutting
applications on an x-y cutting table. Refer to the CommandTHC instruction manual 802780 for more detailed
information.

Specifications
System Requirements
Power Requirements:
Refer to LHF 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 Flow Rates:

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 90 scfh (2549 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 Flow Rates:

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)
Oxygen .........................................................................120 psi +/- 10 psi (8.3 bar +/- 0.7 bar) at 35 scfh (991 l/h)

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 SPECIFICATIONS

Power Supply
Maximum OCV (U0) ......................................................280 VDC
Output Current (I2) ........................................................40 – 200 amps
Output Voltage (U2) ......................................................150 VDC
Duty Cycle Rating (X) ..................................................100% up to 30 kW. Beyond 30 kW, Duty Cycle (X) =
(30 kW/Actual Power)2 Eg: If Actual Power = 32 kW, then Duty
Cycle (X) = (30 kW/32 kW)2 = 88%
Ambient Temperatures/Duty Cycle ...............................Power supplies will operate between +14° and 104° F (-10° and
+40° C). Power supplies operated in an ambient temperature
above 86° F (30° C) may show some decrease in duty cycle.
Power Factor (cosϕ) .....................................................0.86

Input Power (Input Voltage (U1) x Input Current ( I1)):

073227 with THC; 073228 without THC .......................200 VAC, 3PH, 50 Hz, 108 amps
073229 with THC; 073230 without THC .......................208 VAC, 3PH, 60 Hz, 104 amps
073231 with THC; 073232 without THC .......................240 VAC, 3PH, 60 Hz, 90 amps
073235 with THC; 073236 without THC .......................400 VAC, CE, 3PH, 50 Hz, 56 amps
073262 with THC; 073263 without THC .......................440 VAC, 3PH, 50-60 Hz, 49 amps
073233 with THC; 073234 without THC .......................480 VAC, 3PH, 60 Hz, 45 amps
073237 with THC; 073238 without THC .......................600 VAC, 3PH, 60 Hz, 36 amps

Dimensions and Weight:

Width.............................................................................28-1/4" (710 mm)
Height ...........................................................................35-1/2" (900 mm); 40-3/4" (1035 mm) on CE units
Depth ............................................................................41-1/4" (1045 mm)
Weight...........................................................................780 lbs (351 kg); 800 lbs (363 kg) on CE units
Cooling..........................................................................Forced Air (Class F)
Coolant Tank Capacity ..................................................2.9 gallons (11 liters)

HySpeed LHF Machine Torch

2" (50 mm) or

1.75" (44 mm)
2" 4.3"
See Sect. 6 (51 mm) (109 mm)

6"
(152 mm)
15.4"
(391 mm)
23.25"
(590 mm)

Figure 2-1 LHF Machine Torch (standard torch shown. See Section 6 for figure of stainless steel torch)

Maximum cutting thickness...........................................2" (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 specific gas
requirements.

Water coolant flow rate .................................................0.8 gpm (3.0 l/min)

Weight...........................................................................3 lbs (1.36 kg)

HySpeed HT2000LHF Instruction Manual 2-3

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SPECIFICATIONS

Gas Console
2"
3.75" 3.75" (51 mm)
2"
Dimensions and Weight: (95 mm) (95 mm)
(51 mm)
Width .......................................................11.5" (290 mm)
Height ......................................................14.5" (370 mm)
4"
Depth.......................................................4" (100 mm) (102 mm)
Weight .....................................................23 lbs (10.4 kg)
3"
(76 mm)

0.5" 1/4-20 PEM (6) – Use 1/4-20 screws

(13 mm) that do not enter more than 1/2" into
enclosure

Figure 2-2 Mounting Dimensions – Gas Console

0.5" 5"
Argon-Hydrogen Manifold – Optional (13 mm) 5"
(127 mm)
4"(1024"mm)
Dimensions and Weight:
Width .......................................................5" (127 mm) 13/64"
(5 mm) dia.
Height ......................................................10" (254 mm) 4 places
Depth.......................................................5" (127 mm)
Weight .....................................................5.75 lbs (2.6 kg) 5"
(127 5"
mm)

4"
4"
(102 mm)

Figure 2-3 Mounting Dimensions – Argon-

Hydrogen Manifold

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 SPECIFICATIONS

Digital Remote Voltage & Current 11.4" (290 mm)

0.5" 10.5" (267 mm)
Control Console (13 mm)

Controls....................Voltage adjust potentiometer: Adjusts arc

cutting voltage and displays value on LEDs.
Current adjust potentiometer: Adjusts arc
5"
current and displays value on LEDs. (127 mm)
Control range ...........Current: 40-200 amps/Voltage: 100-200 volts
Control resolution .....Current: 10 amps/ Voltage: 5 volts

Dimensions and Weight:

Width .......................................................11.4" (290 mm) 11.65" (296 mm)
7/32"
Height ......................................................3" (76 mm) (5.5 mm)
dia.
Depth.......................................................13.4" (340 mm) 4 places
Weight .....................................................5.3 lbs (2.4 kg)

Figure 2-4 Mounting Dimensions – Digital

Remote Voltage & Current Control Console

Programmable Remote Voltage & Current 11.4" (290 mm)

0.5" 10.5" (267 mm)
Control Console (13 mm)

Controls....................None. Controlled through guidance CNC.

Control range ...........Current: 40-200 amps/Voltage: 100-200 volts
Control resolution .....Current: 10 amps/ Voltage: 5 volts
5"
(127 mm)
Dimensions and Weight:
Width .......................................................11.4" (290 mm)
Height ......................................................3" (76 mm)
Depth.......................................................12.5" (318 mm)
11.65" (296 mm)
Weight .....................................................5.3 lbs (2.4 kg) 7/32" dia.
(5.5 mm)
4 places

Figure 2-5 Mounting Dimensions – Programmable

Remote Voltage & Current Control Console

Remote Current Control Console

Dimensions and Weight: 5/32" ø (4 mm) – 4 places

Width .......................................................6-1/2" (165 mm)

Height ......................................................2-1/2" (64 mm)
Depth.......................................................8-5/8" (219 mm) 6.50"
(165 mm)
Weight .....................................................3 lbs (1 kg)
3.38" (86 mm)

0.50" (13 mm)

6.25" (159 mm)

1.17"
(30 mm) 8.5" (216 mm)

Figure 2-6 Mounting Dimensions –

Remote Current Control Console

HySpeed HT2000LHF Instruction Manual 2-5

6
SPECIFICATIONS

Initial Height Sensing (IHS) – Optional 8" (290 mm)

6" (152 mm)

Input power .............................................120VAC from power supply

Air pressure .............................................20 psi (1.4 bar) regulated
shop air input to solenoid

Dimensions and Weight: 11.5"

(292 mm)
Width .......................................................9" (229 mm)
Height ......................................................4.5" (114 mm)
Depth.......................................................11.5" (292 mm) 10.75"
Weight .....................................................13 lbs (6 kg) (273 mm)

5/16" dia.
(8 mm)
4 places

Figure 2-7 Mounting Dimensions – IHS

Timer/Counter – Optional
Dimensions and Weight: 5/32" ø (4 mm) – 4 places
Width .......................................................6-1/2" (165 mm)
Height ......................................................2-1/2" (64 mm)
Depth.......................................................8-5/8" (219 mm) 6.50"
(165 mm)
Weight .....................................................3 lbs (1 kg)
3.38" (86 mm)

0.50" (13 mm)

6.25" (159 mm)

1.17"
(30 mm) 8.5" (216 mm)

Figure 2-8 Mounting Dimensions – Timer/Counter

Water Muffler – Optional

Refer to the Water Muffler Instruction Manual 802050. The water muffler cannot be used with the stainless steel
torch.

CommandTHC – Optional
Refer to the CommandTHC Instruction Manual 802780.

2-6 HySpeed HT2000LHF Instruction Manual

6
 Section 3

INSTALLATION

Upon Receipt
• Verify that all system components on your order have been received. Contact your supplier if any items are
missing.

• Inspect the system components for any physical damage that may have occurred during shipping. If there is
evidence of damage, refer to Claims. All communications regarding claims must include the model number and
serial number located on the back of the power supply.

Claims
Claims for damage during shipment – If your unit was damaged during shipment, you must file a claim with the
carrier. Hypertherm will furnish you with a copy of the bill of lading upon request. If you need additional assistance,
call Customer Service listed in the front of this manual, or your authorized Hypertherm distributor.

Claims for defective or missing merchandise – If any of the merchandise is defective or missing, contact your
supplier. If you need additional assistance, call Customer Service listed in the front of this manual, or your
authorized Hypertherm distributor.

Installation Requirements
All installation and service of the electrical and plumbing systems must conform to national or local
electrical and plumbing codes. This work should be performed only by qualified, licensed personnel.

Direct any technical questions to the nearest Hypertherm Technical Service Department listed in the front of this
manual, or your authorized Hypertherm distributor.

Gas Requirements
All gases are provided by the customer. Refer to Section 2 for specifications.

HySpeed HT2000LHF Instruction Manual 3-1

6
INSTALLATION

Caution: Gas supply pressures not within the parameters outlined in Section 2 can cause
poor cut quality, poor consumable life, and operational problems.

If the purity level of the gas is too low or if there are leaks in the supply hoses or
connections,

• Cut speeds can decrease

• Cut quality can deteriorate
• Cutting thickness capability can decrease
• Parts life can shorten

The LHF system can cut with air, oxygen, nitrogen or argon-hydrogen as the plasma gas, and use air, nitrogen or
carbon dioxide as the shield gas.

Air may be supplied from cylinders, a liquid supply, or from an on-site compressor. Hypertherm recommends a
three-stage coalescing filtration system when using air as a supply gas. See the appendix section for suggested
filtration.

Other gases may be supplied from cylinders or liquid storage tanks.

Gas Supply Plumbing

If making hard plumbing connections, avoid using iron pipe. Never use PTFE tape on any joint preparation. After
installation, pressurize the entire system and check for leaks.

For flexible-hose systems, use a hose designed for inert gas to carry air, nitrogen, argon-hydrogen or carbon-
dioxide.

Caution: Only hose designed to carry oxygen may be used for oxygen lines.

Note: When cutting with oxygen as the plasma gas, nitrogen must also be connected to the gas console to
achieve the proper oxygen/nitrogen mixtures in the preflow and cut flow conditions.

WARNING

Cutting with oxygen as the plasma gas can cause a potential fire hazard due to the oxygen-
enriched atmosphere that it creates. As a precaution, Hypertherm recommends that an exhaust
ventilation system be installed when cutting with oxygen.

3-2 HySpeed HT2000LHF Instruction Manual

6
 INSTALLATION

Torch Coolant Requirements

The power supply is shipped to the customer without any coolant in the tank. Hypertherm recommends a mixture
of 30% propylene glycol, 69.9% purified water, and 0.1% benzotriazole. This mixture resists freezing to +10° F
(-12° C) and protects copper surfaces in the coolant loop.

Caution: For operating temperatures colder than +10° F (-12° C), the percentage of
propylene glycol must be increased to avoid the risk of a cracked torch head,
hoses, or other damage to the torch coolant system due to the freezing of the
torch coolant.

Caution: Always use propylene glycol in the coolant. Do not substitute automotive
antifreeze which will damage the torch cooling system.

Caution: Always use purified water in the coolant mixture in order to prevent corrosion
in the cooling system. The hardness of the purified water should be between
0.2 and 8.5 ppm. If using a conductivity meter to measure water purity, the
recommended level is between 0.5 and 18 µSiemens/cm at 77° F (25° C).

See the chart in the appendix section to determine if a stronger propylene glycol/purified water solution is needed
for your particular application. The standard coolant mixture is available in 1-gallon containers by ordering 028872.
100% propylene glycol is available by ordering 028873.

Refer to the Material Safety Data Sheets in the appendix section for data on safety, handling, and storage of
propylene glycol and benzotriazole.

WARNING

Propylene glycol and benzotriazole are irritating to skin and eyes, and harmful or fatal if
swallowed. Upon contact, flush skin or eyes with water. If swallowed, drink water and call a
physician immediately. Do not induce vomiting.

Grounding Requirements
Proper grounding is essential for personal safety and to prevent emission of high-frequency interference.

See Appendix for system grounding requirements.

Connect the worktable to a high-quality earth ground, not more than 20 feet (6 m) from the table. A suitable ground
consists of a solid copper rod of at least 1/2" (12 mm) diameter driven to a depth of at least 8 feet (2.5 m) into the
earth, below the permanent moisture level. Ensure that all grounding connections are tight to avoid excessive
heating. The power supply enclosure is grounded through the incoming AC conductor and does not require an
additional ground. See also Grounding in the Safety section. For additional information consult national or local
electric codes.

HySpeed HT2000LHF Instruction Manual 3-3

9
INSTALLATION

Caution: All accessory modules in the system must be grounded to earth. Use a minimum
of 8 AWG wire connected from the stud on the side of each module enclosure to
the worktable ground.

Noise levels
This plasma system may produce noise that is harmful to the operator or to those close to the cutting table. See
Noise Protection in the Safety section.

Power Requirements
All switches, slow-blow fuses and power cables are customer supplied and must be chosen as outlined by
applicable national and/or local electrical codes. Installation must be performed by qualified personnel.
Use a separate primary line disconnect switch for the power supply.

Rated Input
Input Current @ Recommended Recommended
Voltage Phase 30 kw Output Slow-Blow Fuse Size Cable Size (AWG)

200 VAC 3 108 amps 150 amps 1

208 VAC 3 104 amps 150 amps 1
240 VAC 3 90 amps 150 amps 1
400 VAC 3 56 amps 80 amps 4
440 VAC 3 49 amps 70 amps 6
480 VAC 3 45 amps 60 amps 6
600 VAC 3 36 amps 50 amps 8

Line Disconnect Switch

The line disconnect switch serves as the supply voltage disconnecting (isolating) device. Install this switch on a
wall near the power supply for easy accessibility by the operator. The line disconnect switch must be installed
by qualified personnel following all applicable local and national codes. The switch should:

• isolate the electrical equipment and disconnect all live conductors from the supply voltage when in the
“OFF” position
• have one “OFF” and one “ON” position clearly marked with “0” (OFF) and “1” (ON)
• have an external operating handle capable of being locked in the “OFF” position
• contain a power operated mechanism that serves as an emergency stop
• have slow-blow fuses installed for the proper breaking capacity (see table above)

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 INSTALLATION

Power Cable

Wire sizes vary based on the distance of the receptacle from the main box. The wire sizes listed in the table above
were taken from the National Electric Code 1990 handbook, table 310.16. Use a 4-conductor Type SO input power
cable with a conductor temperature rating of 140°F (60°C). The cable should be installed only by a licensed
electrician.

Positioning the Power Supply

WARNING

Remove all electrical connections to power supply before moving or positioning. Transporting
unit can cause personal injury and equipment damage.

Note: A lifting eye is provided for moving the power supply into place with a crane or hoist. It may also be moved
by forklift if the forks are long enough to extend the entire length of the base. Take care when lifting with the
forks so that the underside of the power supply is not damaged.

• Place the power supply in an area that is free of excessive moisture, has proper ventilation, and is relatively
clean. Allow room for accessing the sides of the power supply for servicing.

• Cooling air is drawn in through the front panel grating, and is exhausted through the rear of the unit by a
cooling fan. Do not place any filter device over the air intake locations. This reduces cooling efficiency and
VOIDS THE WARRANTY.

Connecting the Power

WARNING

The line disconnect switch must be in the OFF position before making the power cable
connections! In the U.S., use a "lock-out/tag-out" procedure until installation is complete. In
other countries, follow appropriate local or national safety procedures.

HySpeed HT2000LHF Instruction Manual 3-5

6
INSTALLATION

Connecting the Power (continued)

1. Insert the power cable through the strain relief at the lower left rear of the power supply. Connect the power
cable leads to TB1 located at the center wall, right side.

2. Connect the power leads to the L1, L2, and L3 terminals of TB1. See Fig. 3-1.

3. Connect the ground lead as shown.

To connect the power Ground lead

cable to the 400V CE
power supplies refer to
the appendix section.

Figure 3-1 Power Cable Connections

WARNING

There is line voltage at the contactor if the line disconnect switch is in the ON position, even if the
ON (1) pushbutton on the power supply has not been pressed. As a common safety practice,
ALWAYS verify that the line disconnect switch is in the OFF position before installing, disconnecting
or servicing in this area.

3-6 HySpeed HT2000LHF Instruction Manual

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 INSTALLATION

Power Cable from LHF Power Supply to Power Source.

1. Be certain that the line disconnect switch is in the OFF position and remains in the OFF position for the
remainder of the installation of the LHF system.

2. Connect the power cord leads to the line disconnect switch following local and applicable electrical codes.

Torch Lifter Requirements

The LHF system requires a high-quality, motorized torch lifter with sufficient travel to cover all cutting thickness
requirements. The lifter must provide 10 inches (254 mm) of vertical travel. The unit should have a constant
speed of at least 20 ipm (508 mm/min) with positive braking. A unit which drifts through the stop point is not
acceptable.

Optional Equipment

Water Muffler

Refer to Water Muffler instruction manual 802050. A power cable for the Water Muffler pump must be provided by
the customer. The pumps provided by Hypertherm take a three-phase input. Part numbers and corresponding
voltages are listed in the Water Muffler manual. Input current information is provided on the motor data plate.
Present pump systems all draw less than 20 amps and cable sizes should be selected accordingly.

The water muffler cannot be used with the stainless steel torch.

System Units Placement

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

• Ground all external modules in the LHF system to earth.

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

Torque Specification
Gas or water
hose size lbf-in lbf-ft kgf-cm

up to 3/8" 75-85 6.25-7 86-98

1/2" 360-480 30-40 415-550

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 the
diagram to find out specific information on each cable, hose or connection. The numbered items are detailed on the
pages following the interconnection diagram.

HySpeed HT2000LHF Instruction Manual 3-7

6
 2

Blue Green Red Gray

Power Supply

1X1 1X2 1X3 1X9

1X6 1X7 1X5 1X4 1X10

3 22
1 See Valve Cluster and Torch
Connections – pages 3-17 to 3-18.
Worktable
6 16

4
5 15

7
Customer
Supplied
Interface 8

9
14
10
Initial Height
To water muffler pump Sensing

13
To argon-hydrogen
manifold – see the
appendix section
To IHS probes and air supply
– see the appendix section

12 To Second LHF Power Supply

11
Timer/Counter
11X1

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2

17
To shield gas supply
18
To oxygen gas supply
19
To nitrogen or air
gas supply

Gas Console
20 21

See Valve Cluster Connections –

16 page 3-18.

15

8 5X1

Digital Remote

5X2 5X1

Programmable Remote

15X1

Remote Current

Figure 3-2 System Interconnections

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INSTALLATION

Power Supply Connections

1 Positive Lead – Power Supply to Worktable

1 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)

2 Gas Console Cable – Power Supply to Gas Console

2 Part No. Length

1X2 3X1 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)
1x2 3x1 Color Signal 1x2 3x1 Color Signal 123044 60 ft (18.3 m)
2 2 Black LT1 / DC ON 19 19 Black S1 / N2 / O2 023607 75 ft (23 m)
3 3 Green LT1 / DC ON 20 20 Orange S1 / N2 / O2 123077 85 ft (25.9 m)
7 7 Shield 13 13 Shield
8 8 Black SV1B / O2 / N2 023608 100 ft (30.5)
14 14 Red S2 / Test / Preflow
9 9 Blue SV1B / O2 / N2 15 15 White S2 / Test / Common
023963 115 ft (35.1 m)
4 4 Shield 21 21 Shield 123147 120 ft (36.6 m)
16 16 Black SV2 / O2 / N2 35 35 Red S2 / Test / Operate 023743 125 ft (38.1 m)
17 17 Yellow SV2 / O2 / N2 36 36 Green S2 / Test / Common
10 10 Shield 023609 150 ft (46 m)
31 31 Shield 023953 200 ft (62 m)
27 27 Red SV1A / O2 / N2 32 32 Red PS1&PS2
28 28 Brown SV1A / O2 / N2 33 33 Blue PS1&PS2
22 22 Shield 37 37 Shield
11 11 Black SV3 / Preflow Trap
12 12 Brown SV3 / Preflow Trap
18 18 Shield

3 Off-Valve Cable – Power Supply to Valve Cluster Cable

See valve cluster connections on page 3-18.

3 Part No. Length

1X3 4X1 123283 15 ft (4.6 m)

123284 20 ft (6 m)
123285 25 ft (7.6 m)
123286 30 ft ( 9.2 m)
1x3 4x1 Color Signal 123287 35 ft (10.7 m)
1 1 Red SV4A Cutflow 123288 40 ft (12.2 m)
2 2 White SV4A Cutflow 123289 50 ft (15 m)
3 3 Green Shield
5 5 Orange SV4B Preflow
6 6 White SV4B Preflow
4 4 White Shield
7 7 Black SV5 Plasma OFF
8 8 White SV5 Plasma OFF
9 9 Yellow Shield

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 INSTALLATION

4 Machine I/O Interface Cable – Power Supply 4 Part No. Length Part No. Length
to Machine Interface 023841 6 ft (1.8 m) 123080 85 ft (25.9 m)
023842 15 ft (4.6 m) 023847 100 ft (30.5)
023843 25 ft (7.6 m) 023962 115 ft (35.1 m)
1X6
023844 35 ft (10.7 m) 123148 120 ft (36.6 m)
023845 50 ft (15 m) 023848 125 ft (38.1 m)
123047 60 ft (18.3 m) 023849 150 ft (46 m)
023846 75 ft (23 m) 023850 200 ft (62 m)

1x6 Color Signal 1x6 Color Signal

2 Yellow Initial Height Sig. (OFF=Closed) 9 Blue Plasma START (START=Closed)
6 Black Initial Height Com. 15 Black Plasma START
11 Shield 14 Shield
4 Orange Auto Height Sig. (OFF=Closed) 37 Red †Arc Transfer (TRANSFER=Closed)
8 Black Auto Height Com. 32 Green †Arc Transfer
13 Shield 26 Shield
34 Red *†Lifter DOWN Load (DOWN=Closed) 1 White Hold Ignition Sig. (HOLD=Closed)
29 Black Lifter DOWN Line 5 Black Hold Ignition Com.
23 Shield 10 Shield
35 Green *†Lifter UP Load (UP=Closed) 3 Brown Ramp Down Error
30 Black Lifter UP Line 7 Black Ramp Down Error
24 Shield 12 Shield
36 Red Upper Limit Switch ( OFF=Closed)
31 Blue Upper Limit Switch
25 Shield

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

WARNING

When installing or servicing the power supply, 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 certain
that all line disconnect switches relating to the system are OFF during installation and when servicing.

5 Machine V/C Interface Cable – Power Supply 5 Part No. Length Part No. Length
to Machine Interface
023902 6 ft (1.8 m) 023855 75 ft (23 m)
023851 15 ft (4.6 m) 023856 100 ft (30.5)
023852 25 ft (7.6 m) 023903 125 ft (38.1 m)
1X7 023853 35 ft (10.7 m) 023857 150 ft (46 m)
023854 50 ft (15 m) 023858 200 ft (62 m)

Note: If you are using a remote V/C to set voltage and current, skip this step.

Before connecting the machine V/C interface cable, see the wiring diagrams in this manual and verify that
the correct plug is attached to the µP control PCB REC6 receptacle.

1x7 Color Signal 1x7 Color Signal

2 White Current 10 16 Black/Red Voltage V5
3 Red Current 20 17 White/Red Voltage V10
4 Green Current 40 18 Orange/Red Voltage V20
5 Orange Current 80 19 Blue/Red Voltage V40
6 Blue Current 100 20 Red/Green Voltage V80
7 White/Black Current 200 21 Orange/Green Voltage V100
10 Shld Shield 22 Black/White/Red Voltage V200
11 Blue/Black Current Common 23 White/Black/Red Voltage VCommon

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INSTALLATION

6 Remote I/O Cable – Power Supply to Remote Interface

6 Part No. Length Part No. Length
123294 6 ft (1.8 m) 123301 85 ft (25.9 m)
123295 15 ft (4.6 m) 123302 100 ft (30.5)
123296 25 ft (7.6 m) 123303 115 ft (35.1 m)
1X1 123297 35 ft (10.7 m) 123304 120 ft (36.6 m)
123298 50 ft (15.3 m) 123305 125 ft (38.1 m)
123299 60 ft (18.3 m) 123306 150 ft (46 m)
123300 75 ft (23 m) 123307 200 ft (62 m)

1x1 Color Signal 1x1 Color Signal

2 Yellow PB1 LT1 24VAC 19 White FS1 Interlock
3 Black PB1 LT1 24VAC 20 Red FS1 Interlock
7 Shield Ground 13 Shield Ground
5 Orange TS1 Interlock 23 Blue LT1 120 VAC
6 Black TS1 Interlock 24 Black LT1 120 VAC
1 Shield Ground 25 Shield Ground
8 Red LS1 Interlock 26 Red PB2A 24 VAC
9 Black LS1 Interlock 27 Green PB2A 24 VAC
4 Shield Ground 28 Shield Ground
11 Green PS3 Interlock 29 White PB2B 120 VAC
12 Black PS3 Interlock 30 Black PB2B 120 VAC
18 Shield Ground 34 Shield Ground
14 Red PS1,PS2 Interlock 32 Brown PB1A 24 VAC
15 Blue PS1,PS2 Interlock 33 Black PB1A 24 VAC
21 Shield Ground 37 Shield Ground
16 Red TS2 Interlock 35 Red PB1B 120 VAC
17 Yellow TS2 Interlock 36 Brown PB1B 120 VAC
10 Shield Ground 31 Shield Ground

Notes: • If using this Remote I/O Cable, remove jumpers from power supply
TB5 terminals 1&2 and 4&5 and terminate Remote I/O Cable wires for
PB2A and PB2B to a normally closed switch.
Remove jumper Remove jumper
• Terminate wires for PB1A and PB1B to a normally open switch.
• Input requirements for interlocks: DC current between 15 and 20 mA; DC
voltage between 12 and 15 V.
• Refer also to pages 3 and 6 of the wiring diagrams in Section 7.

WARNING
• Be certain to properly terminate 120 VAC wire connections!
• Provide proper strain relief for remote I/O cable at customer interface.

7 Remote Voltage and Current Cable – Power Supply to Digital Remote or Programmable Remote
Note: If you are using a machine computer interface to set voltage and current and do not want the programmable
voltage current readout, skip references 7-9.
7 Part No. Length Part No. Length
1X4 5X1 023990 7 ft (2.1 m) 123188 120 ft (36.6 m)
023911 15 ft (4.6 m) 023882 125 ft (38.1 m)
023878 25 ft (7.6 m) 023883 150 ft (45.8 m)
1x4 5x1 Color Signal 023879 50 ft (15.3 m) 023884 200 ft (61 m)
123040 60 ft (18.3 m) 023885 250 ft (76.3 m)
4 1 Green SID Data
8 2 Black SID Common 023880 75 ft (22.9 m) 023886 275 ft (83.9 m)
13 Grn/Blk Shield 123073 85 ft (25.9 m) 023887 300 ft (91.5 m)
9 3 Red SOD Data 023881 100 ft (30.5 m)
15 6 Black SOD Common
14 Red/Blk Shield
35 7 White AC Power
36 8 Black AC Power
31 Wht/Blk Shield
5 Key
22 Key

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 INSTALLATION

8 Programmable Remote Voltage and Current Cable – Power Supply to Programmable Remote
Note: If you are using the digital remote to set voltage and current, skip this reference.

8 Part No. Length Part No. Length

1X5 5X2
023834 15 ft (4.6 m) 023898 125 ft (38.1 m)
023835 25 ft (7.6 m) 023839 150 ft (45.8 m)
023836 50 ft (15.3 m) 023840 200 ft (61 m)
023837 75 ft (22.9 m) 023899 250 ft (76.3 m)
023838 100 ft (30.5 m) 023900 275 ft (83.9 m)
023901 300 ft (91.5 m)

1x5 5x2 Color Signal 1x5 5x2 Color Signal

1 1 Black Current 20 10 10 Black/Green Voltage 20
2 2 Blue Current 40 11 11 Black/Orange Voltage 40
3 3 Green Current 80 12 12 Black/Red Voltage 80
4 4 White Current 100 13 13 White/Green Voltage 100
5 5 Orange Current 200 14 14 White/Red Voltage 200
7 7 White/Black Common 15 15 Black/White Spare
8 8 White/Blue Voltage 5 16 16 Shld Shield
9 9 Black/Blue Voltage 10

9 Current Control Cable – Power Supply to Remote Current Control

Note: If you are using the digital remote, programmable remote or machine computer to set current, skip
this reference.

9 Part No. Length

1X7 15X1 123150 10 ft (3 m)

023871 25 ft (7.6 m)
023872 38 ft (11.6 m)
023873 50 ft (15 m)
1X7 15X1 Color Current Signal (I) 023874 75 ft (23 m)
2 8 Black I-10 023875 100 ft (30.5 m)
3 7 White I-20 123068 110 ft (33.6 m)
4 10 Black I-40 123277 120 ft (36.6 m)
5 9 Green I-80
6 15 Black I-100 123088 125 ft (38.1 m)
7 16 Red I-200 023876 150 ft (46 m)
11 3 I-Com 123032 170 ft (51.9 m)
023877 200 ft (61 m)

10 Water Muffler Pump Cable – Power Supply to Water Muffler Pump

See water muffler instruction manual 802050 to connect cable to pump motor, and to make remaining water
muffler connections. The water muffler cannot be used with the stainless steel torch.

1X10
10 Part No. Length
023866 50 ft (15 m)
023867 75 ft (23 m)
From 1X10 Color To WM Pump Contactor 023868 100 ft (30.5)
2 Black Coil
4 White AC Neut.
3 Green Ground

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INSTALLATION

11 Timer/Counter Cable – Power Supply to Timer/Counter

11 Part No. Length

023687 10 ft (3 m)
023692 25 ft (7.6 m)
11X1
023758 38 ft (11.6 m)
023693 50 ft (15 m)
123046 60 ft (18.3 m)
023694 75 ft (23 m)
11x1 TB3 Color Signal 123079 85 ft (25.9 m)
023695 100 ft (30.5)
1 2 White Starts and Arc time (CON1 Closed)
023993 115 ft (35.1 m)
2 1 Black Starts and Arc time (CON1 Closed)
123189 120 ft (36.6 m)
3 3 Drain Drain
023696 150 ft (46 m)
15 5 Red Error Counter (Ramp Down Error)
023954 200 ft (62 m)
16 4 Black Error Counter (Ramp Down Error)
12 6 Drain Drain

12 Hold Cable – Power Supply 1 to Power Supply 2

12 Part No. Length
023340 15 ft (4.6 m)
023341 25 ft (7.6 m)
Color TB3 Signal 023342 50 ft (15 m)
Black 13 Hold Signal 023343 100 ft (30.5)
Red 14 Hold Common 023344 150 ft (46 m)
Shield 15 Hold Shield

13 Argon-Hydrogen Cable – Power Supply to Argon-Hydrogen Manifold

See the appendix section for Argon-Hydrogen installation and operation.

14 Initial Height Sensing Cable – Power Supply to Initial Height Sensing Console
See the appendix section for Initial Height Sensing connections.

Gas Console Connections

See page 3-9 for gas console connection to power supply.

15 Part No. Length

15 Shield Gas Hose – Gas Console to Power Supply
024348 5 ft (1.5 m)
Note: Turn counterclockwise to tighten 024313 10 ft (3 m)
024302 15 ft (4.6 m)
024349 20 ft (6.1 m)
024303 25 ft (7.6 m)
024350 30 ft (9.1 m)
024351 35 ft (10.7 m)
024352 40 ft (12.2 m)
024353 45 ft (13.7 m)
024304 50 ft (15 m)
024305 75 ft (23 m)
024306 100 ft (30.5 m)
024312 150 ft (46 m)

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 INSTALLATION

16 Part No. Length

16 Shield Gas Sense Hose – Gas Console to Power Supply
024061 5 ft (1.5 m)
024063 10 ft (3 m)
024065 15 ft (4.6 m)
024067 20 ft (6.1 m)
024069 25 ft (7.6 m)
024071 30 ft (9.1 m)
024356 35 ft (10.7 m)
024092 40 ft (12.2 m)
024403 45 ft (13.7 m)
024096 50 ft (15 m)
024174 60 ft (18.3 m)
024468 75 ft (23 m)
024523 100 ft (30.5 m)

17 Part No. Length

17 Shield Gas Supply Hose – Shield Supply to Gas Console
024043 4 ft (1.2 m)
Any supply gases that will be used for the shield gas, attach to 024341 10 ft (3 m)
the same point on the gas console. 024200 15 ft (4.6 m)
024342 20 ft (6 m)
024133 25 ft (7.6 m)
024448 35 ft (10.7 m)
024407 45 ft (13.7 m)
024012 50 ft (15 m)
024472 60 ft (18.3 m)
024147 75 ft (23 m)
024486 85 ft (25.9 m)
024115 100 ft (30 m)
024452 110 ft (33.6 m)
024449 115 ft (35.1 m)
024515 120 ft (36.6 m)
024395 125 ft (38.1 m)
024119 150 ft (46 m)
024480 170 ft (51.9 m)
024184 180 ft (55 m)
024123 200 ft (61 m)

18 Part No. Length

18 Oxygen Plasma Supply Hose – Oxygen Supply to
Gas Console 024204 15 ft (4.6 m)
024205 25 ft (7.6 m)
Note: If cutting with oxygen as the plasma gas, nitrogen 024155 50 ft (15 m)
must also be connected to the gas console to 024398 75 ft (22.9 m)
achieve the proper oxygen/nitrogen mixtures in the 024487 85 ft (25.9 m)
preflow and cut flow conditions. 024206 100 ft (30 m)
024481 110 ft (33.6 m)
024450 115 ft (35.1 m)
024516 120 ft (36.6 m)
024490 125 ft (38.1 m)
024159 150 ft (46 m)
024470 180 ft (54.9 m)
024333 200 ft (61 m)

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INSTALLATION

Gas Console Connections (continued)

19 Nitrogen Plasma Supply Hose – Nitrogen Supply to Gas Console 19 Part No. Length
024505 6 ft (1.8 m)
024210 10 ft (3 m)
024203 15 ft (4.6 m)
024232 20 ft (6 m)
024134 25 ft (7.6 m)
024211 35 ft (10.6 m)
024112 50 ft (15 m)
024148 75 ft (23 m)
024488 85 ft (25.9 m)
024116 100 ft (30 m)
024482 110 ft (33.6 m)
024451 115 ft (35.1 m)
024517 120 ft (36.6 m)
024491 125 ft (38.1 m)
024120 150 ft (46 m)
024185 180 ft (55 m)
024124 200 ft (61 m)

19 Air Plasma Supply Hose (Customer Supplied) – Air Supply to Gas Console

20 Plasma Preflow Gas Hose – Gas Console to Valve Cluster 20 Part No. Length

See valve cluster connections on page 3-18. 024317 5 ft (1.5 m)

024026 10 ft (3 m)
024027 15 ft (4.6 m)
024017 20 ft (6.1 m)
024028 25 ft (7.6 m)
024029 30 ft (9.1 m)
024030 35 ft (10.7 m)
024031 40 ft (12.2 m)
024207 45 ft (13.7 m)
024340 50 ft (15 m)
024419 56 ft (17.1 m)
024127 60 ft (18.3 m)
024343 75 ft (23 m)
024344 100 ft (30.5 m)

21 Part No. Length

21 Plasma Cut Flow Gas Hose – Gas Console to Valve Cluster
024316 5 ft (1.5 m)
See valve cluster connections on page 3-18. 024307 10 ft (3 m)
024320 15 ft (4.6 m)
024308 20 ft (6.1 m)
024321 25 ft (7.6 m)
024309 30 ft (9.1 m)
024322 35 ft (10.7 m)
Note: Turn counterclockwise to tighten 024310 40 ft (12.2 m)
024323 45 ft (13.7 m)
024311 50 ft (15 m)
024420 56 ft (17.1 m)
024367 60 ft (18.3 m)
024357 75 ft (23 m)
024358 100 ft (30.5 m)

3-16 HySpeed HT2000LHF Instruction Manual

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 INSTALLATION

Valve Cluster and Torch Connections

Routing the Torch Leads

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

Route the torch leads from the power supply to the torch through a festoon or a power track.

Connecting the Torch Leads to the Torch

See page 3-8 for torch lead connections to the power supply.
See page 3-7 for torque specifications.

22 Torch Leads – Power Supply to Torch 22 Part No. Length

028657 10 ft (3 m)
028658 15 ft (4.6 m)
Torch Side Power Supply Side 028659 20 ft (6.1 m)
Pilot/Shield Lead 028546 25 ft (7.6 m)
028660 30 ft (9.1 m)
028661 35 ft (10.7 m)
Gray 028662 40 ft (12.2 m)
028663 45 ft (13.7 m)
Red 028547 50 ft (15 m)
Green

Red and Green Tubes

1. If the 12" off-valve hose is connected from the torch to the valve cluster,
disconnect it at the valve cluster. Note that the fitting is left-hand threaded
and turns in a clockwise direction to remove. 12" Off-Valve
Hose

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

3. Attach the red and green torch leads to the red and green tubes of the torch
main body using a 3/8" wrench to hold the torch fittings, and a 1/2" wrench
to tighten the torch lead fittings. Gray

4. Attach the pilot/shield lead to the shortest tube on the torch main body. Use Pilot/Shield
a 5/16" wrench to hold the torch body fitting and a 7/16" wrench to tighten Lead
the torch lead fitting.

5. Attach the gray torch lead to the remaining torch fitting. Use a 5/16" wrench
to hold the torch body fitting and a 7/16" wrench to tighten the torch lead
fitting.

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

6. Slide the torch sleeve over the torch main body and screw together. Figure 3-3 Torch Lead
Connections to Torch

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INSTALLATION

Valve Cluster Connections

See page 3-9 for plasma preflow and cutflow hose connections to the gas console.
See page 3-16 for plasma preflow and cutflow hose part numbers.
See page 3-7 for torque specifications.

1. Loosen the valve cluster screw and slide the valve cluster up the torch sleeve. Secure in place approximately as
shown in Figure 3-5.

2. Attach the plasma preflow hose from the gas console to SV4B.

3. Attach the plasma cut flow hose from the gas console to SV4A. Note that this connection is left-hand threaded.

4. Attach the 12" plasma hose from the torch to off-valve SV5. Note that this connection is left-hand threaded.

20 21
Preflow SV4B Cut Flow SV4A

Valve Cluster Screw

12" Plasma Hose from

torch to Off-Valve SV5

Figure 3-4 Valve Cluster Connections – Top View

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 INSTALLATION

23 Valve Cluster Cable – Valve Cluster to Power Supply Off-Valve Cable

23 Part No. Length

2 123282 10" (254 mm)

Gnd 123321 24" (610 mm)
4X1 1

2
Gnd SV
1
4x1 Socket Color Signal
1 SV4A-1 Red SV4A
2 2 SV4A-2 Black SV4A
Gnd 3 SV4A-Gnd Clear Ground
1 4 SV4B-Gnd Clear Ground
5 SV4B-1 Red SV4B
6 SV4B-2 Black SV4B
7 SV5-1 Red SV5
8 SV5-2 Black SV5
9 SV5-Gnd Clear Ground

23 Valve Cluster Cable

to Power Supply
Off-Valve Cable 3

12" plasma hose from torch

SV5

Torch Sleeve

Figure 3-5 Torch with Valve Cluster and Cable Attached

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INSTALLATION

Mounting the Machine Torch

1. Loosen the securing screws and install the machine torch (with torch leads attached) in the torch mounting
bracket. See Figure 3-6.

2. Position the torch until the torch body extends all the way through the bracket, so that the bracket is now around
the 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.

Torch sleeve

Securing screws

Torch mounting
bracket

Torch (typical)

Figure 3-6 Torch Alignment

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 3-6.

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 Section 4

OPERATION

Front Panel Controls and Indicators

Status Indicators Before Startup

When power is applied from the line disconnect switch and before the POWER ON (I) button is pushed, the coolant
flow LED will always be illuminated. Once the POWER ON button is pushed and held for a few seconds, this LED
will extinguish if the system is in proper working condition.

Other fault conditions may also be indicated when the line power is switched on. Be sure to press and hold the
power supply POWER ON (I) button (in some cases up to 1 minute) to extinguish all status indicators. If any LEDs
remain illuminated, shut down the system and correct the problem. See Status LED Troubleshooting in Section 5,
if necessary.

Power Supply
ON (I) OFF (O) DC ON INTERLOCK LED TRANSFORMER LED
Activates the power Shuts the power Illuminates when main Spare. This LED is When illuminated, indicates that
supply and its control supply down. contactor closes, always extinguished. either the power supply main
circuits. Indicator indicating DC power is transformer or one of the choppers is
illuminates when power being supplied to the operating above the proper
up is complete and torch. temperature range.
status indicators are
satisfied.

COOLANT LEVEL LED PLASMA GAS LED COOLANT TEMP LED

When illuminated, indicates that When illuminated, When illuminated, indicates that
the coolant level is inadequate. indicates that the the torch coolant temperature is
plasma gas pressure is too hot.
inadequate.
SHIELD GAS/CAP LED COOLANT FLOW LED
When illuminated, indicates that either the shield When illuminated, indicates that the
gas pressure is inadequate, or that the retaining coolant flow from the torch is
cap is installed improperly on the torch. inadequate.

Figure 4-1 Power Supply Front Panel Controls and Indicators

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OPERATION

Gas Console

FM1 S1 PG1
Indicates the flow rate % of nitrogen or air Selects the use of either nitrogen, Indicates the nitrogen or air plasma inlet
plasma gas. Percentages are specified in the air or oxygen as the plasma cutting pressure. Gas inlet pressures are specified
Cut Charts. gas. in the Cut Charts.

LT1
Illuminates when the main
contactor closes, indicating
PLASMA DC that DC power is being
supplied to the torch.
PG2 N2/Air O2
Indicates the oxygen plasma
inlet pressure. Gas inlet
pressures are specified in the
Cut Charts. SHIELD
10 10

9
psi
9
PG3
8 8
psi Indicates the shield gas
7 7 pressure at the torch.
6 6

5 5
MV2 N2/Air
Adjusts flow rate % of nitrogen, 4 4

or air plasma gas while in the 3 3

Test Preflow mode. Preflow 2 2

plasma gas flow rate percent-

psi
1 1

ages are specified in the 0 0

MV4
Cut Charts. Adjusts shield gas pressure
to the torch.
O2

N2/Air PLASMA O2
PreFlow Cut Flow PreFlow
Run

FM2
MV1
Test
Preflow
Test
Cutflow
Indicates the flow rate % of
Adjusts flow rate % of nitrogen, oxygen plasma gas.
® ®
air or oxygen plasma gas while HySpeed HT2000LHF Oxygen flow rate percent-
in Test Cut Flow mode. Cut age is specified in the
Flow plasma gas flow rate Cut Charts.
percentages are specified in the
Cut Charts.

MV3 S2
Adjusts flow rate % of oxygen plasma gas Test Preflow – Used when setting the
while in Test Preflow mode. Preflow plasma preflow flow rate on the flowmeter. In
plasma gas flow rate percentages are this position the contactor is disabled.
specified in the Cut Charts. Test Cut Flow – Allows the selected plasma
gas flow rate to be adjusted on the flowmeter
for cutting conditions. In this position the
Designations contactor is disabled.
FM1-FM2 –– Flowmeters Run – Enables the contactor and the
LT1 –– Indicator Lamp subsequent firing of the arc after the gas
MV1-MV3 –– Motor Valve rates have been set in the Test Preflow and
PG1-PG3 –– Pressure Gauges Test Cut Flow positions.
S1-S2 –– Toggle Switch

Figure 4-2 LHF Gas Console Front Panel Controls and Indicators

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6
 OPERATION

Digital Remote Voltage & Current Control Console

VOLTAGE LEDs VOLTAGE Adjust Potentiometer CURRENT LEDs

Display cutting voltage. Adjusts the cutting arc voltage from 100 to 200 Display cutting current.
volts. Values are chosen from the Cut Charts
and depend on the thickness and type of metal
to cut.

UP / DOWN LEDs CURRENT Adjust Potentiometer

Indicate that torch height Adjusts the cutting arc current from
is being adjusted up or 40 amps to 200 amps. Values are
down. chosen from the
Cut Charts and depend on the
thickness and type of metal
to cut.

Figure 4-3 Digital Remote Voltage & Current Control Console Front Panel Controls and Indicators

Programmable Remote Voltage & Current Control Console

VOLTAGE LEDs CURRENT LEDs

Display cutting voltage during Display cutting current during
cut sequence cut sequence

UP / DOWN LEDs
Indicate that torch height
is being adjusted up or
down.

Figure 4-4 Programmable Remote Voltage & Current Control Console Front Panel Indicators

Remote Current Control Console AMPS Thumbwheel

Adjusts the cutting arc current from 40 amps to 200 amps. Values are
chosen from the Cut Charts and depend on the thickness and type of
metal to cut.

Figure 4-5 Remote Current Control Console Front Panel Controls

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OPERATION

Timer/Counter

STARTS LCD Counter (w/Reset) ARC TIME LCD Counter ERRORS LCD Counter (w/Reset)
Indicates the number of arc starts Indicates the cumulative time Indicates the number of times that the arc cut
that the arc is on in hours. cycle ended before the programmed current
ramp-down time had elapsed. This reading
Reset Reset provides a direct correlation to the long-life
operation of the electrode; the higher the
reading, the shorter the electrode life.

Figure 4-6 Timer/Counter Front Panel Controls

System Checkout
The following procedure assumes the plasma system includes an IHS system, a Digital Remote (DR) Voltage &
Current Control Console, and the optional internal THC.

Set Switches and Check Torch

1. Ensure that the switches listed below are positioned as follows:

The main disconnect switch for the power supply is set to Off.

S2 toggle switch on the gas console is set to Run.

2. Ensure that the proper consumables are installed in the torch. Refer to the Cut Charts to choose the correct
consumables for your cutting needs. See also Changing Consumable Parts at the end of this section.

3. Ensure that the torch is squared to the material. Refer to Section 3 for the torch alignment procedure.

Turn Gases On

4. Set S1 toggle switch on the gas console to N2/Air or O2.

5. Turn the required supply gases On.

• When using oxygen, or nitrogen as the plasma gas, adjust supply regulator to read 120 psi +/- 10 psi
(8.3 bar +/- 0.7 bar).

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

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

4-4 HySpeed HT2000LHF Instruction Manual

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 OPERATION

Turn Power Supply On and Adjust Voltage/Current

6. Set the main disconnect switch for the power supply to the On position. See Status Indicators Before Startup.
Depress the POWER ON (I) button on the power supply. Ensure that the green POWER ON indicator on the
power supply illuminates.

7. Set the VOLTAGE and CURRENT on the Digital Remote. Select the arc current and arc voltage from the
Cut Charts for the type and thickness of metal to test cut.

Adjust Preflow Gases

8. Set S2 toggle switch to Test Preflow . Verify that the plasma gas pressure gauges on the gas console both
read 120 psi (8.3 bar).

9. Look at FM1 and/or FM2 and set the Preflow plasma gas flow rate. Refer to the Cut Charts for flow rate
percentage.

10. Look at PG3 on the gas console, and set the Shield gas flow rate. Refer to the Cut Charts for flow rate
percentage.

Adjust Cut Flow Gases and Check Initial Height Sensing (IHS)

11. Set S2 toggle switch to Test Cut Flow.

12. Look at FM1 and/or FM2 and set the Cut Flow plasma gas flow rate. Refer to the Cut Charts for flow rate
percentage.

13. Set S2 to Run after setting the preflow and plasma flow rates.

14. Check the pilot arc operation by positioning the torch a minimum of 3 inches (75 mm) above the work.

15. Depress the START button. After 2 seconds of gas preflow, the primary contactor will close and the pilot arc
will start. The pilot arc should emit a steady, hissing sound and a cone of light should appear at the face of the
torch nozzle. The pilot arc will continue for approximately 300ms (O2) and 600 ms (Air/N2) and then extinguish
automatically.

16. Place the workpiece on the work table to make a test pierce. With manual starting, no machine motion will
occur.

Note: The cutting machine must retract the torch at least 1 inch (25.4 mm) from the work before the start
cycle, or probes may hit the workpiece when the START button is depressed.

17. Depress the START button. The IHS probes will immediately descend and approximately 0.5 seconds later, the
torch will move toward the workpiece. The DOWN indicator lamp on the Digital Remote should be illuminated.
When the torch nears the workpiece, the probes will inductively detect the work surface and the down motion
should stop. The DOWN indicator lamp on the Digital Remote will extinguish and the probes will retract.

At this point, depress the STOP button and disable the IHS system. You are now ready for the Final Torch
Adjustment.

HySpeed HT2000LHF Instruction Manual 4-5

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OPERATION

Final Torch Adjustment

18. Make a reference mark on the top and bottom of the torch sleeve where it meets the torch mounting bracket.

19. Loosen the securing screw on the torch mounting bracket and position the torch higher in the mounting bracket
until the arc will not transfer when the START button is depressed.

20. Slowly lower the torch in 1/16" (1.6 mm) increments until the arc transfers after the START button is
depressed. Tighten the securing screw at this position.

21. Enable the IHS system and press the START button. Once the arc transfers and the machine delay time has
elapsed, the metal should be pierced. Press the STOP button to terminate the plasma arc. Observe that the
UP indicator illuminates and the torch retracts to the upper limit switch.

22. Disable the IHS system.

Check Torch Height Control (THC) and Digital Remote Voltage & Current Console

23. Position the workpiece on the work table with one end higher than the other end to check the auto height (torch
height control) mode. Position the torch at the highest point on the workpiece. Program a square cut pattern
into the controller. (See controller instruction manual.)

24. Enable the Auto Height Control for the THC.

25. Manually lower the torch to approximately .25 inches (6 mm) above the workpiece.

26. Start the arc transfer from the controller.

27. When the arc transfers and the machine delay time has elapsed, the workpiece should be pierced and
machine motion will start. As the torch travels from a high point to a low point on the workpiece, note that the
torch stand-off distance from the workpiece should remain constant, and that the DOWN indicator illuminates
on the Digital Remote.

As the torch travels from a low point to a high point on the workpiece, note that the torch stand-off distance
from the workpiece should remain constant and that the UP indicator illuminates on the Digital Remote.

As the torch makes a corner cut, the machine motion speed should remain constant and the UP and DOWN
indicators do not illuminate. Machine motion and plasma arc will automatically stop when the cut is complete.

The system is now operational.

If the system does not function as outlined in this procedure, recheck the installation requirements and directions in
this manual. If all installation directives have been followed and you are still experiencing difficulty with the system,
call the Hypertherm Technical Service number listed in the front of this manual.

4-6 HySpeed HT2000LHF Instruction Manual

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 OPERATION

Noise Levels
Acceptable noise levels as defined by national or local codes may be exceeded by this plasma system. Always
wear proper ear protection when cutting or gouging with the plasma system. See also Noise Protection in the
Safety section of this manual.

Daily Startup
Prior to startup, ensure that your cutting environment and that your clothing meet the safety requirements outlined
in the Safety section of this manual.

WARNING

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

Note: For operation with argon-hydrogen manifold, see the appendix section of this manual.

Check Torch

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

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

• Wipe the current ring in the torch with a clean paper towel or cotton swab (see Figure 4-7).

• 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 on
replacing consumables.

3. Ensure that the torch is perpendicular to the material. Refer to Section 3 for the torch alignment procedure.

HySpeed HT2000LHF Instruction Manual 4-7

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OPERATION

Turn Gases On

4. Set S2 toggle switch on the gas console to Run.

5. Set S1 on the gas console to N2/Air (for nitrogen or air as plasma gas), or O2 (for oxygen as plasma gas).

6. Turn the required supply gases On.

Note: See the Cut Charts to set the plasma and shield gas inlet pressures.

Turn Power Supply On and Adjust Voltage & Current

7. Turn the main disconnect switch ON. See Status Indicators Before Startup earlier in this section.

8. Turn on the power supply by depressing and holding down the POWER ON (I) button (PB1) on the power
supply. Ensure that the green POWER ON indicator illuminates. Hold PB1 down until all of the status indicators
extinguish.

9. Set the voltage and current from the Digital Remote Voltage and Current Console or from the machine computer
interface. Select the arc current and arc voltage from the Cut Charts for the type and thickness of metal to cut.

FM1 S1 FM2 Adjust Preflow Gases

10. Set S2 on the gas console to Test Preflow. Verify the

PLASMA DC
plasma gas inlet pressure reading on the plasma
N2/Air O2 pressure gauges (PG1, PG2) on the gas console.
Refer to the Cut Charts for the proper pressure
PG1 10 10
SHIELD
PG3 setting.
9 9
psi
8 8
psi
7 7
11. Look at the oxygen (FM2) and/or nitrogen-air (FM1)
flowmeters on the gas console and set the Preflow
6 6

5 5
N2/Air

plasma gas flow rate % by referring to the Cut Charts

4 4

3 3

PG2
2

1
psi
2

1
and turning the oxygen (MV3) and/or nitrogen / air
MV4
0 0
(MV2) preflow metering valves.
O2

12. Look at the shield gas pressure gauge (PG3) on the

N2/Air
PreFlow
PLASMA
Cut Flow
O2
PreFlow gas console, and set to the Cut Chart specifications
Run
by turning the shield gas metering valve (MV4).
Test Test
Preflow Cutflow

Note: If you have changed consumable parts or if the

® ®
HySpeed HT2000LHF
power supply has been off for more than 1 hour,
purge gas lines by leaving system in Test Preflow
MV2 MV1 MV3 S2 for 1 minute.

4-8 HySpeed HT2000LHF Instruction Manual

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 OPERATION

Adjust Cut Flow Gases and Prepare for Cutting

13. Set S2 on the gas console to Test Cut Flow.

14. Look at the oxygen (FM2) and/or nitrogen / air (FM1) flowmeters on the gas console and set the Cut Flow
plasma gas flow rate % by referring to the Cut Charts and adjusting the Plasma Cut Flow metering valve
(MV1).

Note: If you have changed consumable parts or if the power supply has been off for more than 1 hour, purge gas
lines by leaving the system in Test Cut Flow for one minute.

15. Set S2 to Run after the test preflow and test operate flow rates have been set.

The system is now ready for operation.

Common Cutting Faults

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

1. Work cable connection on the cutting table is not making good contact.

2. Malfunction in the system. See Section 5.

• The workpiece is not totally penetrated, and there is excessive sparking on top of the workpiece. Causes can 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 is set too low (check Cut Chart information).

3. Torch parts are worn (see Changing Consumable Parts).

• Cut angle is 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).

HySpeed HT2000LHF Instruction Manual 4-9

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OPERATION

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
the 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 that is magnetized
or becomes magnetized easily.

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

Also see Cutting Techniques later in this section for methods to improve cutting performance.

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 the Hypertherm Technical Service number 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 system to be
successful in plasma arc cutting. The system 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 minimal dross.

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

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

4-10 HySpeed HT2000LHF Instruction Manual

7
 OPERATION

CUT CHART AND CONSUMABLE PARTS INDEX

Plasma Gas/ Retaining Swirl
Metal Amps Shield Gas Shield Cap Nozzle Ring Electrode Page

Mild 200 HySpeed O2 / Air 220239 220242 220237 220236 220235 4-12
Steel 200 O2 / Air 020424 120837 020605 120833 120667 4-13
200 Air / Air 020424 120837 020608 020679 120667 4-14
200 N2 / CO2 020424 120837 020608 020607 020415 4-15
100 Air / Air 020448 120837 020611 020607 120547 4-16
100 O2 / Air 020424 120837 020690 020613 120547 4-17
50 O2 / O2 120186 120185 120182 120179 120178 4-18

Stainless 200 Air / Air 020424 120837 020608 020679 120667 4-19
Steel 200 N2 / Air 020424 120837 020608 020607 020415 4-20
200 N2 / CO2 020424 120837 020608 020607 020415 4-21
200 H35 / N2* 020602 120837 020608 020607 020415 Ap-A
100 Air / Air 020448 120837 020611 020607 120547 4-22
100 H35 / N2* 020448 120837 020611 020607 020415 Ap-A
40 Air / Air 020688 020423 020689 020613 120667 4-23

Aluminum 200 Air / Air 020424 120837 020608 020679 120667 4-24
200 N2 / Air 020424 120837 020608 020607 020415 4-25
200 N2 / CO2 020424 120837 020608 020607 020415 4-26
200 H35 / N2* 020602 120837 020608 020607 020415 Ap-A
100 Air / Air 020448 120837 020611 020607 120547 4-27
100 H35 / N2* 020448 120837 020611 020607 020415 Ap-A
40 Air / Air 020688 020423 020689 020613 120667 4-28

BEVEL Mild 200 O2/Air 120260 120837 120259 120833 120258 4-29
CUTTING Steel

Mild 200 Air / Air 020485 120837 020615 020607 120667 4-30
Steel
Stainless 200 H35 / N2* 020485 120837 020615 020607 020415 Ap-A
Steel

Aluminum 200 H35 / N2* 020485 120837 020615 020607 020415 Ap-A

* Argon-Hydrogen Manifold required. See appendix for installation and operation with argon-hydrogen manifold.

200 HySpeed O2 / Air 220239 220238 220237 220236 220235

200 O2 / Air 020566 020423 020605 120833 120667
Consumables 100 O2 / Air 020566 020423 020690 020613 120547
used with
200 Air / Air 020566 020423 020608 020679 120667
Hyspeed
100 Air / Air 020618 020423 020611 020607 120547
HT2000LHF
Water Muffler** 200 N2 / CO2 020566 020423 020608 020607 020415

200 N2 / Air 020566 020423 020608 020607 020415

** Do not use the water muffler when cutting with argon-hydrogen (H35)!
Water Muffler cannot be used with the stainless steel torch
Note: If the Command THC or other ohmic contact sensing device is NOT in use, retaining caps with no IHS tab: 020423
clockwise; 020955 counterclockwise can be used for all cutting currents except 50A; 120185 for 50A cutting only. For Hyspeed
200A O2 cutting only; use retaining cap part # 220238 (clockwise cutting) & 220241 (counter-clockwise cutting).

HySpeed HT2000LHF Instruction Manual 4-11

9
OPERATION

Mild Steel
HySpeed 200 amps • O2 Plasma / Air Shield
This gas combination gives superior cut speed, minimum dross, minimum surface nitriding and excellent
weldability.

220242 (cw) 220236 (cw)

220239 220243 (ccw) 220237 220244 (ccw) 220235
Shield Retaining cap Nozzle Swirl ring Electrode

Above Water
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) (O2 % N2 %) (O2 % N2 %) (psi) (inches) (mm) (inches) (mm) (volts) (ipm) (mm/min.) (sec)

1/4 6 12 38 76 0 60 1/16 1.5 1/8 3 145 230 5800 0.3

5/16 8 (12 / 50 (90 / 0 (275 1/8 3 1/4 6 151 165 4200 0.3
3/8 10 SCFH) SCFH) SCFH) 5/32 4 5/16 8 155 140 3500 0.3
1/2 12 1/8 3 1/4 6 155 120 3000 0.3
5/8 15 1/8 3 1/4 6 155 100 2500 0.5
3/4 20 1/8 3 1/4 6 155 75 1900 0.6
7/8 22 1/8 3 1/4 6 159 60 1500 0.7
1 25 1/8 3 1/4 6 160 50 1300 0.7
1 1/4 32 1/8 3 5/16 8 168 30 760 2.6
1-1/2 38 1/8 3 5/16 8 175 20 500 4.0
1-3/4 44 1/8 3 N/A N/A 180 15 380 N/A
2 50 1/8 3 N/A N/A 188 10 250 N/A

3" Under Water

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) (O2 % N2 %) (O2 % N2 %) (psi) (inches) (mm) (inches) (mm) (volts) (ipm) (mm/min.) (sec)

1/4 6 12 38 76 0 60 1/16 1.5 1/8 3 149 230 5800 0.3

5/16 8 (12 / 50 (90 / 0 (275 1/8 3 1/4 6 151 165 4200 0.3
3/8 10 SCFH) SCFH) SCFH) 5/32 4 5/16 8 159 140 3500 0.3
1/2 12 1/8 3 1/4 6 155 105 2700 0.3
5/8 15 1/8 3 1/4 6 161 90 2300 0.5
3/4 20 1/8 3 1/4 6 161 65 1600 0.6
7/8 22 1/8 3 1/4 6 161 55 1400 0.7
1 25 1/8 3 1/4 6 164 45 1100 0.7

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

4-12 HySpeed HT2000LHF Instruction Manual

9
 OPERATION

Mild Steel
200 amps • O2 Plasma / Air Shield
This gas combination gives superior cut speed, minimum dross, minimum surface nitriding and excellent
weldability.

020423 (cw) 120833* (cw) 120667 (standard)

020424 020955 (ccw) 020605 120834 (ccw) Electrode
Shield Retaining cap Nozzle Swirl ring 220084 (optional)
SilverPlus electrode+

Above Water
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) (O2 % N2 %) (O2 % N2 %) (psi) (inches) (mm) (inches) (mm) (volts) (ipm) (mm/min.) (sec)

1/4 6 5 45 64 0 60 1/8 3 1/4 6 120 160 4060 0.5

.315 8 (5.3 / 62.4 (79.6 / 0 (270 1/8 3 1/4 6 125 120 3000 0.5
3/8 10 SCFH) SCFH) SCFH) 1/8 3 1/4 6 125 100 2540 1.0
1/2 12 .157 4 .314 8 125 80 2030 2.0
5/8 15 .157 4 .314 8 130 70 1780 2.0
3/4 20 3/16 5 3/8 10 135 55 1400 2.5
7/8 22 1/4 6 1/2 12 135 45 1140 2.5
1 25 1/4 6 1/2 12 140 35 890 2.5
1-1/4 32 1/4 6 1/2 12 150 22 560 3.0
1-1/2 38 1/4 6 1/2 12 155 15 380 3.0
1-3/4 44 5/16 8 5/8 12 165 10 250 3.0
2 50 5/16 8 5/8 12 170 7 180 3.0

3" Under Water

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) (O2 % N2 %) (O2 % N2 %) (psi) (inches) (mm) (inches) (mm) (volts) (ipm) (mm/min.) (sec)

1/4 6 5 45 64 0 70 1/8 3 1/4 6 125 145 3700 0.5

.315 8 (5.3 / 62.4 (79.6 / 0 (280 1/8 3 1/4 6 125 110 2800 0.5
3/8 10 SCFH) SCFH) SCFH) 1/8 3 1/4 6 130 80 2000 1.0
1/2 12 1/8 3 1/4 6 130 70 1800 2.0
5/8 15 .157 4 .314 8 135 60 1500 2.0
3/4 20 3/16 5 3/8 10 140 48 1200 2.5
7/8 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

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 a standard electrode (120667). Arc voltage may need to be increased by 5-10
volts throughout the electrode life to maintain proper cut height parameters.

HT2000LHF Instruction Manual 4-13

6
OPERATION

Mild Steel
200 amps • Air Plasma / Air Shield
This gas combination gives good cut speed, low dross levels and is very economical. Some surface nitriding can
occur.

020424 120837 020608 020679 120667

Shield Retaining cap Nozzle Swirl ring Electrode

Above Water
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 5080

1/4 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 0.5
3/8 10 1/8 3 1/4 6 135 100 2540 1.0
1/2 12 .157 4 .314 8 140 80 2030 2.0
5/8 15 .157 4 .314 8 145 60 1520 2.0
3/4 20 3/16 5 3/8 10 150 45 1140 2.5
7/8 22 1/4 6 1/2 12 155 30 760 2.5
1 25 1/4 6 1/2 12 160 25 635 2.5
1-1/4 32 1/4 6 165 15 380
1-1/2 38 1/4 6 170 10 250
1-3/4 44 5/16 8 180 7 180
2 50 5/16 8 185 5 130

3" Under Water

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)

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 0.5
3/8 10 SCFH) SCFH) SCFH) 1/8 3 1/4 6 135 95 2400 1.0
1/2 12 1/8 3 1/4 6 140 75 1900 2.0
5/8 15 .157 4 .314 8 145 50 1200 2.0
3/4 20 3/16 5 3/8 10 150 35 850 2.5
7/8 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

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 recommended
Drop cutting above 1-1/2" (38 mm) not recommended

4-14 HySpeed HT2000LHF Instruction Manual

7
 OPERATION

Mild Steel
200 amps • N2 Plasma / CO2 Shield
This gas combination may be used when cut edge quality and surface nitriding are less important. Electrode life is
extended when using this combination.

020424 120837 020608 020607 020415

Shield Retaining cap Nozzle Swirl ring Electrode

Above Water Only

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 60/4 1/8 3 1/4 6 120 130 3300 0.5

1/4 6 (62.3 (75.0 (270 1/8 3 1/4 6 125 110 2800 1.0
3/8 10 (SCFH) SCFH) SCFH) 1/8 3 1/4 6 130 85 2160 1.5
1/2 12 1/8 3 1/4 6 130 55 1400 2.0
5/8 15 .157 4 .314 8 135 45 1140 2.0
3/4 20 3/16 5 3/8 10 145 25 635 2.5
7/8 22 1/4 6 1/2 12 150 20 510 3.0
1 25 1/4 6 1/2 12 160 15 380 3.0
1-1/4 32 1/4 6 165 10 250
1-1/2 38 1/4 6 175 5 130

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

HySpeed HT2000LHF Instruction Manual 4-15

7
OPERATION

Mild Steel
100* amps • Air Plasma / Air Shield
This gas combination gives good cut speed, low dross levels 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).

020448 120837 020611 020607 120547

Shield Retaining cap Nozzle Swirl ring Electrode

Above Water
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)

.075* 2 48 39 60 3/32 2.5 3/16 5 120 235 6050

1/8 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 0.5
1/4 6 1/8 3 1/4 6 130 125 3175 0.5
3/8 10 1/8 3 1/4 6 135 50 1270 1.0
1/2 12 1/8 3 140 35 890
5/8 15 .157 4 145 25 635
3/4 20 3/16 5 150 20 510

3" Under Water

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)

1/8 3 48 39 70 5/64 2 5/32 4 130 120 3050

3/16 5 (55.3 (44.9 (270 1/8 3 1/4 6 135 90 2300 0.5
1/4 6 SCFH) SCFH) SCFH) 1/8 3 1/4 6 140 70 1730 0.5
3/8 10 1/8 3 1/4 6 145 42 1050 0.5
1/2 12 1/8 145 28 700

* 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

4-16 HySpeed HT2000LHF Instruction Manual

7
 OPERATION

Mild Steel
100 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).

020423 (cw) 020613 (cw)

020424 020955 (ccw) 020690 120252 (ccw) 120547*
Shield Retaining cap Nozzle Swirl ring Electrode

Above Water
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) (O2 % N2 %) (O2 % N2 %) (psi) (inches) (mm) (inches) (mm) (volts) (ipm) (mm/min.) (sec)

1/8 3 3 32 36 0 60 3/32 2.5 3/16 5 125 240 6100

3/16 5 (3.3 / 39.6 (44.8 / 0 (270 1/8 3 1/4 6 125 180 4570
1/4 6 SCFH) SCFH) SCFH) 1/8 3 1/4 6 125 120 3050 0.5
3/8 10 1/8 3 1/4 6 130 90 2280 0.5
1/2 12 1/8 3 1/4 6 130 60 1520 1.0
5/8 15 .157 4 .314 8 140 45 1140 1.0
3/4 20 3/16 5 3/8 10 145 30 760 1.5

3" Under Water

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) (O2 % N2 %) (O2 % N2 %) (psi) (inches) (mm) (inches) (mm) (volts) (ipm) (mm/min.) (sec)

1/8 3 3 32 36 0 60 5/64 2 5/32 4 125 220 5580

3/16 5 (3.3 / 39.6 (44.8 / 0 (270 1/8 3 1/4 6 125 160 4060 0.5
1/4 6 SCFH) SCFH) SCFH) 1/8 3 1/4 6 125 110 2790 0.5
3/8 10 1/8 3 1/4 6 130 85 2160 0.5
1/2 12 1/8 3 1/4 6 135 60 1520 1.0

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 in
place of electrode P/N120547.

HT2000LHF Instruction Manual 4-17

5/00 6
OPERATION

Mild Steel
50 amps • O2 Plasma / O2 Shield

120185 120186 120182 120179 120178

Retaining cap Shield Nozzle Swirl ring Electrode

Above Water Only

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

.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

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 achievable
setting.
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 is
being purged from the gas line when changing from preflow to cut flow (up to 2 seconds). To compensate, either
increase 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 the
machine motion delay option is used.

4-18 HySpeed HT2000LHF Instruction Manual

7
 OPERATION

Stainless Steel
200 amps • Air Plasma / Air Shield
This gas combination gives good cut speed, low dross and is very economical. Some surface nitriding and surface
oxidation of alloying elements can occur.

020424 120837 020608 020679 120667

Shield Retaining cap Nozzle Swirl ring Electrode

Above Water
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 5 125 220 5600

1/4 6 (62.3 (75.0 (270 1/8 3 1/4 6 130 195 5000 0.5
3/8 10 SCFH) SCFH) SCFH) 1/8 3 1/4 6 130 145 3700 1.0
1/2 12 1/8 3 1/4 6 135 105 2700 2.0
5/8 15 .157 4 .314 8 140 75 1900 2.0
3/4 20 3/16 5 3/8 10 140 55 1400 2.5
7/8 22 1/4 6 1/2 12 145 40 1000 3.0
1 25 1/4 6 150 30 760
1-1/4 32 ` 1/4 6 160 15 380
1-1/2 38 1/4 6 170 10 250

3" Under Water

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 70 1/8 3 1/4 6 125 210 5320

1/4 6 (62.3 (75.0 (280 1/8 3 1/4 6 130 180 4500 0.5
3/8 10 SCFH) SCFH) SCFH) 1/8 3 1/4 6 135 125 3150 1.0
1/2 12 1/8 3 1/4 6 140 90 2300 2.0
5/8 15 .157 4 .314 8 145 60 1520 2.0
3/4 20 3/16 5 3/8 10 145 45 1150 2.5
7/8 22 1/4 6 1/2 12 150 30 750 3.0
1 25 1/4 6 155 22 570

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

HySpeed HT2000LHF Instruction Manual 4-19

7
OPERATION

Stainless Steel
200 amps • N2 Plasma / Air Shield
This gas combination is used when cut edge quality, surface nitriding and surface oxidation of alloying elements
are less important. Electrode life is extended when this combination is used.

020424 120837 020608 020607 020415

Shield Retaining cap Nozzle Swirl ring Electrode

Above Water
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) (N2 %) (N2 %) (psi) (inches) (mm) (inches) (mm) (volts) (ipm) (mm/min.) (sec)

3/16 5 50 60 60 1/8 3 1/4 5 125 135 3430

1/4 6 (66.4 (79.6 (270 1/8 3 1/4 6 130 120 3050 0.5
3/8 10 SCFH) SCFH) SCFH) 1/8 3 1/4 6 130 100 2540 1.0
1/2 12 1/8 3 1/4 6 135 75 1900 2.0
5/8 15 .157 4 .314 8 140 60 1520 2.0
3/4 20 3/16 5 3/8 10 140 45 1140 2.5
7/8 22 1/4 6 1/2 12 145 35 890 2.5
1 25 1/4 6 150 20 510
1-1/4 32 ` 1/4 6 160 15 380
1-1/2 38 1/4 6 160 10 250

3" Under Water

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) (N2 %) (N2 %) (psi) (inches) (mm) (inches) (mm) (volts) (ipm) (mm/min.) (sec)

3/16 5 50 60 70 1/8 3 1/4 6 125 130 3250

1/4 6 (66.4 (79.6 (280 1/8 3 1/4 6 130 110 2750 0.5
3/8 10 SCFH) SCFH) SCFH) 1/8 3 1/4 6 135 85 2160 1.0
1/2 12 1/8 3 1/4 6 140 60 1520 2.0
5/8 15 .157 4 .314 8 145 45 1140 2.0
3/4 20 3/16 5 3/8 10 145 30 800 2.5

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

4-20 HySpeed HT2000LHF Instruction Manual

7
 OPERATION

Stainless Steel
200 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.

020424 120837 020608 020607 020415

Shield Retaining cap Nozzle Swirl ring Electrode

Above Water
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 6 125 190 4800 0.5

1/4 6 (66.4 (79.6 (210 1/8 3 1/4 6 130 170 4300 1.0
3/8 10 SCFH) SCFH) SCFH) 1/8 3 1/4 6 130 125 3200 1.5
1/2 12 1/8 3 1/4 6 135 95 2400 2.0
5/8 15 .157 4 .314 8 140 70 1800 2.0
3/4 20 3/16 5 3/8 10 140 50 1250 2.5
7/8 22 1/4 6 1/2 12 145 40 1000 3.0
1 25 1/4 6 150 30 760
1-1/4 32 ` 1/4 6 160 15 380
1-1/2 38 1/4 6 170 10 250

3" Under Water

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 6 125 180 4550 0.5

1/4 6 (66.4 (79.6 (210 1/8 3 1/4 6 130 150 3850 1.0
3/8 10 SCFH) SCFH) SCFH) 1/8 3 1/4 6 135 110 2700 1.5
1/2 12 1/8 3 1/4 6 140 75 1920 2.0
5/8 15 .157 4 .314 8 145 50 1350 2.0
3/4 20 3/16 5 3/8 10 145 38 950 2.5
7/8 22 1/4 6 1/2 12 150 28 700 3.0

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

HySpeed HT2000LHF Instruction Manual 4-21

7
OPERATION

Stainless Steel
100 amps • Air Plasma / Air Shield
This gas combination gives good cut speed, low dross and is very economical. Some surface nitriding and surface
oxidation of alloying elements can occur.

020448 120837 020611 020607 120547

Shield Retaining cap Nozzle Swirl ring Electrode

Above Water
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)

1/8 3 48 39 60 3/32 2.5 3/16 5 125 140 3560

3/16 5 (53.3 (44.9 (270 1/8 3 1/4 6 130 110 2800 0.5
1/4 6 SCFH) SCFH) SCFH) 1/8 3 1/4 6 130 80 2030 0.5
3/8 10 1/8 3 1/4 6 135 55 1400 0.5
1/2 12 1/8 3 140 35 890
5/8 15 .157 4 145 25 635
3/4 20 3/16 5 150 20 510

3" Under Water

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)

1/8 3 48 39 60 5/64 2 5/32 4 125 135 3400

3/16 5 (53.3 (44.9 (270 1/8 3 1/4 6 130 100 2520 0.5
1/4 6 SCFH) SCFH) SCFH) 1/8 3 1/4 6 135 65 1720 0.5
3/8 10 1/8 3 1/4 6 140 45 1120 0.5
1/2 12 1/8 3 145 25 670

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 3/8" (10 mm) not recommended

4-22 HySpeed HT2000LHF Instruction Manual

7
 OPERATION

Stainless Steel
40 amps • Air Plasma / Air Shield
This gas combination gives good cut speed, low dross level and is very economical. Some surface nitriding and
surface oxidation of alloying elements can occur.

020688 120837 020689 020613 120667

Shield Retaining cap Nozzle Swirl ring Electrode

Above Water Only

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)

.050 (18 GA.) 40 20 60 3/32 2.5 3/16 5 120 145 3700

1/16 1.5 (46.0 (23.1 (275 3/32 2.5 3/16 5 120 120 3050
1/8 3 SCFH) SCFH) SCFH) 3/32 2.5 3/16 5 125 75 1900 0.5
1/4 6 1/8 3 135 24 610
3/8 10 1/8 3 140 12 300

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 1/8" (3 mm) not recommended

HySpeed HT2000LHF Instruction Manual 4-23

7
OPERATION

Aluminum
200 amps • Air Plasma / Air Shield
This gas combination gives good cut speed, low dross levels and is very economical.

020424 120837 020608 020679 120667

Shield Retaining cap Nozzle Swirl ring Electrode

Above Water
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 6 130 220 5600 0.5

1/4 6 (62.3 (75.0 (270 1/8 3 1/4 6 140 190 4800 1.0
3/8 10 SCFH) SCFH) SCFH) 1/8 3 1/4 6 140 145 3700 2.0
1/2 12 1/8 3 1/4 6 145 110 2800 2.5
5/8 15 .157 4 .314 8 150 85 2200 2.5
3/4 20 3/16 5 3/8 10 155 65 1650 2.5
7/8 22 1/4 6 1/2 12 160 50 1300 2.5
1 25 1/4 6 165 35 900
1-1/4 32 ` 1/4 6 170 20 500
1-1/2 38 1/4 6 175 12 300

3" Under Water

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 70 1/8 3 1/4 6 135 210 5300 0.5

1/4 6 (62.3 (75.0 (280 1/8 3 1/4 6 140 170 4300 1.0
3/8 10 SCFH) SCFH) SCFH) 1/8 3 1/4 6 145 125 3150 2.0
1/2 12 1/8 3 1/4 6 150 90 2240 2.5
5/8 15 .157 4 .314 8 155 65 1650 3.0
3/4 20 3/16 5 3/8 10 160 45 1150 3.0

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 7/8" (22 mm) not recommended

4-24 HySpeed HT2000LHF Instruction Manual

7
 OPERATION

Aluminum
200 amps • N2 Plasma / Air Shield
This gas combination is used when cut edge quality is less important. Electrode life is extended when this
combination is used.

020424 120837 020608 020607 020415

Shield Retaining cap Nozzle Swirl ring Electrode

Above Water
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) (N2 %) (N2 %) (psi) (inches) (mm) (inches) (mm) (volts) (ipm) (mm/min.) (sec)

3/16 5 50 60 60 1/8 3 1/4 6 130 180 4570 0.5

1/4 6 (66.4 (79.6 (270 1/8 3 1/4 6 135 160 4060 1.0
3/8 10 SCFH) SCFH) SCFH) 1/8 3 1/4 6 135 120 3050 1.5
1/2 12 1/8 3 1/4 6 140 80 2030 2.0
5/8 15 .157 4 .314 8 140 70 1780 2.0
3/4 20 3/16 5 3/8 10 150 50 1270 2.5
7/8 22 1/4 6 1/2 12 160 35 890 2.5
1 25 1/4 6 165 25 635
1-1/4 32 ` 1/4 6 175 20 510
1-1/2 38 1/4 6 185 10 250

3" Under Water

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) (N2 %) (N2 %) (psi) (inches) (mm) (inches) (mm) (volts) (ipm) (mm/min.) (sec)

3/16 5 50 60 70 1/8 3 1/4 6 135 170 4350 0.5

1/4 6 (66.4 (79.6 (280 1/8 3 1/4 6 140 140 3650 1.0
3/8 10 SCFH) SCFH) SCFH) 1/8 3 1/4 6 140 100 2600 1.5
1/2 12 1/8 3 1/4 6 145 65 1620 2.0
5/8 15 .157 4 .314 8 145 55 1350 2.5
3/4 20 3/16 5 3/8 10 155 35 890 3.0
7/8 22 1/4 6 1/2 12 165 25 620 3.0

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 7/8" (22 mm) not recommended

HySpeed HT2000LHF Instruction Manual 4-25

7
OPERATION

Aluminum
200 amps • N2 Plasma / CO2 Shield
This gas combination is used when cut edge quality is less important. Electrode life is extended when this
combination is used.

020424 120837 020608 020607 020415

Shield Retaining cap Nozzle Swirl ring Electrode

Above Water
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 6 130 185 4700 0.5

1/4 6 (66.4 (79.6 (210 1/8 3 1/4 6 135 160 4050 1.0
3/8 10 SCFH) SCFH) SCFH) 1/8 3 1/4 6 135 120 3050 2.0
1/2 12 1/8 3 1/4 6 140 95 2400 2.5
5/8 15 .157 4 .314 8 140 70 1800 2.5
3/4 20 3/16 5 3/8 10 150 55 1400 3.0
7/8 22 1/4 6 1/2 12 160 42 1050 3.0
1 25 1/4 6 165 33 840
1-1/4 32 ` 1/4 6 175 20 510
1-1/2 38 5/16 8 185 11 280

3" Under Water

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 6 130 175 4450 0.5

1/4 6 (66.4 (79.6 (220 1/8 3 1/4 6 135 145 3650 1.0
3/8 10 SCFH) SCFH) SCFH) 1/8 3 1/4 6 140 100 2600 2.0
1/2 12 1/8 3 1/4 6 145 75 1820 2.5
5/8 15 .157 4 .314 8 145 55 1350 2.5
3/4 20 3/16 5 3/8 10 155 40 980 3.0
7/8 22 1/4 6 1/2 12 165 30 750 3.0

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 7/8" (22 mm) not recommended

4-26 HySpeed HT2000LHF Instruction Manual

7
 OPERATION

Aluminum
100 amps • Air Plasma / Air Shield
This gas combination gives good cut speed, low dross levels and is very economical.

020448 120837 020611 020607 120547

Shield Retaining cap Nozzle Swirl ring Electrode

Above Water
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)

1/8 3 48 39 60 3/32 2.5 3/16 5 135 110 2800

3/16 5 (55.3 (44.9 (270 1/8 3 1/4 6 140 90 2290 0.5
1/4 6 SCFH) SCFH) SCFH) 1/8 3 1/4 6 145 70 1780 0.5
3/8 10 1/8 3 1/4 6 145 50 1270 0.5
1/2 12 1/8 3 150 40 1010
5/8 15 .157 4 155 30 760
3/4 20 3/16 5 160 25 635

3" Under Water

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)

1/8 3 48 39 70 5/64 2 5/32 4 135 100 2650

3/16 5 (55.3 (44.9 (280 1/8 3 1/4 6 140 80 2050 0.5
1/4 6 SCFH) SCFH) SCFH) 1/8 3 1/4 6 145 60 1510 0.5
3/8 10 1/8 3 1/4 6 150 40 1000 0.5
1/2 12 1/8 3 155 30 750

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

HySpeed HT2000LHF Instruction Manual 4-27

7
OPERATION

Aluminum
40 amps • Air Plasma / Air Shield
This gas combination gives good cut speed, low dross levels and is very economical.

020688 020423 020689 020613 120667

Shield Retaining cap Nozzle Swirl ring Electrode

Above Water Only

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)

3/32 2.5 40 20 60 3/32 2.5 3/16 5 120 140 3550

1/8 3 (46.0 (23.1 (275 3/32 2.5 3/16 5 130 100 2550 0.5
1/4 6 SCFH) SCFH) SCFH) 1/8 3 140 35 900
3/8 10 1/8 3 150 15 350

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 1/8" (3 mm) not recommended

4-28 HySpeed HT2000LHF Instruction Manual

7
 OPERATION

Mild Steel - Beveling Consumables

200 amps • O2 Plasma / Air Shield

120837 (cw) 120833 (cw)

120260 120838 (ccw) 120259 120834 (ccw) 120258
Shield Retaining cap Nozzle Swirl ring Electrode

120257
Water Tube

Above Water Only

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) (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 6 115 160 4060 0.5

.315 8 (14.9 / 50.4 (79.6 / 0 (270 1/8 3 1/4 6 120 120 3000 0.5
3/8 10 SCFH) SCFH) SCFH) 1/8 3 1/4 6 120 100 2540 1.0
1/2 12 .157 4 .314 8 120 80 2030 2.0
5/8 15 .157 4 .314 8 125 70 1780 2.0
3/4 20 3/16 5 3/8 10 130 55 1400 2.5
7/8 22 1/4 6 1/2 12 135 45 1140 2.5
1 25 1/4 6 1/2 12 135 35 890 2.5
1 1/4 32 1/4 6 140 22 560
1-1/2 38 1/4 6 150 15 380
1-3/4 44 5/16 8 160 10 250
2 50 5/16 8 170 7 180

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.

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OPERATION

Mild Steel Gouging

200 amps • Air Plasma / Air Shield

020485 120837 020615 020607 120667

Shield Retaining cap Nozzle Swirl ring Electrode

Shield Arc Plasma Gas Shield Gas

Plasma Gas Flow Rate %
Gas (Air) Current (Air) Inlet (Air) Inlet
Preflow Cut Flow Pressure Setting Pressure Pressure
(Air %) (Air %) (psi) (amps) (psi) (psi)

71 71 50 200 90 90
(81.8 SCFH)

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 OPERATION

CHANGING CONSUMABLE PARTS

WARNING

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

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

Removal and Inspection – Refer to Figure 4-7

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
along the 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
should be 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,
lubricate them lightly with a very thin film of the lubricant provided in the consumable parts kit. If they are
damaged, replace them.

5. Using the 3/4" side of the wrench supplied with the consumable parts kit, remove the nozzle. Inspect it for
damage or signs of wear. You can clean the inside of the nozzle with steel wool, but be sure to remove any
remnants 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 an all copper
electrode has a pit more than .044" (1.1 mm) deep, replace it. A SilverPlus electrode should be replaced
when the pit depth exceeds approximately double the recommended depth of a standard copper electrode.
Use the electrode gauge assembly supplied in the spare parts kit to measure pit depth. If the electrode is
still good, inspect its O-ring: it should be lubricated and undamaged. If it is dry, lubricate it lightly with a
very thin film of 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
sides should not be plugged. Inspect its O-ring. It should be lubricated and undamaged. If it is dry,
lubricate it lightly with a very thin film of the lubricant provided in the consumable 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
of the torch body should be clean and undamaged. Use a clean paper towel or cotton swab to remove dirt,
grease, etc. A preferred method to clean the current ring is with a clean paper towel or cotton swab dipped
in water or 3% hydrogen peroxide. If the water tube is damaged at all, it may need to be replaced. See
Changing the Water Tube.

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OPERATION

Replacement

1. Before installing the electrode, be sure to lubricate the O-ring lightly with a very thin film of the lubricant
provided in the consumable parts kit. Replace the electrode and tighten it with the wrench. Do not
overtighten.

2. Before installing the swirl ring, be certain to lubricate the O-rings lightly with a very thin film of the lubricant
provided in the consumable parts kit. Install the swirl ring with the bottom O-ring facing the inside of the
torch. Push it into place. Be sure to hold 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 tighten by hand. 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 and
tighten by hand. Make sure that it is tightened snugly; if it is loose, it can affect the shield gas flow.

Shield Retaining cap Nozzle Swirl ring Electrode

Water tube

Current ring
Torch body (shown without off valve SA and sleeve)

O-rings

Figure 4-7 Changing Consumable Parts

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 OPERATION

Changing the Water Tube

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

• Short electrode life: The water tube is not screwed in tightly.

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

• Humming or rattling sound coming from the torch: The water tube is bent or loose.

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

1. Disconnect the power supply from the power source.

2. Remove all consumables from the 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 supplied by Hypertherm –
Fig. 4-8. When installing the water tube, do not overtighten it! Tighten by hand only.

WARNING

Always disconnect the power supply

from the main power source before
inspecting or changing the torch parts.

Figure 4-8 Changing the Water Tube

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OPERATION

How to Optimize Cut Quality

The following tips and procedures will help produce square, straight, smooth and dross-free cuts.

Tips for Table and Torch

• Use a square to align the torch at right angles to the workpiece.

• The torch may travel more smoothly if you clean, check and “tune” the rails and drive system on the cutting
table. Unsteady machine motion can cause a regular, wavy pattern on the cut surface.

• The torch must not touch the workpiece during cutting. Contact can damage the shield and nozzle, and
affect the cut surface.

Plasma Set-Up Tips

Follow carefully each step in the Daily Start-Up procedure described earlier in this section.

Purge the gas lines before cutting.

Maximize the Life of Consumable Parts

Hypertherm’s LongLife® process automatically “ramps up” the gas and current flows at the start and ramps them
down at the end of each cut, to minimize erosion of the electrode’s center surface. The LongLife process also
requires that cuts start and stop on the workpiece.

• The torch should never fire into the air.

– Starting the cut at the edge of the workpiece is acceptable, as long as the arc is not fired in the air.
– To start with a pierce, use a pierce height that is 1.5 to 2 times the torch-to-work distance. See Cut Charts.

• Each cut should end with the arc still attached to the workpiece, to avoid arc blow-outs (ramp-down errors).
– When cutting drop parts (small parts that drop down after being cut from the workpiece), check that the
arc stays attached to the edge of the workpiece, for proper ramp-down.

• If arc blow-outs occur, try one or more of the following:

– Reduce the cutting speed during the final part of the cut.
– Stop the arc before the part is completely cut, to allow completion of the cut during the ramp-down.
– Program the path of the torch into the scrap area for ramp-down.
Note: Use a “chain cut” if possible, so the path of the torch can lead directly from one cut part into
the next, without stopping and starting the arc. However, do not allow the path to lead off
the workpiece and back on, and remember that a chain cut of long duration will cause
electrode wear.
Note: It may be difficult to achieve the full benefits of the LongLife process in some conditions.

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 OPERATION

Additional Factors of Cut Quality

Cut Angle

A cut part whose 4 sides average less than 4° of cut angle is considered acceptable.
Note: The squarest cut angle will be on the right side with respect to the forward motion of the torch.
Note: To determine whether a cut-angle problem is being caused by the plasma system or the
drive system, make a test cut and measure the angle of each side. Next, rotate the torch
90° in its holder and repeat the process. If the angles are the same in both tests, the
problem is in the drive system.

If a cut-angle problem persists after “mechanical causes” have been eliminated (See Tips for Table and Torch,
previous page), check the torch-to-work distance, especially if cut angles are all positive or all negative.

• A positive cut angle results when more material is removed from the top of the cut than from the bottom.

• A negative cut angle results when more material is removed from the bottom of the cut.

Problem Cause Solution

Negative cut angle The torch is too low. Increase arc voltage to raise the torch.

Square cut

Positive cut angle

\
The torch is too high. Decrease arc voltage to lower the torch.

Dross

Low-speed dross forms when the torch’s cutting speed is too slow and the arc shoots ahead. It forms as a heavy,
bubbly deposit at the bottom of the cut and can be removed easily. Increase the speed to reduce the dross.

High-speed dross forms when the cutting speed is too fast and the arc lags behind. It forms as a thin, linear bead of
solid metal attached very close to the cut. It is welded to the bottom of the cut and is difficult to remove. To reduce
high-speed dross:

• Decrease the cutting speed.

• Decrease arc voltage, to decrease the torch-to-work distance.
• Increase O2 in the shield gas to increase the range of dross-free cutting speeds. (Only HyDefinition and
HT4400 systems can accommodate mixed-gas shield gases.)
Notes: Dross is more likely to form on warm or hot metal than on cool metal. For example, the
first cut in a series of cuts will likely produce the least dross. As the workpiece heats up,
more dross may form on subsequent cuts.
Dross is more likely to form on mild steel than on stainless steel or aluminum.
Worn or damaged consumables may produce intermittent dross.

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OPERATION

Straightness of the Cut Surface

A typical plasma cut surface is slightly concave.

The cut surface may become more concave, or convex. Correct torch height is required to keep the cut
surface acceptably close to straight.

A strongly concave cut surface occurs when the torch-to-work distance is too low. Increase the arc
voltage to increase the torch-to-work distance and straighten the cut surface.

A convex cut surface occurs when the torch-to-work distance is too great or the cutting current is too
high. First, reduce the arc voltage, then reduce the cutting current. If there is overlap between different
cutting currents for that thickness, try the consumables designed for the lower current.

Additional Improvements

Some of these improvements involve trade-offs, as described.

Smoothness of Cut Surface (Surface Finish)

• (HyDefinition and HT4400 only) On mild steel, a higher concentration of N2 in the O2-N2 shield mixture may
produce a smoother cut surface.
Trade-off: This may produce more dross.

• (HyDefinition and HT4400 only) On mild steel, a higher concentration of O2 in the O2-N2 shield mixture may
increase the cutting speed and produce less dross.
Trade-off: This may produce a rougher cut surface.

Piercing

• The pierce delay must be sufficiently long that the arc can pierce the material before the torch moves, but
not so long that the arc “wanders” while trying to find the edge of a large hole.

• A higher shield gas preflow may help blow the molten metal away during piercing.
Trade-off: This may reduce starting reliability.

Note: When piercing at maximum thicknesses, the ring of dross that forms during the pierce may
be high enough to contact the torch when the torch begins to move after the pierce is
complete. A “flying pierce,” which makes the pierce while the torch is moving, may
eliminate the torch vibration that follows contact between the torch and the ring of dross.

How to Increase Cutting Speed

• Decrease the torch-to-work distance.

Trade-off: This will increase the negative cut angle

Note: The torch must not touch the workpiece while piercing or cutting.

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 Section 5

MAINTENANCE

Introduction
Hypertherm assumes that the service personnel performing the troubleshooting testing are high-level
electronic service technicians that have worked with high voltage electro-mechanical systems. Knowledge
of final isolation troubleshooting techniques is also assumed.
In addition to being technically qualified, maintenance personnel must perform all testing with safety in
mind. Refer to the Safety section for operating precautions and warning formats.
If you need additional assistance or need to order parts, call our Customer Service or Technical Service groups
listed at the front of this manual.

WARNING

SHOCK HAZARD: The large chopper capacitors store large amounts of energy in the form of
electric voltage. Even if the power is off, dangerous voltages exist at the capacitor terminals,
on the chopper, and the diode heatsinks. Never discharge capacitors with a screwdriver or
other implement…explosion, property damage and/or personal injury will result. Wait at least
five minutes after turning the power supply off before touching the chopper or the capacitors.

Routine Maintenance
Torch and Torch Leads (See also Torch Coolant Draining at the end of this section)

Inspection
Inspect the torch and torch leads on a routine basis.
• The torch consumable parts and torch main body should always be inspected prior to cutting. Worn or
damaged parts can cause gas and water leaks which can affect the cut quality. Check for pitting and burn
marks on the consumable parts and replace them, if necessary. See Changing Consumable Parts in
Section 4.
• Ensure that all connections are tight, but do not overtighten.
• The torch leads should be checked occasionally for cracking and damage.

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MAINTENANCE

Power Supply (See also Torch Coolant Draining at the end of this section)

Inspection and Cleaning

Inspect the power supply on a routine basis.

• Check the exterior for any damage. If there is damage, ensure that it does not affect the safe operation of
the power supply.

• Remove covers and inspect the interior. Check wiring harnesses and connections for wear and damage.
Check for loose connections, and look for areas of discoloration due to overheating.

• At the rear of the power supply, inspect the filter element of the water coolant assembly. If the filter
becomes excessively dirty, torch coolant flow can slow down causing the flow switch to open (turn off) and
make the coolant flow interlock status LED illuminate. The filter changes to a brown color when it is dirty.
Replace the filter element (027005) when it starts to turn color.

• Every 2 weeks, inspect the air filter in the front panel of the power supply by removing the access cover and
lifting the filter out. Replace the filter (027441) when dirty.

• Every 6 months, flush the power supply of its torch coolant and replace with new coolant (028872). Also,
replace the water filter (027005) every 6 months.

• Every 6 months, clean the pump strainer with a mild soap and water solution.
Note: Remove the pump from the system before removing the strainer to avoid any debris from falling into
the pump housing. See Fig. 5-1.

Strainer

Brass Coupler
031122

Pump

Figure 5-1 Cleaning the Pump Strainer

Cleaning

Check the inside of the power supply periodically for dust and foreign matter.

• Open the cover and blow out the power supply with compressed air. It is important to keep the cover closed
except when cleaning or when maintenance is being performed.

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 MAINTENANCE

Gas Console

Inspection

Inspect the gas console on a routine basis.

• Check the exterior for any damage. Look for damaged glass tubes in the flowmeters and check the
pressure gauges for damage.

• Inspect all interconnecting cables, hoses and leads for wear and damage. Ensure that all connections are
tight and that there are no leaks. Do not overtighten fittings.

Cleaning

Keep the flowmeters and pressure gauges free of dirt, dust and foreign matter.

Start Sequence
Shaded boxes represent Turn line disconnect
switch on
action taken by the operator.

12VDC to the following interlocks:

1. TSW1, TSW2 (Chopper temperature switches)
2. TS1 (Power Supply transformer temperature switch)
3. LS1 (Power Supply coolant level switch)
4. PS3 (Power Supply shield pressure switches)
5. PS1, PS2 (Gas Console plasma pressure switches)
6. TS2 , (Power Supply coolant temperature switch)
7. FS1 (Power Supply coolant flow switch – note this interlock
will not be satisfied until M1 coolant pump is activated.) Correct
Interlock
Correct Problem
Interlock
Problem
Push and hold
ON button (PB1)

No
All interlocks First 5 interlocks
listed above listed above
satisfied satisfied No
? ?

Yes Yes

CR3 (240V relay) on Power

CR1 (24V/120V relay) on Power Distribution CR2 (120V relay) on Power
Distribution Board (PCB1)
Board (PCB1) closes. Distribution Board (PCB1)
closes.
24VAC to closes.
LT1 (Power Supply ON light) 120VAC to
240VAC to
PCB2 (Power Supply-µP Control Board M1 (Power Supply Coolant
24VAC interlock) M2, M3, M4 (Power Supply
Pump)
120VAC to Fans)
CH1, CH2 (Power Supply Choppers) M5-M8 (Power Supply Heat
PCB3 (Power Supply Analog Board) Exchange Fans)
PCB4 (Power Supply Relay Board)
PCB2 (Power Supply-µP
PCB9 (Power Supply THC Board)
Control Board)

All STATUS LEDs on

PCB5 (Interlock Display
Board) are extinguished.

Release ON button (PB1)

System initialization
is complete.

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MAINTENANCE

Initial Checks
Before tracking down specific problems, it is good practice to do a visual check, and verify proper voltages are
present at the power source, transformer and power distribution board.

WARNING

SHOCK HAZARD: Always use caution when servicing a power supply when it is plugged in and the
covers are removed. Dangerous voltages exist within the power supply which could cause injury or
death.

1. Place the line disconnect switch in the off position.

2. Using a Phillips head screwdriver, remove the top plate, two side plates, front plate, and rear plate.

3. Inspect the interior of the power supply for discoloration on pc boards, or other apparent damage. If a
component or module is obviously defective upon visual inspection, remove and replace it before testing.
Refer to Section 6 to identify parts and part numbers.

4. If no damage is apparent, place the line disconnect switch in the on position.

5. Measure the voltage at TB1 between L1, L2 and L3. Refer to Figure 5-2 for detail of TB1. The voltage between
any two of the three points at TB1 should be equal to your supply voltage. If there is a problem at this point,
disconnect the main power and check connections, power cable, and fuses at the line disconnect switch.
Repair and/or replace defective component(s) if necessary.

Measure the voltage for the 400 volt CE power supplies between the U, V and W
terminals of TB1 in the EMI filter located on the top of the power supply. Refer
to the appendix section.

WARNING

There is line voltage at the contactor if the line

disconnect switch is in the ON position, even if the
ON (1) pushbutton on the HT2000 power supply has
not been pressed. Use extreme care when
measuring primary power in this area. Voltages
present at the terminal block and contactor can
cause injury or death!

Figure 5-2 Primary Power Measurement Location – HT2000LHF

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 MAINTENANCE

F3 F4 F2 F1

Figure 5-3 Power Distribution Board PCB1

6. Measure the voltage at Power Distribution Board PCB1. Refer to Figure 5-3 for detail of PCB1. Look on the
board for fuses F1-F4. Measurements between each fuse and chassis ground should be as follows:

F1: 24VAC
F2: 120VAC
F3: 240VAC
F4: 120VAC

If voltages are not present, or incorrect at one or more of these points, disconnect the power and troubleshoot
PCB1 fuses and associated pins, connectors and wiring between power distribution board connector REC1 and
transformer secondary T1. Refer to Section 6 for location of T1.

Also, check the main power circuit breaker CB1 and associated wiring and connections between T1 and points L1
and L2.

Repair and/or replace defective component(s) if necessary.

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MAINTENANCE

Troubleshooting
The troubleshooting section is presented by following normal operational sequence.

Before troubleshooting for specific problems, be sure that the unit passes Initial Checks as outlined earlier in this
section.

WARNING

SHOCK HAZARD: Always use caution when servicing a power supply when the covers are
removed. Dangerous voltages exist within the power supply which could cause injury or death.
If questions or problems arise during servicing, call the Hypertherm Technical Services Department
listed at the front of this manual.

Problem Possible Causes / Solutions

1. The green POWER ON pushbutton 1.1. The POWER ON (I) PB1 pushbutton is defective.
switch PB1 is pressed, but the fans Check that the switch is operating correctly. The POWER
are not operating and the green ON switch is normally open.
POWER ON indicator does not
illuminate. 1.2. The POWER OFF (0) PB2 pushbutton is defective.
Check that the switch is operating correctly. The POWER
OFF switch is normally closed.

1.3. No jumper for PB2A and PB2B at TB5.

TB5 terminals 1&2 and 4&5 need a jumper if there is no
optional remote I/O cable for switching the power supply on
and off.

1.4. Associated wiring not making good contact.

Check wiring and repair or replace, if necessary.

2. The green POWER ON pushbutton 2.1. CR2 on the power distribution board PCB1 is defective.
switch PB1 is pressed, the POWER Check that CR2 switches when the POWER ON pushbutton
ON indicator illuminates, but the is pressed. See Figure 5-3 for location of CR2. If CR2 is
fans are not running. defective, replace PCB1.

2.2. Connector from the power distribution board is not seated

securely.
Check pins, connectors and associated wiring for continuity.
Repair or replace, if necessary.

3. The green POWER ON pushbutton 3.1. Pushbutton PB1 was not held down for a long enough
switch PB1 is pressed, the fans are period of time.
operating, but the green POWER Press and hold PB1 for a minimum of 5 seconds.
ON indicator does not illuminate.
3.2. Relay CR1 on the power distribution board is defective.
Check that CR1 switches when the POWER ON pushbutton
is pressed. See Figure 5-3 for location of CR1. If CR1 is
defective, replace PCB1.

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 MAINTENANCE

Problem Possible Causes / Solutions

3.3. One or more of the STATUS LEDs remains illuminated,

indicating a fault condition.
To troubleshoot STATUS fault conditions, see Status LED
Troubleshooting later in this section.

4. The green POWER ON indicator is 4.1. There is no spark between the spark gap electrodes.
illuminated, the START command is Clean (with emery cloth), align and reset the electrode gaps
given and the DC ON indicator is to .020" (0.51 mm), if necessary. The electrode surfaces
illuminated, but there is no high between the gaps should be flat. If the surfaces are
frequency and no pilot arc. rounded, replace and reset the gap.

• Inspect the high voltage transformer T3 in the power

supply for signs of overheating. See Figure 6-7 for
location of T3 . Replace T3 if it is overheating.

• Check for 120VAC at T3 after the START command is

given.

• If there is no 120VAC at T3, use wiring diagrams in

Section 7 to check pins, connectors and associated
wiring from T3 to relay board PCB4. If connections are
OK, there may be a problem with either PCB4 or PCB2.

• If there is 120VAC at T3 , shut down the system and

remove capacitors C4, C5 and C6. (See Figure 6-7 for
location of C4, C5 and C6) Restart the system and look
for a faint spark across the gaps.

• If a spark is not observed at the gaps, replace T3. If there

is a spark, shut down system, and replace capacitors C4,
C5 and C6. (Always replace all the capacitors.)

4.2. There is no high frequency at the torch.

Check for a shorted torch, or loose lead connections.
Replace the torch or tighten the lead connections.

5. The green POWER ON indicator is 5.1. Pilot arc relay CR1 is not closing.
illuminated, the torch START See if the CR1 relay contacts close after the START
command is given and the DC ON command is given. See Figure 6-7 for location of CR1. If
indicator illuminates, and there is CR1 does not close:
high frequency, but there is no
pilot arc. • With an AC voltmeter across the relay, see if 120VAC is
coming from PCB4 after the START command is given.

• If there is no 120VAC, check connectors, terminals, pins,

and associated wiring to PCB4.

• If wiring is OK, there is a problem either with PCB4 or

PCB2.

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MAINTENANCE

Problem Possible Causes / Solutions

5.2. Pilot arc relay CR1 is defective.

If there is 120VAC across the relay (see previous steps),
and CR1 does not close, replace CR1.

5.3. Main contactor (CON1) or PCB4 is defective.

• With an AC voltmeter, see if there is 120VAC at contactor

CON1 after the START command is given. If there is no
120VAC, check pins, connectors and associated wiring
from CON1 to PCB4.

• If wiring is OK, PCB4 or PCB2 may be defective.

• If there is 120VAC at CON1 as described above, measure

the voltage between secondary terminals of the main
transformer T2 after the START command is given. The
voltage between any two of the three points connected to
each chopper input should be equal to about 200VAC.

If there is no voltage at any of the above points, replace

CON1.

If there is voltage at some but not all of the above points,

check wiring and connections to and from T2. If wiring
checks out OK, return to Initial Checks section and repeat
steps 1-5.

5.4. Choppers are defective or not functioning.

See Chopper Module Test Procedure later in this section.

6. The unit stops cutting during cut, or 6.1. The work cable is not connected or it is broken.
cuts poorly. Connect or repair the work cable.

6.2. Arc not transferring to workpiece.

Check the work cable connection to the workpiece. Good
contact must be made in order for the arc to transfer.

6.3. There is insufficient air or gas pressure.

Check the gas inlet pressures and the plasma and shield
gas pressures in TEST and RUN modes as specified in the
Cut Charts.

6.4. Torch is getting insufficient current.

Check the arc current setting in the Cut Charts for the type
and thickness of metal you are cutting.

6.5. The power supply has overheated.

Shut down the system and wait for the power supply to cool
down. If the power supply will not restart, see Status LED
Troubleshooting guide later in this section.

6.6. Choppers are defective or not functioning.

See Chopper Module Test Procedure later in this section.

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 MAINTENANCE

Status LED Troubleshooting

Be certain that the power supply has been through the Initial Checks as outlined earlier in this section before
troubleshooting STATUS LEDs.

When any one of the STATUS LEDs illuminates, there is a fault condition that must be corrected in order for the
HT2000LHF power supply to become operational. See Section 7 in this manual for reference.

Problem Possible Causes / Solutions

1. INTERLOCK LED illuminated: This LED should never illuminate. Call the Technical Services
department listed in the front of this manual if this LED
illuminates.

2. TRANSFORMER LED illuminated: 2.1. Main Transformer T2 or one of the choppers is overheating.
This LED will extinguish when the main transformer (T2) is
operating in a normal temperature range (under 165° C
(329° F)) and choppers CH1 and CH2 are also operating in
a normal temperature range (under 82° C (180° F)).

• Check the temperature switches (normally closed).

• Check pins, connectors and wiring to temperature

switches.

• Leave the fans running, and try restarting the unit after
one hour. If LED still illuminates, one of the choppers or
the main transformer may need to be replaced.

3. COOLANT LEVEL LED illuminated: 3.1. Coolant level is low.

This LED will extinguish when a proper coolant level in the
coolant reservoir is maintained. Level switch LS1 is located
in the coolant reservoir, and will open when it senses that
coolant level is too low.

• Check the coolant level.

• If the coolant level is adequate, check to see if LS1 switch

is closed.

• Check connections and wiring from LS1 to PCB1.

Repair and/or replace defective component(s), if necessary.

HySpeed HT2000LHF Instruction Manual 5-9

6
MAINTENANCE

Problem Possible Causes / Solutions

4. SHIELD GAS/CAP LED illuminated: 4.1. Shield gas pressure is too low.
This LED will extinguish when shield gas pressure of 12 psi
(0.83 bar) or greater is sensed by PS3 (located in the power
supply).

• Check to see that the shield gas supply is set to 90 psi (6.2
bar) as defined in the Specifications section of this manual.

• Verify that all shield gas connections are secure, and that
there are no leaks in any hoses connected to the power
supply or gas console.

4.2. Torch cap not tightened securely.

If the torch retaining cap is not tightened securely, or there is
debris in the retaining cap, the shield gas may escape and
cause pressure switch PS3 to remain open.

• Listen at the torch for a hissing sound during startup.

• Remove the retaining cap and check for debris or O-ring

damage. Clean or replace, if necessary. See Changing
Consumable Parts in the Operation section.

4.3. Pressure switch PS3 in the power supply is not functioning.

PS3 is normally open, and closes when shield gas pressure is
12 psi (0.83 bar) or greater.

• Using the wiring diagrams, check pins, connectors and wiring

from the power distribution board (PCB1) to PS3.

Repair and/or replace defective component(s), if necessary.

5. PLASMA GAS LED illuminated: 5.1. Plasma gas pressure is too low.
This LED will extinguish when PS1 and/or PS2 in the gas
console senses plasma gas pressure of 80 psi (5.5 bar) or
greater.

• Verify that the plasma gas supply is set to 120 psi (8.3 bar) as
defined in the Specifications section of this manual.

• Verify that all plasma gas connections are secure, and that
there are no leaks in any hoses connected to the gas console.

5.2. Pressure switches PS1 and/or PS2 not functioning.

These switches are normally open, and close when plasma gas
pressure is at or above 80 psi (5.5 bar). After PS1 and PS2 are
closed (in O2 mode) or PS1 is closed (in N2 mode), the Plasma
Gas LED extinguishes.

• Using the wiring diagrams, check pins, connectors and wiring

from the power distribution board (PCB1) to PS1 and PS2.

Repair and/or replace defective component(s), if necessary.

5-10 HySpeed HT2000LHF Instruction Manual

6
 MAINTENANCE

Problem Possible Causes / Solutions

6. COOLANT TEMP LED illuminated: 6.1. Coolant is too hot.

This LED will extinguish when temperature switch TS2
senses that the temperature of coolant in the coolant
reservoir is under 160° F (71° C).

• Check to see if the water coolant is above 160° F (71° C).

• Check to see if TS2 (located in the coolant reservoir) is

open. TS2 is normally closed, and is opened when a
temperature above 160° F (71° C) is reached.

• Using the wiring diagrams, check pins, wires and

connections from TS2 to PCB1.

Repair and/or replace defective component(s), if necessary.

7. COOLANT FLOW LED illuminated: 7.1. Coolant flow is restricted.

This LED will extinguish when flowswitch FS1 senses a
coolant flow of at least 0.5 gpm (1.9 lpm) to the torch. FS1
is a normally open switch that closes when a flow greater
than 0.5 gpm (1.9 lpm) is sensed. See Coolant Flow Test
Procedure later in this section to troubleshoot coolant flow
problems.

Note: Coolant flow LED illuminates when the line disconnect

switch is turned ON because coolant reservoir pump M2 is
not activated until the power supply POWER ON (PB1) is
pressed.

HySpeed HT2000LHF Instruction Manual 5-11

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MAINTENANCE

Chopper Module Test Procedure

Note: Take voltages with a digital multimeter capable of storing min. and max. readings.

WARNING

SHOCK HAZARD: Use extreme care when working near the chopper modules. The large chopper
capacitors store large amounts of energy in the form of electric voltage. Even if the power is off,
dangerous voltages exist at the capacitor terminals, on the chopper, and the diode heatsinks.
Never discharge capacitors with a screwdriver or other implement…explosion, property damage
and/or personal injury will result.

1. Turn all power to the power supply OFF.

Disconnect the mating receptacles in the power supply to disable the high frequency transformer T3.
See Figure 6-7 for location of T3.

2. Remove large fuses F1 and F2. Check to see if the fuses are open.

3. Place the positive lead to the + side of the bridge and the negative lead to the – side of the bridge. See Figure
5-4. Note that actual connection points are hidden by cap support bracket in Figure 5-4.

4. Turn power to the power supply ON, and start the system up. After the START command has been given, check
the voltage. The input to the chopper at these points should be about +280 VDC. If the input is OK and
corresponding fuse F1 or F2 was blown, replace the chopper module.
If there is no +280 VDC input, check input to bridge for shorts. Also, check contactor (CON1), connections and
associated wiring to the contactor. Repair and/or replace defective component(s) if necessary.

5. If the voltage from above step is +280 VDC and corresponding fuse is not blown, check output of CH1 by
placing the positive lead of the voltmeter at point + WORK on the chopper module (wire #48A) and negative
lead at point - TORCH (wire #39A). (Check the output of CH2 by placing the leads of the voltmeter at the
corresponding points on the other chopper module.)

6. Turn the system on and press the START command. After the START command has been given, check the
voltage. If the output from each chopper at these points is +280 VDC, then the choppers are OK.

7. If the chopper does not output +280 VDC, check to see if the LED1 logic power light is illuminated. If LED1 is
extinguished, check if 120V is going to JP6. If there is no 120V at JP6, check wiring back to the power
distribution board. Repair or replace defective component(s), if necessary. Also check to see if LED3 is turning
green when enabled (normal condition). If LED1 is illuminated and LED3 is red when enabled (fault condition),
then make sure that JP9 is seated properly.

8. If the chopper still does not output 280V after completing step 7, there may be a problem with the control signal
or the chopper module. The chopper drive signal comes through the analog board PCB3 as an analog level
from 0 to +8 VDC, which varies the duty cycle and subsequent output current of the chopper. These analog
signals are on pins 3&4 REC1 of PCB3 for CH1, and 5&6 REC1 for CH2.

5-12 HySpeed HT2000LHF Instruction Manual

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 MAINTENANCE

To determine if there is a problem with the chopper modules or with control board PCB2 or analog board PCB3,
proceed as follows:

• Ensure that the high frequency is still disabled (see step 1).

• Disconnect PL3.1 from REC1 on PCB3.

• Place voltmeter across the output of the chopper and press the START command.

• If the voltmeter reads +280 VDC, then replace either control board PCB2 or analog board PCB3.

• If the voltmeter reads 0 volts, then replace the corresponding chopper module CH1 or CH2.

Bridge (+) Bridge (–)

LED1

LED3

JP9

- TORCH

+ WORK JP6

Figure 5-4 Chopper Module – Front View

HySpeed HT2000LHF Instruction Manual 5-13

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MAINTENANCE

Error Codes
The microcontroller on control board PCB2 will alert the user when certain errors occur in the system, by flashing
the Error Code LED on the control board . The power supply front cover must be removed to observe control board
PCB2 and the Error Code LED (see Figure 6-1 for location of PCB2 and Figure 5-5 for location of Error Code LED
on PCB2).

The Error Code LED will blink on for .5 seconds and off for .5 seconds with a 2-second gap before repeating the
blinking sequence. The number of blinks between the 2-second gap is 1 of 10 error indications listed below.

During the error code flashing, all outputs from the control board are turned off, and the power supply is in an idle
mode. After the error is corrected, you may resume operation of the system.

Note: 8 or 9 blinks will occur during normal operation. If the Error Code LED remains on without blinking, this
indicates that a microcontroller internal RAM or ROM self-check error has occurred (power supply will
hang up).

For troubleshooting purposes, the Plasma Start LED is also shown in Figure 5-5. When illuminated, this LED
indicates that the plasma START command has been received at the control board.

Number
ERROR CODE PLASMA START
LED LED of blinks Explanation

1 Indicates that the IHS Complete signal has not been

returned within 30 seconds after the plasma START
command has been given.

2 Indicates that an "interlock" error has occurred.

3 Indicates that the HOLD input (for multi-torch systems) was

not released within 30 seconds after the end of preflow.

4 Indicates that there was no transfer within 300ms.

5 Indicates that transferred current arc was lost during

ramp up.

6 Indicates that the current was lost from chopper #1 (CH1).

7 Indicates that the current was lost from chopper #2 (CH2).

8 Indicates that transferred current arc was lost during ramp

down.

9 Indicates that the software has an error.

Terminals are normally disconnected.
10 Indicates that the input voltage has dropped below 15% of
the nominal value. Eg: Input voltage for a 480V power
supply drops below 408V.

Figure 5-5 Control Board Error Code LED Location and Code Explanation

5-14 HySpeed HT2000LHF Instruction Manual

7
 MAINTENANCE

Coolant Flow Test Procedure

WARNING

Push the OFF (0) button on the power supply and place the main disconnect switch in the OFF
position before proceeding.

If the COOLANT FLOW Status LED illuminates, verify that the proper flow is maintained by following the
troubleshooting sequence outlined in this procedure:

Check Reservoir Coolant

1. Shut off the power supply.

2. Remove the torch coolant reservoir cap.

3. Remove the power supply rear cover.

4. Verify that the reservoir is full of coolant. Add coolant, if necessary.

Verify Flow Rate Return from Torch

1. Find a clean 1-gallon (3.8 liter) container.

2. Locate the two coolant hoses that come off of the cathode block at the rear of the power supply (black hoses:
one with a green tape band and one with a red tape band – See Fig. 5-6).

3. Remove the torch coolant return hose (black hose with the red band) from the cathode block.

4. Place the red banded hose into the 1-gallon container.

Torch Coolant Supply Hose

(Black with Green Band)

Cathode Block

Torch Coolant Return Hose

(Black with Red Band)
Remove this hose

Figure 5-6 Torch Coolant Supply and Return Hoses

HySpeed HT2000LHF Instruction Manual 5-15

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MAINTENANCE

5. Turn the power supply power on.

6. Hold down the ON (I) button on the power supply.

7. Start timing for 30 seconds, and then release the button.

8. Verify that the container is 1/2 full. If not 1/2 full, repeat this test and time discharge for 1 minute. After 1 minute
verify that the container is at least 3/4 full.

8.1. If the 1-gallon container is less than 3/4 full after step 8, go to Verify Flow Rate to Torch.

8.2. If the 1-gallon container is at least 3/4 full after step 8, the problem is either with the flow switch or the
particulate filter.

• Remove the filter element and re-connect the coolant hose to the cathode block on the rear of the power
supply.

• Start the power supply. If the COOLANT FLOW LED remains illuminated, replace the flow switch. If the LED
does not illuminate, replace the filter element.

Verify Flow Rate to Torch

1. Press the power supply OFF (0) button and place the main disconnect switch to the OFF position.

2. Remove the torch consumables.

3. Replace only the retaining cap on the torch. (Do not replace the electrode, nozzle and swirl ring back in the
torch.)

4. Place the empty 1-gallon container under the torch.

5. Turn the power back on and press and hold down the power supply ON (I) button.

6. Start timing for 1 minute. The torch should deliver at least 1 gallon (3.8 liters) of fluid in 1 minute.

7. If the torch delivers at least 1 gallon (3.8 liters) of fluid per minute, then the flow rate to the torch is OK. Replace
the torch. If the torch does not deliver at least 1 gallon (3.8 liters) of fluid per minute, go to Check Pump, Motor,
and Solenoid Valve (V1).

8. If replacing the torch does not satisfy the flow switch, then replace the torch leads.

Check Pump, Motor and Solenoid Valve (V1)

1. If the coolant is not flowing, check to see if the motor and valve V1 are getting 240VAC. Note: The 240VAC
relay (CR3) on PCB1 will not close until the first 5 interlocks (STATUS) indicators are satisfied. (See Start
Sequence flowchart earlier in this section.)

2. If the motor, pump and valve all seem to be functioning and the flow is not sufficient, replace the pump and
motor assembly.

5-16 HySpeed HT2000LHF Instruction Manual

6
 MAINTENANCE

Coolant Reservoir
Float Switch
LS1

Flow Switch
FS1

Temperature Switch Particulate

TS1 Filter

Solenoid Valve Check

V1 Valve
Pump with Heat
Relief Valve Exchanger

Cathode Block
(in back of
power supply)

Torch

Figure 5-7 Plumbing Schematic of Power Supply Reservoir Assembly and Torch

Torch Coolant Draining

Hypertherm recommends draining the torch coolant from the power supply and torch before transporting the
system. After this draining procedure, a small amount of coolant will remain in the system pump and valves. For
this reason, Hypertherm also recommends that a suitable ratio of propylene glycol be purged through the system
prior to draining if the system will experience extremely cold temperatures. Note that Hypertherm's stock propylene
glycol solution 028872 is rated to 10° F (-12° C).

1. Disconnect all power to the system.

2. Remove the fill inlet cap from the reservoir to allow proper venting.

HySpeed HT2000LHF Instruction Manual 5-17

6
MAINTENANCE

Fill inlet cap

Fill inlet

Drain petcock

Figure 5-8 Coolant Tank Reservoir Drain Petcock Location

3. Drain the power supply reservoir by opening the petcock on the bottom of the reservoir tank. Close petcock
after coolant is drained. See Fig. 5-8. On older systems, there is either no petcock, or the petcock is in a
different position than the one shown in the figure above. Siphon coolant out of the tank through the fill inlet if
there is no petcock.

4. Ensure that the torch and consumables are installed and connected to the power supply.

5. Disconnect the torch coolant supply hose (black hose with the green band) from the rear of the power supply .
See Fig. 5-6.

6. Blow clean, dry, oil-free air at 80-120 psi (5.5 - 8.3 bar) into the torch coolant supply hose until coolant stops
flowing into the reservoir.

7. Drain or siphon remaining coolant from the reservoir as in step 3.

8. Unscrew the coolant filter housing from the rear of the power supply. See Fig. 6-8 for location of filter housing.

9. Empty coolant from the filter housing.

10. Screw the coolant filter housing back into the rear of the power supply.

5-18 HySpeed HT2000LHF Instruction Manual

6
 MAINTENANCE
Preventative Maintenance Schedule Year________

Daily:
Verify proper inlet gas pressure -- See Instruction Manual, Specification section

Verify proper gas flow settings -- Mandatory at every consumable change -- See Instruction Manual, Operation section

Verify proper coolant pressure and temperature -- Water Chillers only -- See Instruction Manual, Specification section

Replace consumables as needed, and inspect torch

Weekly: Date Completed:

Jan Feb March April May June July Aug Sept Oct Nov Dec

Week 1

Week 2

Week 3

Week 4

Week 5

Clean power supply with dry, oil free compressed air, or vacuum Clean torch threads and current ring

Verify cooling fans are working properly Verify proper coolant level

Monthly: Date Completed:

Jan Feb March April May June July Aug Sept Oct Nov Dec

Inspect for loose wire connections

Inspect contacts on main contactor for wear

Inspect pilot arc relay for pitting

Verify proper operation of coolant flow switches

Perform coolant flow test

Check gas console packing nuts for tightness

Perform gas leak test

Inspect cable connections

Bi-Annually: Date Completed:

Service 1________ Service 2________

Drain coolant system -- See Instruction Manual, Maintenance section

Replace coolant filter element - See Instruction Manual, Maintenance section

Replace coolant with genuine Hypertherm coolant

Annually: Date Completed:________

Replace pilot arc relay

Replace main contactor

Hypertherm, Inc. 8/28/00

HySpeed HT2000LHF Instruction Manual 5-19

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MAINTENANCE

5-20 HySpeed HT2000LHF Instruction Manual

7
 Section 6

PARTS LIST

Introduction

See Section 3: Installation and appendices A and C to find part numbers for cables and hoses.

HySpeed HT2000LHF Instruction Manual 6-1

6
PARTS LIST

HT2000LHF Power Supply: Front Panel

See Figure 6-3
for detail of
control panel

9 7

6
8

See Figure 6-2

for detail of
THC module

3
2

1
5

Figure 6-1 HT2000LHF Power Supply – Front Panel

Part
Item Number Description Designator Qty.
1 001233 Panel, HT2000 Front 1
2 129307 Fan SA:225CFM M3 1
027080 Fan:225CFM 120VAC 50-60HZ
027568 Fan Guard:6.375 DIA
3 129307 Fan SA:225CFM M2 1
027080 Fan:225CFM 120VAC 50-60HZ
027568 Fan Guard:6.375 DIA
4 129308 Fan SA:450-550CFM M4 1
027079 Fan:450-550CFM 120VAC 50-60HZ
027567 Fan Guard:8.75 DIA
5 008509 Bushing 1.75 MTG X 1.37 ID 3
6 008245 Bushing, 7/8" Hole X 11/16" ID 1
7 041764 PCB Assy: HT2000LHF Control PCB2 1
8 041276 PCB Assy: HT2000 Anlg PCB3 1
9 041246 PCB Assy: Relay, HD1070 / HT2000 PCB4 1
001566* Panel:HT2000 Front Filter 1
001567* Cover:HT2000 Front Filter Panel 1
027441* Filter:24 X 24 X 2 Fiberglass air 1
029697** HT2000 THC SA

* Items not shown in Figure 6-1

** Used only in HT2000LHF power supplies with the THC option – see Figure 6-2

6-2 HySpeed HT2000LHF Instruction Manual

6
 PARTS LIST

HT2000LHF Power Supply: THC Assembly (optional)

2

3
1

Figure 6-2 HT2000LHF Power Supply – THC Assembly

Part
Item Number Description Designator Qty.
029697 HT2000 THC Assembly 1
1 001297 Cover: HT2000 THC Dust 1
2 004338 Hinge: THC Pan, HT2000 2
3 041294 PCB Assy: HT2000 THC Mother PCB9 1
4 041186 PCB Assy: HT2000 Torch Hght Cntrl PCB10 1

HT2000LHF Power Supply: Control Panel

7
8 9 2, 3, 4 1 5 6

Figure 6-3 HT2000LHF Power Supply – Control Panel

Part
Item Number Description Designator Qty.
129331 Contr Pnl SA, HT2000LHF 1
1 001661 Pnl :HT2000LHF Cont 1
2 005151 Lamp holder 1
3 005149 Bulb, 120VAC LT2 1
4 005089 Lens:White for 005088 1
5 041536 PC BD Assy Intlk Dsply 200/4001 PCB12 1
6 009063 Diode, Ind LED Amber 7
7 002278 Cover:HT2000 Cont. Panel SA 1
8 005121 Pushbutton, 2 NO Green Illumin PB1/LT1 1
9 005122 Pushbutton, 2 NC Red Extended PB2 1

HySpeed HT2000LHF Instruction Manual 6-3

6
PARTS LIST

HT2000LHF Power Supply: Center Wall Right Side

7 1

4 2

Figure 6-4 HT2000LHF Power Supply – Center Wall Right Side

Part
Item Number Description Designator Qty.
1 003138 Circuit Breaker, 2 Pole, 600V 20A CB1 1
2 003139 Contactor:90A 3P 120VAC CON1 1
3 029316* Incoming Power TB1 SA, MAX200 TB1 1
4 029422 Cont Transformer SA 200V/3φ φ/50Hz T1 1
4 029441 Cont Transformer SA 208V/3φ φ/60Hz T1 1
4 129311 Cont Transformer SA 240V/3φ φ/60Hz T1 1
4 029362 Cont Transformer SA 400V/3φ φ/50Hz T1 1
4 029713 Cont Transformer SA 440V/3φ φ/50-60Hz T1 1
4 129312 Cont Transformer SA 480V/3φ φ/60Hz T1 1
4 029404 Cont Transformer SA 600V/3φ φ/60Hz T1 1
5 041534 PC BD Assy, Power Distribution PCB1 1
008322 Fuse:8A 250V 1/4 X 1-1/4 Slow F1,F2,F3 3
6 014080 Inductor, 4mh 100A L1 1
7 004262 Plate, Lift, MAX100 & 80 1
001601** Plate:CE/LVD Lift Eye 1
001602** Gasket:CE/LVD Lift Eye 1

* See Appendix D for location of 029316 on 400V CE power supplies.

** Items not shown in Figure 6-4

6-4 HySpeed HT2000LHF Instruction Manual

7
 PARTS LIST

HT2000LHF Power Supply: Center Wall Left Side

6 1 7 8

13 4

5
12
10

14
9
11

Figure 6-5 HT2000LHF Power Supply – Center Wall Left Side

Part
Item Number Description Designator Qty.
1 004261 Bar, Lift, MAX100 & 80 1
2 004334 Busbar, HT2000 Shunt 1
3 007022 Shunt, 100A, 100mv R2 1
4 007022 Shunt, 100A, 100mv R1 1
5 007024 Shunt, 200A, 100mv R3 1
6 008945 Fuseholder:100A/1000V 2
7 008317 Fuse, Semiconductor 125A, 250V F1 1
8 008317 Fuse, Semiconductor 125A, 250V F2 1
9 014111 Transformer 30KW 200V/3φ/50Hz T2 1
9 014097 Transformer 30KW 208V/3φ/60Hz T2 1
9 014078 Transformer 30KW 240V/480V/3φ/60Hz T2 1
9 014088 Transformer 30KW 400V/3φ/50Hz T2 1
9 014158 Transformer 30KW 440V/460V/3φ/50-60Hz T2 1
9 014082 Transformer 30KW 600V/3φ/60Hz T2 1
10 005102 Thermostat, 160°C, 6 Amp TS1 1
11 014080 Inductor, 4mh 100A L2 1
129283 Shield SA: HT2000LHF
12 006032 Solenoid Valve:150# 1/4 FPT 120V NC SV6 1
13 006106 Solenoid Valve:1/8FPT 120V TFE-Plunger SV7 1
14 005227 Pressure Switch:12 PSI PS3 1

HySpeed HT2000LHF Instruction Manual 6-5

7
PARTS LIST

HT2000LHF Power Supply: Front Wall Inside

2 4 2

Figure 6-6 HT2000LHF Power Supply – Front Wall Inside

Part
Item Number Description Designator Qty.
1 129118 CH130 CE/LVD Chopper SA CH1 1
005199 Temperature Switch 82°C TSW1 1
2 129118 CH130 CE/LVD Chopper SA CH2 1
005199 Temperature Switch 82°C TSW2 1
3 008509 Bushing 1.75 MTG X 1.37 ID 3
4 041564 PCB Assy:Phase Loss Detection Circuit 1

6-6 HySpeed HT2000LHF Instruction Manual

6
 PARTS LIST

HT2000LHF Power Supply: Rear Wall Inside

17 19 18 14 20
16
15
8
13

21

4
7

2 6

11
3

5 10

12

Figure 6-7 HT2000LHF Power Supply – Rear Wall Inside

Part
Item Number Description Designator Qty.
1 009684 Resistor:4-ohm 420W with bracket R6A, R6B 2
2 003021 Relay, 120VAC NO SPST CR1 1
3 009015 Resistor: 10K Ohm, 10W R5 1
4 009506 Capacitor: 250UF, 350VDC C1 1
5 009438 Resistor: 5 Ohm, 50W R4 1
129274 Harness SA HT2000LHF
6 008073 Terminal Strip (16) TB3 1
7 008079 Terminal Strip (12) TB4 1
8 008134 Terminal Strip (8) TB5 1
9 008447 Receptacle, 23-37, Std Sex 1X6, 1X5 2
10 008208 Receptacle, 23-37, Rev Sex 1X1,1X2,1X7, 1X4 4
11 008201 Receptacle, 17-14, Rev Sex 1X9, 1X3 2
12 008210 Receptacle, 11-4, Rev Sex 1X10 1
13 129284 Shield SA: HT2000LHF Shield Sense 1
129285 HF-I/O PNL SA:HT2000-LHF 1
14 009349 Coil Assembly:200A High Frequency T4 1
109077 Spark Gap Assembly HT2000LHF SG1 1
15 004061 Electrode:Spark Gap 1/8 X 1.6 3
16 004140 Base:40/0/100/200/HD Spark Gap 1
17 004141 Block:009350 Spark Gap End 2
18 004142 Block:009350 Spark Gap Center 1
19 009975 Capacitor: 1400pF 20KV C4, C5, C6 3
20 041145 PCB ASSY:MAX200 I/O 1
029202 Current Sensor Assembly CS1 1
21 129150 High Voltage Transformer SA 6kV T3 1

HySpeed HT2000LHF Instruction Manual 6-7

6
PARTS LIST

HT2000LHF Power Supply: Rear Wall Outside

3 1 4 5 14 10

12 11

13
7

6 (item 6 hidden
from this view)

8, 9

Figure 6-8 HT2000LHF Power Supply – Rear Wall Outside

Part
Item Number Description Designator Qty.
029313 Reservoir SA, HT2000 1
1 002304 Coolant Res. 1
3 022036 Gauge: Liquid Level 1
4 129618 Switch, Level SA, 1/2 NPT LS1 1
5 029323 Switch, Temp SA, 162 Deg F TS2 1
6 029361 Flowswitch, 0.5GPM FS1 1
7 006053 Valve, Check 1/3 PSI, 1/4 NPTM 1
8 027005 Filter Element 1
9 027139 Filter Housing, 10" X 3/8 NPT 1
10 029324 Heat Exchanger SA, MAX200 1
027978 Heat Exchanger, Water/Air M5,M6 1
11 129383 Valve SA:HT2000 Power Supply 1
006046 Valve, Sol 240V 3/8 NPT NC V1 1
129252 Water Pump SA 1
12 128385 Kit: Motor, 1/3 HP Carbon 230/50-60 M1 1
13 128384 Kit: Pump, 70 GPH Positive Displace 1
031122* Coupler:Pro Pump-Motor 1
129285 HF-I/O PNL SA:HT2000-LHF 1
14 004314 Block:200 Cathode 1
* Item is not shown in Figure 6-8. See page 5-2 for illustration of part.

6-8 HySpeed HT2000LHF Instruction Manual

7
 PARTS LIST

HT2000LHF Gas Console

5, 8, 9 11 12 4

1
PLASMA DC

4 N2/Air O2

2
SHIELD
10 10

22 9
psi
9
22
8 8
psi
7 7
21
19 6 6

5
N2/Air
5 6
4 4

20 3 3
7
2 2
psi
1 1 18 23
0 0
23
15
O2
14
N2/Air
PreFlow
PLASMA
Cut Flow
O2
PreFlow 13 16
3 Run

Test Test
Preflow Cutflow
17
® ®
HySpeed HT2000LHF 10

Figure 6-9 HT2000LHF Gas Console

Part
Item Number Description Designator Qty.
073239 HT2000LHF Gas Console
1 001335 Encl: 2000 Gas Csl 1
2 001649 Pnl: HT2000LHF Gas Csl 1
3 004117 Cap: Ndl Valve 4
4 005181 Tgl Sw: DPDT Maint ON/NONE/ON S1 1
5 005089 Lens:White for 005088 1
6 005243 Switch, Pressure 80 PSI PS1 1
7 005243 Switch, Pressure 80 PSI PS2 1
8 005149 Bulb, 120VAC T2 LT1 1
9 005151 Lamp Holder 1
10 005180 Tgl Sw: SP3T, Maint ON/OFF/ON S2 1
11 006109 Solenoid Valve:150# Manf 120V 2-Way NC SV1A 1
12 006109 Solenoid Valve:150# Manf 120V 2-Way NC SV1B 1
13 006109 Solenoid Valve:150# Manf 120V 2-Way NC SV2 1
14 006109 Solenoid Valve:150# Manf 120V 2-Way NC SV3 1
15 006064 Valve, Ndl 1/8 FPT .125 Orf MV1 1
16 006064 Valve, Ndl 1/8 FPT .125 Orf MV2 1
17 006064 Valve, Ndl 1/8 FPT .125 Orf MV3 1
18 006064 Valve, Ndl 1/8 FPT .125 Orf MV4 1
19 011053 Flowmeter: 7.8 GPM/44 CFH FM1 1
011058 Fltube w/Float /BP-8 Flt:0-10 SC Cal 2%
011008 Shield: Plastic, for 011053 or 011056
011081 Flowmeter Float Stop
20 011053 Flowmeter: 7.8 GPM/44CFH FM2 1
011058 Fltube w/Float /BP-8 Flt:0-10 SC Cal 2%
011008 Shield: Plastic, for 011053 or 011056
011081 Flowmeter Float Stop
21 022008 Gauge, Press 100#/Bar 2.5" Dia. PG3 1
22 022020 Gauge, Press 160#/Bar 2" Dia. PG1 1
23 022020 Gauge, Press 160#/Bar 2" Dia. PG2 1
015299* Filter:.10 Micron 1/8FPT Brass Inline FL1, FL2 2
004718** Manifold, valve 2
* Located behind O2 and N2 inlet connections
** Located behind solenoid valves

HySpeed HT2000LHF Instruction Manual 6-9

6
PARTS LIST

Digital Remote Voltage & Current Control Console

11 5 11 19 7, 8

9
20

10

18
16 15

17
14

3, 4 6 1 12, 13
Figure 6-10 Digital Remote Voltage & Current Control Console
Part
Item Number Description Designator Qty.
073007 Control Station, Digital Remote V/C MAX200 1
002107* Cov: DR/PR V/C Top 1
002106* Cov: DR/PR V/C Bottom 1
1 002119 Panel, Rear, DR V/C 1
2 004119 Bracket, Mtg, DR/PR V/C 1
3 008069 Fuse, 3/8 Amp 313, 375 1
4 008165 Fuseholder, REM V/C 1
5 008164 Knob 2
6 014012 Transf'mer, DR/PR/SR V/C 1
002118 Encl, Assy DR V/C 1
7 001133 Pl: HT400 DR V/C MDL FR 1
8 001131 Flg: HT400 DR/PR V/C MDL Fr 1
9 001137 FR: HT400 DR/PR/ST V/C Mdl LS 1
10 001138 FR: HT400 DR/PR/ST V/C Mdl RS 1
029302 Filter PNL-PCB SA DR/SR V/C 1
11 009871 Potentiometer, 500 Ohm 10 turn 2
12 008175 Receptacle, Shell Size 13-9 1
13 008176 Pin, 20-24 AWG Type III+ 6
14 041070 PC BD Assy Opto-Iso 1
15 041187 PC BD Assy Dig/Sta V/C MAX200 1
16 004116 Heatsink, DR/PR SR V/C 1
17 042059 IC, LM340AK-5.0 1
18 009274 Capacitor, 2600 UF 15VDC 1
19 041076 PC BD Assy Rem Volt Disp 1
20 041077 PC BD Assy Rem Curr Disp 1
* Items are not shown in Figure 6-10.

6-10 HySpeed HT2000LHF Instruction Manual

6
 PARTS LIST

Programmable Remote Voltage & Current Control Console

19 18 6, 7

9 8

16 14
17

15 13

12, 11 2, 3 4 1 10, 11

Figure 6-11 Programmable Remote Voltage & Current Control Console

Part
Item Number Description Designator Qty.
055004 Control, Programmable V/C 1
002107* Cov: DR/PR V/C Top 1
002106* Cov: DR/PR V/C Bottom 1
1 002123 Panel, Rear, PR V/C 1
2 008069 Fuse, 3/8 Amp 313, 375 1
3 008165 Fuseholder, REM V/C 1
4 014012 Transf'mer, DR/PR/SR V/C 1
5 004119 Bracket, Mtg, DR/PR V/C 1
002122 Encl Assy, PR V/C 1
6 001139 PL: HT400 PR V/C MDL FR 1
7 001131 Flg: HT400 DR/PR V/C MDL Fr 1
8 001137 FR: HT400 DR/PR/ST V/C Mdl LS 1
9 001138 FR: HT400 DR/PR/ST V/C Mdl RS 1
029089 Filter PNL-PCB SA PR V/C 1
10 008175 Receptacle, Shell 13-9 Size 1
11 008176 Pin, 20-24 AWG Type III+ 22
12 008193 Recp, CPC 17-16 Standard Sex 12
13 041070 PC BD Assy Opto-Iso 1
14 041085 PC BD Assy, PR V/C 1
15 004116 Heatsink, DR/PR SR V/C 1
16 009274 Capacitor, 2600 UF 15VDC 1
17 042059 IC, LM340AK-5.0 1
18 041076 PC BD Assy, Rem Volt Disp 1
19 041077 PC BD Assy, Rem Curr Disp 1
* Items are not shown in Figure 6-11.

HySpeed HT2000LHF Instruction Manual 6-11

6
PARTS LIST

Initial Height Sensing Control Console

13 7, 8 4 5, 6

11

12
3

10

Figure 6-12 Initial Height Sensing Control Console

Part
Item Number Description Designator Qty.
053016 Control Console, IND IHS, HT400
1 002095 Encl., Control Console UW-IHS 1
2 006021 Valve, SOL 75# 1/4 NPTF 1
3 008073 Terminal Strip (16) 1
4 008071 Strain Relief, 1/2 X .375-.500 1
5 008175 Receptacle, Shell Size 13-9 1
6 008176 Pin, 20-24 AWG Type III+ 7
7 008186 Socket, 20-24 AWG Type III+ 8
8 008210 Receptacle, 11-4 2
9 009041 Filter, AC, 1 Amp 1B3 1
10 024038 Hose Assy, #4 x 7" 1
11 041043 PC BD Assy UW-IHS 1
12 041023 Power Source, IHS 1
13 008094 Terminal Strip (8) 1

6-12 HySpeed HT2000LHF Instruction Manual

6
 PARTS LIST

Argon-Hydrogen Manifold

7, 8

6 9 4 1 2 2

3 5 10

Figure 6-13 Argon-Hydrogen Manifold

Part
Item Number Description Designator Qty.

073109 Argon-Hydrogen Manifold 1

1 002050 Bracket: Ar/H2 Manifold 1
2 011005 Flowmeter: 0-10 SC/BT-8 w/valve FM1 1
3 024143 Hose Assy, #4 X 9" 1
029831 Manifold SA: 073109 H35 Manifold 1
4 005046 Pressure Switch: 0-200 1/4FPT PS1 1
5 006009 Solenoid Valve:200# 1/4FPT 120V NC SV5 1
023702 Cable: HT2000 H35 Manifold Press. Sw. 1
6 008195 CACLP:CPC Size 11 1
7 008205 Pin: 18-16 AWG Type III + CRP 4
8 008807 Receptacle Shell:CPC 11-4 14X1 1
9 047055 Cable, 18-2 TW PR, Unshielded 6 ft
10 015049 Connector: LH Male Brass 1

HySpeed HT2000LHF Instruction Manual 6-13

6
PARTS LIST

Timer/Counter
1 4 3 8 4 7 5, 6 2

11X1

Figure 6-14 Timer/Counter

Part
Item Number Description Designator Qty.
073194 HT2000 Cntr-Tmr
1 001068 Encl:DCC/PCC/RCC RVR 1
2 001391 Pnl:DCC RCVR Rear 1
3 001392 Pnl:DCC RCVR Front 1
4 005161 PB Sw:Blk SPST NO Sub-Mini 2
5 008176 Pin:24-20 AWG Type III + CRP 4
6 008193 Receptacle Shell:CPC 17-16 Std Sex 11X1 1
7 027274 Counter, Self Powered LCD 2
8 027275 Meter, Elapsed Time LCD 1
003140* Relay:120VAC DP AU Cont 2

* Items are not shown in Figure 6-14.

Remote Current Control Console

1 4 2 3 5, 6

15X1

Figure 6-15 Remote Current Control Console

Part
Item Number Description Designator Qty.
073045 Remote Current Control Console
1 001068 Enclosure:DCC/PCC/MAX200 RCC 1
2 001339 Panel:MAX200 RCC Front 1
3 001340 Panel:MAX200 RCC Rear 1
4 005123 Thumbwheel Switch:MAX200 1
5 008176 Pin:24-20 AWG Type III+CRP 7
6 008193 Receptacle Shell:CPC 17-16 Std Sex 15X1 1

6-14 HySpeed HT2000LHF Instruction Manual

6
 PARTS LIST

HYSpeed HT2000LHF Torches

2 1 5

4
3
Figure 6-16 HT2000LHF Standard Torch Assembly with Valve Cluster

Part
Item Number Description Designator Qty.
128255 HT2000LHF Machine Torch Assy with Valve Cluster
1 120894 Torch Mounting Sleeve:2" 1
2 120584 HT2000 Torch Main Body 1
020963 Water Tube:PAC200T/2000 Electd Cool 1
044027 O-Ring:Buna 70 Duro 1.301X.070 2
3 024550 Hose Assembly:3/16 Blue with Green LH'A' 1' 1
4 123321 Cable:HT2000-LHF Torch Off-Valve 24" 1
5 129840 Off-Valve Subassembly (Valve Cluster):HT2000LHF 1
006100 Solenoid Valve:150# 1/8 FPT DIN 3
120546 Bracket:HT2000LHF Off-Valve 1
220242* Nozzle Retaining Cap with IHS: Hyspeed, 200A 1
220239* Shield: Hyspeed, 200A 1
220237* Nozzle: Hyspeed, 200A 1
220235* Electrode: Hyspeed, 200A 1
220236* Swirl Ring: Hyspeed, 200A 1
* Hyspeed consumables are for cutting mild steel with Oxygen at 200A only.

2 1 5

4
3

Figure 6-16A HT2000LHF Stainless Steel Torch Assembly with Valve Cluster
Part
Item Number Description Designator Qty.
128369 HT2000LHF Stainless Steel Machine Torch Assy with Valve Cluster
1 020041 Torch Mounting Sleeve:2" Generic 1
2 120356 HT2000 S.S. Torch Main Body 1
020963 Water Tube:PAC200T/2000 Electd Cool 1
044027 O-Ring:Buna 70 Duro 1.301X.070 2
3 024550 Hose Assembly:3/16 Blue with Green LH'A' 1' 1
4 123321 Cable:HT2000-LHF Torch Off-Valve 24" 1
5 129840 Off-Valve Subassembly (Valve Cluster):HT2000LHF 1
006100 Solenoid Valve:150# 1/8 FPT DIN 3
120546 Bracket:HT2000LHF Off-Valve 1
120837 Nozzle Retaining Cap, with IHS tab 1
020424 Shield, 200A 1
020605 Nozzle, 200A .082 O2 1
120667 Electrode:HT2000 200A O2, LL 1
120833 Swirl Ring:HT2000 O2 1

020046 Torch Mounting Bracket with Clevis 2" (not part of 128255 or 128369 assembly)

HySpeed HT2000LHF Instruction Manual 6-15

7
PARTS LIST

HySpeed HT2000 Consumable Starter Kit #128824

1 2 3 4 5

Figure 6-17 HySpeed HT2000 Starter Consumable Parts

Part
Item Number Description Qty.
128824 Kit: HySpeed HT2000 ConsumableStarter
001285 Box: Gray Plastic 1
1 220239 Shield, Hyspeed 200A 1
2 220242 Nozzle Retaining Cap with IHS tab, HySpeed 200A 1
3 220237 Nozzle, Hyspeed 200A 3
5 220236 Swirl RIng: Hyspeed 200A 1
7 220235 Electrode: HySpeed 200A 3
027055 Lubricant, Silicon, 1/4 Oz Tube 1
804560 Quick Set-up Card: HT2000 HySpeed 1

6-16 HySpeed HT2000LHF Instruction Manual

7
 PARTS LIST

HySpeed HT2000 Consumable Parts Kit #128825

1 2 3 4 5

Figure 6-18 HySpeed HT2000 Consumable Parts

Part
Item Number Description Qty.
128825 Kit: HySpeed HT2000 Consumable Parts
001067 Box: Gray Plastic 1
1 220239 Shield, Hyspeed 200A 1
1 020424 Shield, 200A 1
1 020448 Shield, 100A 1
2 220242 Nozzle Retaining Cap with IHS tab, HySpeed 200A 1
2 120837 Nozzle Retaining Cap, with IHS tab 1
3 220237 Nozzle, Hyspeed 200A 3
3 020690 Nozzle, 100A .055 O2 2
4 020608 Nozzle, 200A .086 Air/N2/H35 3
4 020611 Nozzle, 100A .059 Air 3
5 220236 Swirl RIng: Hyspeed 200A 1
6 020607 Swirl Ring, Air/N2/H35 1
6 020613 Swirl Ring, Air 1
6 020679 Swirl Ring, Air/N2 1
7 220235 Electrode: HySpeed 200A 3
7 120667 Electrode: HT2000 200A Oxy LL 2
7 020415 Electrode, N2/H35 2
7 120547 Electrode: HT2000 100A LL 2
8 020963 Water Tube:PAC200T/2000 Electd Cool 1
027055 Lubricant, Silicon, 1/4 Oz Tube 1
027194 Wrench, Nozzle, 3/4" 1
027524 Wrench, Nozzle, 1" 1
044027 O-Ring, Buna-N 2
027347 Tool: Water Tube Removal 1
004147 Electrode Gauge Assy 1

HySpeed HT2000LHF Instruction Manual 6-17

7
PARTS LIST

HT2000 Consumable Parts Kit

3 5

1 2 7

4 6

Figure 6-19 HT2000 Consumable Parts

Part
Item Number Description Qty.
028602 Kit: HT2000 Consumable Parts
001067 Box: Gray Plastic 1
1 020424 Shield, 200A 1
1 020448 Shield, 100A 1
2 120837 Nozzle Retaining Cap, with IHS tab 1
3 020605 Nozzle, 200A .082 O2 5
3 020690 Nozzle, 100A .055 O2 3
4 020608 Nozzle, 200A .086 Air/N2/H35 5
4 020611 Nozzle, 100A .059 Air 3
5 120833 Swirl Ring: HT2000 O2 1
6 020607 Swirl Ring, Air/N2/H35 1
6 020613 Swirl Ring, Air 1
6 020679 Swirl Ring, Air/N2 1
7 120667 Electrode:HT2000 200A O2 LL 5
7 020415 Electrode, N2/H35 5
7 120547 Electrode, HT2000 100A LL 3
8 020963 Water Tube:PAC200T/2000 Electd Cool 1
027055 Lubricant, Silicon, 1/4 Oz Tube 1
027194 Wrench, Nozzle, 3/4" 1
027524 Wrench, Nozzle, 1" 1
044027 O-Ring, Buna-N 2
027347 Tool: Water Tube Removal 1
004147 Electrode Gauge Assy 1

6-18 HySpeed HT2000LHF Instruction Manual

7
 PARTS LIST

HT2000 Beveling Consumable Parts Kit

1 2 3 4 5

Figure 6-20 HT2000 Beveling Consumable Parts

Part
Item Number Description Qty.
128406 Kit: HT2000 Beveling Consumable Parts
001067 Box: Gray Plastic 1
1 120260 Shield: HT2000 Extended 2
2 120837 Nozzle Retaining Cap, with IHS tab 1
3 120259 Nozzle, HT2000 200A Oxygen Extended 5
4 120833 Swirl Ring: HT2000 O2 2
5 120258 Electrode:HT2000 Extended 5
6 120257 Water Tube:Electd Cool Extended 1
027055 Lubricant, Silicon, 1/4 Oz Tube 1
027194 Wrench, Nozzle, 3/4" 1
044027 O-Ring, Buna-N 2
027347 Tool: Water Tube Removal 1

HySpeed HT2000LHF Instruction Manual 6-19

7
PARTS LIST

Recommended Spare Parts

Power Supply

Part Number Description Designation Qty. Pg. Ref.

027080 Fan: 225CFM 120VAC 50/60 Hz M2,M3 1 6-2
027079 Fan: 450-550 CFM 120VAC 50/60 Hz M4 1 6-2
041764 PCB Assy: HT2000LHF Control PCB2 1 6-2
041246 PCB Assy: Relay, HD1070/HT2000 PCB4 1 6-2
005121 Pushbutton: 2 NO Green Illumin PB1/LT1 1 6-3
005122 Pushbutton: 2 NC Red Extended PB2 1 6-3
005149 Bulb: 120VAC LT2 2 6-3
041294 PCB Assy: HT2000 THC Mother PCB9 1 6-3
041186 PCB Assy: HT2000 THC PCB10 1 6-3
003138 Circuit Breaker, 2 Pole, 600V 100A CB1 1 6-4
003139 Contactor: 90A 3 Pole, 120VAC CON1 2 6-4
041534 PCB Assy: Power Distribution PCB1 1 6-4
005102 Thermostat: 160°C, 6 Amp TS1 1 6-5
008317 Fuse: Semiconductor 125A, 250V F1,F2 5 6-5
005227 Switch, Pressure 12 psi PS3 1 6-5
006032 Solenoid Valve:150# 1/4 FPT 120V NC SV6 1 6-5
006106 Solenoid Valve: 3-way 120VAC 1/8FPT SV7 1 6-5
129118 CH130 Chopper SA CH1,CH2 1 6-6
009684 Res: 4 Ohm 420W R6A, R6B 1 6-7
003021 Relay, 120VAC NO SPST CR1 1 6-7
009349 Coil Assembly: 200A HF T4 1 6-7
009975 Cap: .1400pF 20kV C4, C5, C6 3 6-7
004061 Electrode:Sprk Gap 1/8 x 1.6 3 6-7
129150 HV Transformer SA, 6kV T3 1 6-7
029202 Current Sensor Assembly CS1 1 6-7
129618 Switch, Level SA, 1/2 NPT LS1 1 6-8
029323 Switch, Temp SA, 162 Deg. F TS2 1 6-8
006046 Valve, Sol 240V 3/8 NPT NC V1 1 6-8
128384 Kit: Pump, 70 GPH Positive Displace 1 6-8
029361 Flowswitch, 0.5 gpm FS1 1 6-8

Gas Console

Part Number Description Designation Qty. Pg. Ref.

005243 Pressure Switch:80psi PS1,PS2 1 6-9
005149 Bulb, 120VAC LT1 1 6-9
006109 Solenoid Valve: 150# 1/8FPT 120V 2-Way SV1-3 1 6-9
006064 Needle Valve: 1/8 FPT .125 Orifice MV1-MV4 1 6-9
011053 Flowmeter: 7.8 GPM/44CFH FM1,FM2 1 6-9
011058 Flowtube with Float /BP-8 Flt:0-10 SC Cal 2% 2 6-9
011008 Shield: Plastic, for 011053 or 011056 2 6-9
011081 Flowmeter Float Stop 2 6-9
022020 Gauge: Pressure, 160 psi/bar, Panel Mnt PG1-PG2 1 6-9
022008 Gauge, Press 100#/Bar 2.5" Dia. PG3 1 6-9

6-20 HySpeed HT2000LHF Instruction Manual

9
 Section 7

WIRING DIAGRAMS

Introduction
This section contains the wiring diagrams for the HT2000LHF system. When tracing a signal path or referencing
with the Parts List or Troubleshooting sections, please be aware of the following format to assist you in under-
standing the wiring diagrams' organization:

• Sheet numbers are located in the lower right-hand corner.

• Page-to-page referencing is done in the following manner:

SHEET
C 4-D3

Source Connection Source Reference Block Destination Sheet # Destination

Coordinates

SHEET
4-D3 C

Source Sheet # Source Coordinates Source Reference Block Destination

Coordinates

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 road
map).

• When referencing components to the wiring diagrams, designations may appear to be repeated. Eg. C1
appears on sheet 2 in the wiring diagrams in 2 locations. Sections of the power supply on that page are
outlined with a dotted box and a label. Within different sections, the same designation may appear. Be
certain to check the dotted box label when looking for or cross-referencing HT2000LHF parts.

Wiring Diagram Symbols

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

HySpeed HT2000LHF Instruction Manual 7-1

6
6
7-2

WIRING DIAGRAMS
Battery Fuse Push Button,
Normally Open

Cap, polarized Ground Clamp Receptacle

Cap, non-polarized Ground, Chassis Relay, Coil

Cap, feed-thru Ground, Earth Relay, Normally Closed

Circuit breaker IGBT Relay, Normally Open

Coax shield Inductor Relay, Solid State, AC

Current Sensor LED Relay, Solid State, DC

Current sensor Light Relay, Solid State, Dry

DC supply MOV Resistor

HySpeed HT2000LHF Instruction Manual

Pin SCR
Diode

Door interlock Plug Shield

Fan PNP Transistor Shunt

Feedthru LC Potentiometer Spark Gap

Filter, AC Push Button, Switch, Flow

Normally Closed
 HySpeed HT2000LHF Instruction Manual

Switch, Level, Time Delay Closed,

Normally Closed NO/Off Torch Symbols

Switch, Pressure,
Normally Closed Transformer
Electrode

Switch, Pressure,
Normally Open Transformer, Air Core

Switch, 1 Pole, 1 Throw Nozzle

Transformer Coil

Switch, 1 Pole, 2 Throw

Triac
Switch, 1 Pole, 1 Throw, Shield
Center Off

VAC Source
Switch, Temperature,
Normally Closed

Valve, Solenoid
Torch
Switch, Temperature,
Normally Open

Voltage Source
Terminal Block

Torch, HyDefinition™
Time Delay Closed, Zener Diode
NC/Off

WIRING DIAGRAMS
Time Delay Open,
NO/Off

Time Delay Open,

NC/On
7-3
6
Figure 7-1 HT2000LHF Coolant Flow Diagram
7-5
7
7-7
7
7-9
7
7-11
7
7-13
7
7-15
7
7-17
7
7-19
7
7-21
7
7-23
7
7-25
7
Solenoid valve status for N2 timing chart
N2 or Air Cutting Mode
Component Idle Cutflow Preflow
SV1A OFF OFF OFF
SV1B ON ON ON
SV2 OFF OFF ON
SV3 OFF OFF OFF
SV4A OFF ON OFF
SV4B OFF OFF ON
SV5 OFF ON ON
SV6 OFF ON ON
SV7 ON ON ON

7-27
7
Solenoid valve status for O2 timing chart

O2 or Air Cutting Mode

Component Idle Cutflow Preflow
SV1A ON ON ON
SV1B OFF OFF OFF
SV2 OFF OFF ON
SV3 OFF OFF ON
SV4B OFF OFF ON
SV4B OFF OFF ON
SV5 OFF ON ON
SV6 OFF ON ON
SV7 ON ON ON

7-29
7
Solenoid valve status for O2 timing chart

O2 or Air Cutting Mode

Component Idle Cutflow Preflow
SV1A ON ON ON
SV1B OFF OFF OFF
SV2 OFF OFF ON
SV3 OFF OFF ON
SV4B OFF OFF ON
SV4B OFF OFF ON
SV5 OFF ON ON
SV6 OFF ON ON
SV7 ON ON ON

7-31
7
 Appendix A

ARGON-HYDROGEN CUTTING AND GOUGING

Introduction
This section contains installation and operation information for cutting and gouging using argon-hydrogen as the
plasma gas.

• See Installation to make the remaining power supply and gas console connections.
• Do not use the water muffler when cutting with argon-hydrogen!

Argon-Hydrogen Manifold FRONT PANEL CONTROLS and INDICATORS

(Fig. a-1)

MV1
Adjusts argon-hydrogen plasma gas flow rate
% in Test/Preflow mode. Preflow plasma gas
flow rate percentages are specified in the
Argon-Hydrogen Cut Charts.
FM1
Indicates the argon-hydrogen plasma
gas flow rate %. Flow rates for
argon-hydrogen are specified in the
Argon-Hydrogen Cut Charts.

Figure a-1 Argon-Hydrogen Manifold Front Panel Controls and Indicators

Installation

WARNING

Before operating the argon-hydrogen manifold, turn all power and gases connected to the system OFF.
Follow the installation and operation procedures before turning power and gases ON.

HySpeed HT2000LHF Instruction Manual a-1

6
APPENDIX A: ARGON-HYDROGEN CUTTING AND GOUGING

13 Argon-Hydrogen Cable – Argon-Hydrogen Manifold to Power Supply

1. Connect the receptacle end of the argon-hydrogen cable to the cable connection point on the argon-
hydrogen manifold. (Figure a-2)

2. Connect the other end of the cable to TB4 (smaller terminal strip on the inside rear panel of the power
supply). Match up wires 102, 103, 13 and 14 to wires already connected to the strip. Connect the two
shield wires to points labeled as PE (protective earth).
13 Part No. Length
13
14
023660 15 ft (4.6 m)
etc. 023661 25 ft (7.6 m)
14X1 023662 50 ft (15 m)
023663 75 ft (23 m)
023664 100 ft (30 m)
023665 150 ft (46 m)

14x1 TB4 Color Signal

1 13 Red PS1 / Plasma
2 14 Black PS1 / Plasma
12 Shield Shield
3 102 Green SV5 / Plasma Off
4 103 Black SV5 / Plasma Off
9 Shield Shield

Argon-Hydrogen supply to Argon-Hydrogen Manifold

• Attach one end of the supply hose to the argon-hydrogen supply tank regulator, and attach the other end to
the argon-hydrogen supply hose connection on the manifold. (Figure a-2)

Cable Connection Point Plasma Gas

Torch Lead
Connection

Argon-Hydrogen
Supply Hose
Connection

Figure a-2 Argon-Hydrogen Manifold Connection Points

a-2 HySpeed HT2000LHF Instruction Manual

6
 APPENDIX A: ARGON-HYDROGEN CUTTING AND GOUGING

Argon-Hydrogen plasma gas torch lead – Argon-Hydrogen Manifold to Torch

Part No. Length
024355 12 in (305 mm)
024354 10 ft (3 m)
024368 20 ft (6.2 m)
024369 30 ft (9.1 m)
024370 40 ft (12.4 m)
024443 50 ft (15 m)
024467 75 ft (23 m)

4X1 end of the

valve cluster cable
(disconnect from the
power supply off-valve
cable)

1. Turn all plasma and shield gas supply

tanks OFF.

2. Disconnect the 4X1 end of the valve cluster

cable from the power supply off-valve
cable.
Plasma gas hose
3. Disconnect the plasma gas hose that (disconnect at this
comes from the torch and goes to SV5. point)

Figure a-4 Converting the HT2000LHF Torch for Argon-Hydrogen Cutting – 1 of 2

HySpeed HT2000LHF Instruction Manual a-3

6
APPENDIX A: ARGON-HYDROGEN CUTTING AND GOUGING

4. Connect the left-hand threaded connector

015049 to the torch plasma gas hose.
Argon-hydrogen plasma gas
torch lead
5. Attach one end of the argon-hydrogen
plasma gas torch lead to the plasma gas
torch lead connection located on the front
of the argon-hydrogen manifold.
(Figure a-4)

6. Attach the other end of the argon-

hydrogen plasma gas torch lead to the
015049 015049 connector.
connector

Torch
plasma gas
hose

Plasma gas torch lead

connection

Figure a-4 Converting the HT2000LHF Torch for Argon-Hydrogen Cutting – 2 of 2

Nitrogen supply to Gas Console

• Connect the nitrogen supply to the shield connection at the rear of the gas console. (Figure a-5)

2WRENCHES

trogen
Ni

Figure a-5 Nitrogen Supply to Gas Console

a-4 HySpeed HT2000LHF Instruction Manual

6
 APPENDIX A: ARGON-HYDROGEN CUTTING AND GOUGING

Operation
Prior to operation, ensure that your cutting environment and that your clothing meet the safety requirements
outlined in the Safety section of this manual. If problems occur during operation, refer to the Installation portion of
this section as well as Section 3.

WARNING

Before operating this system, you must read the Safety section thoroughly! Verify main disconnect
switch to the power supply is OFF before proceeding with the following steps

Note: For operation without argon-hydrogen manifold, see Section 4: Operation.

Check Torch

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

• Check the pit depth of the electrode. The electrode should be replaced when the depth exceeds
.044 inch (1.1 mm).

• Wipe the current ring in the torch with a clean paper towel or Q-tip (see Figure 4-7).

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

2. Replace the consumable parts. Refer to Changing Consumable Parts in Section 4 for detailed information
on replacing consumables.

3. Ensure that the torch is squared to the material. Refer to Section 3 for the torch alignment procedure.

4. Verify that argon-hydrogen cable 14X1 is connected to the argon-hydrogen manifold.

S1
Turn Gases On
PLASMA DC

N2/Air O2 1. Set S2 toggle switch on the gas console to Run.

2. Set S1 switch to the N2/Air position.

SHIELD
10 10

9 9
psi
8 8
psi
7 7

5
N2/Air
6

5
3. Turn the argon-hydrogen gas supply and the nitrogen gas supply ON.
4

3
4

3
Verify that the oxygen and air gas supplies remain OFF.
2 2
psi
1 1

• Adjust the argon-hydrogen plasma gas supply regulator to read

0 0

O2
120 psi +/- 10 psi (8.2 bar +/- 0.7 bar).
N2/Air PLASMA O2

• Adjust supply regulator for shield gas to read 90 psi +/- 10 psi
PreFlow Cut Flow PreFlow
Run

Test
Preflow
Test
Cutflow (6.2 bar +/- 0.7 bar).
® ®
HySpeed HT2000LHF
S2

HySpeed HT2000LHF Instruction Manual a-5

6
APPENDIX A: ARGON-HYDROGEN CUTTING AND GOUGING

Turn Power Supply On and Adjust Voltage/Current

1. Turn the main disconnect switch ON. See Status Indicators Before Startup in Section 4.

2. Turn on the power supply by depressing the POWER ON (I) button (PB1) on the power supply. Ensure
that the green POWER ON indicator illuminates. Hold PB1 down until all of the status indicators
extinguish.

3. Set the voltage and current. Select the arc current and arc voltage settings from the Argon-Hydrogen Cut
Charts later in this section for the type and thickness of metal to cut.

Adjust Preflow Gases

MV1
1. Set S2 on the gas console to Test Preflow. Verify that the
argon-hydrogen supply regulator reads 120 psi (8.2 bar).

2. Look at the flowmeter (FM1) on the argon-hydrogen

FM1 manifold and set the Preflow plasma gas flow rate % by
referring to the Argon-Hydrogen Cut Charts and turning the
argon-hydrogen flowmeter adjust knob (MV1).

3. Look at the shield gas pressure gauge (PG3) on the gas

console, and set to the Argon-Hydrogen Cut Chart
specifications by turning the shield gas adjust knob (MV4).

Note: If you have changed consumable parts or if the power

supply has been off for more than 1 hour, purge gas
lines by leaving the system in Test Preflow for 1
minute.
PLASMA DC

N2/Air O2

Adjust Cut Flow Gases and Prepare for Cutting

SHIELD

1. Set S2 on the gas console to Test Cut Flow.

10 10

9 9
psi
8 8
psi
7 7

6 6
PG3 2. Look at the flowmeter (FM1) on the argon-hydrogen
manifold and set the Cut Flow plasma gas flow rate % by
5 5
N2/Air
4 4

2
3

2
referring to the Argon-Hydrogen Cut Charts and turning the
argon-hydrogen flowmeter adjust knob (MV1).
psi
1 1

0 0

O2 3. Set S2 to Run after the test preflow and test operate flow
S2 rates have been set.
N2/Air PLASMA O2
PreFlow Cut Flow PreFlow

The system is now ready for operation.

Run

Test Test
Preflow Cutflow

® ®
HySpeed HT2000LHF

a-6 HySpeed HT2000LHF Instruction Manual

6
 APPENDIX A: ARGON-HYDROGEN CUTTING AND GOUGING

After Cutting with Argon-Hydrogen

MV1
1. Turn off the power supply, and disconnect the power.

2. Turn MV1 to the closed position.

3. Disconnect the 14X1 argon-hydrogen cable from the

plasma system. See page a-2.

4. Remove the argon-hydrogen plasma gas torch lead from

the torch. See Figure a-4.

5. Remove the 015049 connector and connect the plasma

hose from the torch to SV5. See Figures a-3 and a-4.

6. Remove the nitrogen supply hose from the shield supply

connection of the gas console.

7. Connect the nitrogen supply hose to the N2 connection of

the gas console. See Figure a-6.

8. Connect the shield gas supply hose to the shield supply

connection of the gas console. See Gas Console
Connections in Section 3.

9. Reconnect the 4X1 end of the valve cluster cable to the

power supply off valve cable. See Figures a-4, 3-5 and
page 3-10.

2WRENCHES

trogen
Ni

Figure a-6 Nitrogen Supply to N2 Input of Gas Console

HySpeed HT2000LHF Instruction Manual a-7

6
APPENDIX A: ARGON-HYDROGEN CUTTING AND GOUGING

Argon-Hydrogen Cut Charts

The Argon-Hydrogen Cut Charts on the following pages provide the necessary information for the operator using
the HT2000LHF system to be successful in plasma arc cutting and gouging using argon-hydrogen as the plasma
gas. The HT2000LHF 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 minimal dross.

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

Argon-Hydrogen Cut Chart and Consumable Parts Index

Plasma Gas/ Retaining Swirl

Metal Amps Shield Gas Shield Cap Nozzle Ring Electrode Page

Stainless 200 H35 / N2 020602 120837 020608 020607 020415 a-9

Steel 100 H35 / N2 020448 120837 020611 020607 020415 a-10

Aluminum 200 H35 / N2 020602 120837 020608 020607 020415 a-11

100 H35 / N2 020448 120837 020611 020607 020415 a-12

Stainless
200 H35 / N2 020485 120837 020615 020607 020415 a-13
Steel
&
Aluminum

a-8 HySpeed HT2000LHF Instruction Manual

6
 APPENDIX A: ARGON-HYDROGEN CUTTING AND GOUGING

Stainless Steel
200 amps • H35 Plasma / N2 Shield
Argon-Hydrogen Manifold (073109) Required*
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.

WARNING

Do not use water muffler

when cutting with argon-hydrogen

020602 120837 020608 020607 020415

Shield Retaining cap Nozzle Swirl ring Electrode

Above Water Only

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 1.0

3/8 10 (89.9 (89.9 (275 3/16 5 3/8 10 140 52 1300 1.0
1/2 12 SCFH) SCFH) SCFH) 3/16 5 3/8 10 140 42 1100 2.0
5/8 15 S 1/4 6 1/2 12 145 37 940 2.0
3/4 20 1/4 6 1/2 12 150 32 810 2.5
7/8 22 5/16 8 5/8 16 155 27 690 2.5
1 25 5/16 8 155 22 560
1-1/4 32 ` 5/16 8 165 16 400
1-1/2 38 5/16 8 170 11 280
1-3/4 44 5/16 8 180 8 200
2 50 5/16 8 185 6 150

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

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

HySpeed HT2000LHF Instruction Manual a-9

6
APPENDIX A: ARGON-HYDROGEN CUTTING AND GOUGING

Stainless Steel
100 amps • H35 Plasma / N2 Shield
Argon-Hydrogen Manifold (073109) Required*
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 alloying
elements can occur.

WARNING

Do not use water muffler

when cutting with argon-hydrogen

020448 120837 020611 020607 020415

Shield Retaining cap Nozzle Swirl ring Electrode

Above Water Only

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)

1/8 3 13 13 60 3/32 2.5 3/16 5 130 50 1260

3/16 5 (46.7 (46.7 (270 1/8 3 1/4 6 135 40 1060 0.5
1/4 6 SCFH) SCFH) SCFH) 3/16 5 3/8 10 140 35 890 0.5
3/8 10 3/16 5 3/8 10 140 30 750 0.5
1/2 12 3/16 5 3/8 10 145 25 630 1.0

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

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

a-10 HySpeed HT2000LHF Instruction Manual

6
 APPENDIX A: ARGON-HYDROGEN CUTTING AND GOUGING

Aluminum
200 amps • H35 Plasma / N2 Shield
Argon-Hydrogen Manifold (073109) Required*
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 is
extended when this combination is used.

WARNING

Do not use water muffler

when cutting with argon-hydrogen

020602 120837 020608 020607 020415

Shield Retaining cap Nozzle Swirl ring Electrode

Above Water Only

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)

3/16 5 25 25 60 3/16 5 3/8 10 130 170 4300 0.5

1/4 6 (89.9 (89.9 (275 3/16 5 3/8 10 130 155 4000 1.0
3/8 10 SCFH) SCFH) SCFH) 1/4 6 1/2 12 135 120 3000 2.0
1/2 12 1/4 6 1/2 12 140 100 2550 2.0
5/8 15 1/4 6 1/2 12 145 80 2000 2.5
3/4 20 5/16 8 5/8 16 150 60 1500 2.5
7/8 22 5/16 8 5/8 16 155 50 1250 2.5
1 25 5/16 8 155 40 1000
1-1/4 32 ` 5/16 8 165 26 660
1-1/2 38 5/16 8 170 18 460
1-3/4 44 5/16 8 180 12 300
2 50 5/16 8 185 7 180

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 7/8" (22 mm) not recommended

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

HySpeed HT2000LHF Instruction Manual a-11

6
APPENDIX A: ARGON-HYDROGEN CUTTING AND GOUGING

Aluminum
100 amps • H35 Plasma / N2 Shield
Argon-Hydrogen Manifold (073109) Required*
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.

WARNING

Do not use water muffler

when cutting with argon-hydrogen

020448 120837 020611 020607 020415

Shield Retaining cap Nozzle Swirl ring Electrode

Above Water Only

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)

1/8 3 13 13 60 3/32 2.5 3/16 5 135 95 2440

3/16 5 (46.7 (46.7 (270 1/8 3 1/4 6 140 85 2200 0.5
1/4 6 SCFH) SCFH) SCFH) 1/8 3 1/4 6 145 80 1980 0.5
3/8 10 1/8 3 1/4 6 145 60 1530 0.5
1/2 12 1/8 3 150 50 1280

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 3/8" (10 mm) not recommended

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

a-12 HySpeed HT2000LHF Instruction Manual

6
 APPENDIX A: ARGON-HYDROGEN CUTTING AND GOUGING

Stainless Steel or Aluminum Gouging

200 amps • H35 Plasma / N2 Shield
Argon-Hydrogen Manifold (073109) Required*
Hypertherm recommends a mixture of 35% hydrogen and 65% argon for the plasma gas.

020485 120837 020615 020607 020415

Shield Retaining cap Nozzle Swirl ring Electrode

Shield Arc Plasma Gas Shield Gas

Plasma Gas Flow Rate %
Gas (N2) Current (H35) Inlet (N2) Inlet
Preflow Cut Flow Pressure Setting Pressure Pressure
(H35 %) (H35 %) (psi) (amps) (psi) (psi)

29 29 50 200 120 90
(81.8 SCFH)

1 psi = .0689 bar = 6.895 KPa

HySpeed HT2000LHF Instruction Manual a-13

6
APPENDIX A: ARGON-HYDROGEN CUTTING AND GOUGING

a-14 HySpeed HT2000LHF Instruction Manual

6
 Appendix B

PROPYLENE GLYCOL SAFETY DATA

BENZOTRIAZOLE SAFETY DATA

In this appendix:

Propylene Glycol Safety Data

Section 1 Chemical Product and Company Identification ............................................... b-2
Section 2 Information on Ingredients .............................................................................. b-2
Section 3 Hazards Identification...................................................................................... b-2
Section 4 First Aid Measures .......................................................................................... b-3
Section 5 Fire Fighting Measures ................................................................................... b-3
Section 6 Accidental Release Measures ......................................................................... b-3
Section 7 Handling and Storage ..................................................................................... b-3
Section 8 Exposure Controls / Personal Protection ........................................................ b-4
Section 9 Physical and Chemical Properties .................................................................. b-4
Section 10 Stability and Reactivity .................................................................................... b-4
Section 11 Toxicological Information ................................................................................ b-4
Section 12 Ecological Information ..................................................................................... b-5
Section 13 Disposal Considerations ................................................................................. b-5
Section 14 Transport Information ...................................................................................... b-5
Section 15 Regulatory Information .................................................................................... b-5
Section 16 Other Information ............................................................................................ b-5

Benzotriazole (COBRATEC) Safety Data

Section I ............................................................................................................................ b-7

Section II Ingredients ........................................................................................................ b-7
Section III Physical Data ................................................................................................... b-7
Section IV Fire and Explosion Hazard Data ...................................................................... b-8
Section V Health Hazard Data .......................................................................................... b-8
Section VI Reactivity Data ................................................................................................. b-9
Section VII Spill or Leak Procedures ................................................................................. b-9
Section VIII Special Protective Information ....................................................................... b-9
Section IX Special Precautions ....................................................................................... b-10
Section X Regulatory Status ........................................................................................... b-10

Instruction Manual b-1

b-2
b-3
b-4
b-5
 40

30

20

10
Temperature, °F

-10

-20

-30

-40

-50

-60

-70
0 10 20 30 40 50 60
% of Propylene Glycol

Figure b-1 Freezing Point of Propylene Glycol Solution

b-6
b-7
b-8
b-9
b-10
 Appendix C

INITIAL HEIGHT SENSING CONNECTIONS

NOTE: If using Command THC refer to Instruction manual # 802780

See page 3-8 for connections to power supply and IHS console. See Fig. c-1 for typical IHS connections.

14 IHS Interface Cable – Power Supply to IHS Part No. Length

14
Power Supply End IHS End 023859 25 ft (7.6m)
023860 50 ft (15m)
023861 75 ft (23m)
1X9 8X1 023862 100 ft (30.5m)
023863 150 ft (46m)
023864 200 ft (61m)

1X9 8X1 Color Signal

1 1 Red IHS Complete Sig
4 4 Black IHS Complete Com
8 Shield Drain
2 2 Green Upper Limit Sw Sig
5 3 Black Upper Limit Sw Com
9 5 Shield Drain
11 9 Black AC Power
14 8 White AC Power
7 Shield Drain
7 Key

14A IHS Sensor cables – IHS to Inductor Probes

The two sensor cables are components of the interconnecting leads for the inductive IHS system – see page c-4.
Part No. Length
14A
8X2 8X4 023888 2 ft (.6 m)
023869 40 ft (12 m)

Part No. Length

8X3 8X5
023889 2 ft (.6 m)
023870 40 ft (12 m)

8X2/8X3 8X4/8X5 Color Signal

4 A Red Power (+15 VDC)
2 B Black Common
1 C Clear Signal
3 Braid Shield

HySpeed HT2000LHF Instruction Manual c-1

6
APPENDIX C: INITIAL HEIGHT SENSING CONNECTIONS

14D
UPPER LIMIT SWITCH
AND CABLE

AIR CYLINDER

14A
14

IHS CONTROL
14B
MODULE
67
4
S

1 TB
TORCH
MOUNTING
SUBASSEMBLY

TORCH LIFTER
(TYPICAL)

SWIVEL FITTING

TORCH
(TYPICAL)
14C

20 PSI REGULATED
SHOP AIR

Figure c-1 Initial Height Sensing Connections

c-2 HySpeed HT2000LHF Instruction Manual

6
 APPENDIX C: INITIAL HEIGHT SENSING CONNECTIONS

14B IHS Inductor Probes

The 2 inductive probes come with the torch mounting subassembly for the inductive IHS system – see page c-4.

Rear View Part No.

14B
005074

Pin Color Signal A C

B
A Brown Power (+15 VDC)
B Blue Common
C Black Signal

14C IHS Air Supply – Air Supply to IHS Console

The customer must supply the 20 psig (1.4 bar) regulated shop air and a 1/4" (6 mm) I.D. air hose between
the regulator and the inductive height control console.

14D Air Hose Assembly – IHS Console to Inductive Sensor Air Cylinder
The 40-foot air hose is a component of the interconnecting leads for the inductive IHS system – see page c-4.
Part No. Length
14D
024144 40 ft (12 m)

Upper Limit Switch and Cable - Upper Limit Switch to IHS Console

Note: The customer must supply the upper limit switch option. Switch specifications: +12 VDC @ 1.2 ma.
Gold-type contacts preferred. Select a normally closed switch that opens when the lever is up (when the
torch fully retracts). Install the upper limit switch behind the torch lifter as in Figure c-1.

Caution: Follow the cable installation procedure below to avoid electromagnetic

interference problems with the torch lead set.

1. Use a shielded, twisted pair of 22-24 gauge wire (stranded). Use Belden #8761.

2. At the upper limit switch, connect the common wire (black) and signal wire (clear) to the upper limit switch. Cut
the shield drain wire (uninsulated). Wrap the cut end with electrician's tape.

3. At the IHS control console, loosen the 2 latches and open the front cover.

4. Route the cable through the strain relief to connect the cable wires to 1TB.

5. Connect the shield drain wire (uninsulated) to 1TB-10 (#S). This connects the cable shield to the power supply
frame. The shield drain must not touch the IHS console case.

6. Connect the common wire (black) to 1TB-11 (#4).

7. Connect the signal wire (clear) to 1TB-12 (#67).

Note: If the upper limit switch signal comes from an interface on the cutting machine, the shield must be
electrically isolated from other shields in other cables. Use a separate cable to avoid ground-loop
problems.

HySpeed HT2000LHF Instruction Manual c-3

6
APPENDIX C: INITIAL HEIGHT SENSING CONNECTIONS

4 6 7 See page c-1 for detail

8 See page c-1 for detail

Figure c-2 Inductive IHS Torch Mounting Assembly with Interconnecting Leads for IHS Assembly

Parent Item No. 028720 Inductive IHS, includes the items listed below, as well as the Initial Height Sensing
Control Console which appears on page 6-11.

Torch Mounting Assembly for the Inductive IHS System

Part
Item Number Description Qty.

029044 Torch MTG SA, Induct IHS

1 004082 Bracket, IND Sensor, UW-IHS 1
2 004083 Bracket, IND IHS Torch Mounting 1
3 015005 Adapter, 1/4 NPT x #4 1
4 027024 Cylinder, IND Sensor, UW-IHS 1
5 005074 Inductive Sensor Assembly 2
020044* Clevis:Torch Mounting Bracket 1

* Item is not shown in Figure c-2.

Interconnecting Leads for the Inductive IHS System

028811 028812 028813 028814 028815 028816
Item 25 ft (7.6 m) 50 ft (15.3 m) 75 ft (22.9 m) 100 ft (30.5 m) 150 ft (45.8 m) 200 ft (61 m)

6 024144 024144 024144 024144 024144 024144

7 023869/023870 023869/023870 023869/023870 023869/023870 023869/023870 023869/023870
8 023859 023860 023861 023862 023863 023864

c-4 HySpeed HT2000LHF Instruction Manual

6
 Appendix D

ELECTROMAGNETIC COMPATIBILITY

General
This appendix will enable a qualified electrician to install the power cable to the EMI filter on the 400V CE power
supplies (073235, 073236).

HySpeed HT2000LHF Instruction Manual d-1

6
APPENDIX D: ELECTROMAGNETIC COMPATIBILITY

Power Cable
The power cable is customer supplied. See Power Requirements on page 3-4 for recommended cable sizes.
Final specification and installation of the power cord should be made by a licensed electrician and according to
applicable national or local codes. See also Mains Supply on page i for further power (supply) cable shielding
recommendations.

Connect Power Cable

Connect one end of the power cable to the EMI filter first and then connect the other end to the line disconnect
switch.

Power Supply

1. Locate the EMI filter on the top rear of the power supply (see Figure d-1).

2. Unscrew the 4 filter cover screws and remove the cover to access the input voltage connections at TB1 (see
Figure d-2).

3. Insert the power cable through the strain relief (see Figure d-1).

4. Connect leads L1 to U, L2 to V, and L3 to W terminals of TB1 (see Figure d-3). Ensure that all connections are
tight to avoid excessive heating.

5. Connect the ground lead to the terminal marked PE at TB1 (see Figure d-3).

EMI Filter Strain Relief

HySpeed HT2000LHF

Figure d-1 Hyspeed HT2000LHF Power Supply with EMI Filter – Side View

d-2 HySpeed HT2000LHF Instruction Manual

6
 APPENDIX D: ELECTROMAGNETIC COMPATIBILITY

Filter

TB1

Figure d-2 Hyspeed HT2000LHF Power Supply with EMI Filter Cover Off – Top View

Figure d-3 Power Cable Connections to TB1

WARNING

There is line voltage at the filter even if the ON (1) pushbutton on the HT2000 power supply has not
been pressed. As a common safety practice, ALWAYS verify that the line disconnect switch is in the
OFF position before installing, disconnecting or servicing in this area.

Line Disconnect Switch

Connecting the power cable to the line disconnect switch must conform to national or local electrical codes.
This work should be performed only by qualified, licensed personnel. See Power Requirements and Line
Disconnect Switch on page 3-4.

HySpeed HT2000LHF Instruction Manual d-3

7
APPENDIX D: ELECTROMAGNETIC COMPATIBILITY

EMI Filter Parts List

Item Number Description Qty.

001557 Cover:Hyspeed HT2000-CE Electronic Filter Enclosure 1

1 001558 Enclosure:Hyspeed HT2000-CE Electronic Filter 1
2 001559 Cover:Hyspeed HT2000-CE Top
3 008489 Bushing:1.97 ID X 2.5 Hole Black-Snap 1
4 008610 Strain Relief:1-1/2NPT 1.5ID 2-Screw 1
5 029316 TB1 Input-Power SA:200/2000/4X00/HD 1
6 109036 Filter:60A 440VAC 3PH 2-Stage Electronic 1
7 109040 Filter Mounting Bracket for 109036 1

3 2

6 7
1

Figure d-4 Hyspeed HT2000LHF EMI Filter Parts

d-4 HySpeed HT2000LHF Instruction Manual

7
 Appendix E

AIR FILTERS

Air Filters
Gas purity is critical for maximizing consumable parts life, as well as for producing the highest quality cutting which
Hypertherm plasma equipment can achieve. Plasma air must be clean, dry and oil-free, and air must be delivered
at the pressure and flow rate specified for each plasma system. If the air supply contains moisture, oil or dirt
particles, cut quality will be lowered and consumable parts life will be shortened, which increase production costs.

To optimize both consumables life and cut quality, Hypertherm recommends a three-stage filtering process for
compressor air for removing contaminants from the air supply.

1. The first stage of filtering should remove at least 99% of all particles and liquids 5 microns and larger in size.

2. The second stage should be a coalescing-type filter to remove oil. This filter should remove 99.99% of particles
0.025 micron and larger in size.

3. The third and final stage of filtration should be an activated carbon adsorbent filter that removes 99.999% of oil
or hydrocarbons that have not been trapped by the previous stages.

Hyspeed HT2000LHF Instruction Manual e-1

6
APPENDIX E: AIR FILTERS

e-2 Hyspeed HT2000LHF Instruction Manual

6
 Appendix F

AERATION MANIFOLD FOR PLASMA CUTTING ALUMINUM

Introduction

When plasma arc cutting aluminum, free hydrogen gas may be generated by the cutting process. The high
temperature of the plasma process causes disassociation of oxygen and hydrogen from the water in the water
table. The hot aluminum, which has a high affinity for oxygen, then combines with the oxygen leaving free
hydrogen.

An effective means of avoiding free hydrogen buildup is to install an aeration manifold on the floor of the water
table to replenish the oxygen content of the water.

Making an Aeration Manifold

Make an aeration manifold with two-inch (50 mm) PVC tubing with one-inch (25 mm) distribution lines connected to
it. Drill 1/8 inch (3 mm) holes every six inches (150 mm) in the distribution lines. Cap the ends of the distribution
lines and install the lines so that oxygen is delivered to all parts of the cutting area.

Connect the manifold to a shop air line. Set a pressure regulator to obtain a steady stream of bubbles.

Aeration Manifold

Distribution Lines

Regulated air in

Figure g-1 Aeration Manifold

Hyspeed HT2000LHF Instruction Manual f-1

7
APPENDIX F: AERATION MANIFOLD FOR CUTTING ALUMINUM

f-2 Hyspeed HT2000LHF Instruction Manual

6
 Appendix G

IEC SYMBOLS

IEC Symbols Used

Direct Current (DC).

Alternating current (AC).

Plasma cutting torch.

AC input power connection.

The terminal for the external protective (earthed) conductor.

A chopper-based power source.

Anode (+) work clamp.

Temperature switch.

Pressure switch.

Plasma torch in the TEST position (cooling and cutting gas exiting nozzle).

The power is on.

The power is off.

Volt/amp curve.

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APPENDIX G: IEC SYMBOLS

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 Appendix H

SYSTEM GROUNDING

System Grounding Requirements

The plasma system must be grounded for safety reasons and to suppress EMI:

• Safety The entire system – power supply, accessory enclosures, and worktable – must be grounded to
protect it and the operator from a ground fault. The protective earth (PE) ground connections must be
installed by a licensed electrician and conform to national and local codes.

• EMI Suppression If allowed by national and local codes, the ground system can also be used to suppress
EMI (electromagnetic interference). Below is a guide to configure the plasma system for minimal EMI. See
Electromagnetic Compatibility in this manual for additional information.

Suggested Ground Cable Routing

Power Supply
Connect the power supply to the PE ground terminal, using a properly sized color-coded conductor. This PE
ground is connected to the service ground through the line disconnect switch. See the Installation section for
further information on the power cord and the line disconnect switch.

Equipment Grounding
All accessory modules that receive power from the plasma power supply must also use the power supply’s
ground – either by connection to the PE terminal of the power supply, or by direct connection to the
equipment ground conductor. Each module should have only one connection to ground to avoid ground loops.
If any enclosure is grounded to the work table, the work table must be grounded to the power supply.

Effective grounding for EMI reduction is highly dependent upon the installation configuration. Two acceptable
configurations are shown in Figures j-1 and j-2.

The RHF console should be installed near the work table, and grounded directly to it. Other modules should
be installed near the power supply, and grounded directly to it (Figure j-1).

All modules may also be installed near the work table, and grounded directly to it (Figure j-2). Do not ground
the RHF console directly to the power supply.

The customer must furnish all conductors for equipment grounding. Grounding conductors may be purchased
through Hypertherm in any length specified by the customer (Part No. 047058). The conductor may also be

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APPENDIX H – SYSTEM GROUNDING

purchased locally, using a minimum 8 AWG UL Type MTW cable (USA specification) or the appropriate cable
specified by national and local codes.

Consult the appropriate manufacturer’s instructions to ground equipment that does not receive power from the
power supply.

Work Table Grounding

If a supplementary ground rod is installed near the worktable to reduce EMI, it must be connected directly to
the PE ground of the building structure, connected to the service ground; or to earth, providing the resistance
between the ground rod and the service ground meets national or local codes. Place the supplementary
ground rod within 20 ft (6 m) of the worktable according to national or local codes.

If any module is grounded to the work table, the work table must be grounded to the power supply, or the
configuration must be changed to comply with applicable national and local electrical codes.

A ferrite choke can be placed in the conductor between the work table ground rod and the PE ground, with a
number of turns through the choke to isolate the safety ground (at 60 Hz) from any electromagnetic
interference (frequencies above 150 Khz). The more turns the better. A suitable ferrite choke can be made by
wrapping 10 turns or more of the ground lead through Magnetics part number 77109-A7, Fair-Rite part
number 59-77011101, or other equivalent ferrite choke. Locate the choke as close as possible to the plasma
power supply.

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 APPENDIX H – SYSTEM GROUNDING

Plasma Power Supply Ignition Console

(PE)
Ferrite Choke
(PE)

Power Cord
Ground
Work Table

Gas Console

(PE)

Supplementary
Grounding Rod
Other Equipment
receiving power from the
plasma power supply

(PE)

Figure j-1 Recommended Ground Connection Configuration

Note: Configuration may vary for each installation and may require a different ground scheme.

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APPENDIX H – SYSTEM GROUNDING

Other Equipment
receiving power from the
plasma power supply

(PE)

Gas Console

(PE)

Plasma Power Supply

Ignition Console

Ferrite Choke
(PE)
(PE)
Power Cord
Ground
Work Table

Supplementary
Grounding Rod

Figure j-2 Alternate Ground Connection Configuration

The preferred cable routing for this configuration is as shown, but it is acceptable to “daisy-chain” the grounds for
the gas console and other equipment to the ignition console. The ignition console should NOT be daisy-chained
through the other components to the work table.

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