HT4400 ®

Plasma Arc Cutting System

Gas Panel
Instruction Manual
804210 - Revision 1

Integrated Plasma System

For use with the ™
 NOTICE

Use the HT4400 instruction manual, 803580 as well as this manual, 804210, to install,
operate and maintain the Titan system.

• This manual contains information to install the HT4400 with Titan Gas Panel. A parts
list is also included.

• See manual 803580 for safety information, general maintenance and detailed system
information.
 HT4400
Gas Panel
for Titan ™

Instruction Manual
(P/N 804210)

Revision 1 March, 2002

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

© Copyright 2002 Hypertherm, Inc.

All Rights Reserved

Hypertherm, HT, HyLife and LongLife are trademarks of Hypertherm, Inc.,

and may be registered in the United States and/or other countries
 Hypertherm, Inc.
Etna Road, P.O. Box 5010
Hanover, NH 03755 USA
603-643-3441 Tel (Main Office)
603-643-5352 Fax (All Departments)
800-643-9878 Tel (Technical Service)
800-737-2978 Tel (Customer Service)
Hypertherm Automation, LLC
5 Technology Drive
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)
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 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 596908 Tel
31 165 596901 Fax
Technical Service:
00 800 49 73 7843 – toll-free in Europe
31 165 596900 Tel
Hypertherm Brasil Ltda.
Rua Visconde de Santa Isabel, 20 – Sala 611
Vila Isabel, RJ
Brasil CEP 20560-120
55 21 2278 6162 Tel
55 21 2578 0947 Fax

3/27/03
 TABLE OF CONTENTS

Electromagnetic Compatibility (EMC) and Warranty - refer to manual 803580

Safety and Grounding Requirements - Refer to HT4400 manual 803580

Section 1 Specifications ............................................................................................................................1-1

System Components.......................................................................................................................................1-1
System Requirements.....................................................................................................................................1-2
Gas Panel - 077044 ........................................................................................................................................1-3

Section 2 Installation ..................................................................................................................................2-1

Gas Panel Connections ..................................................................................................................................2-2
Post Installation...............................................................................................................................................2-3

Section 3 Operation ....................................................................................................................................3-1

Gas Panel .......................................................................................................................................................3-2
Gas Panel Controls and Indicators.........................................................................................................3-3
Status Display Messages on the Gas Panel ..........................................................................................3-4
Leak Tests .......................................................................................................................................................3-5
Gas Schematic................................................................................................................................................3-6
Daily Startup....................................................................................................................................................3-7

Section 4 Parts List ....................................................................................................................................4-1

Gas Panel .......................................................................................................................................................4-2

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TABLE OF CONTENTS

iv HT4400 with Titan Gas Panel Instruction Manual

 Section 1

SPECIFICATIONS

System Components
See Main instruction manual 803580 for details on the system components and interconnections.

System Requirements
Table provides information about the types of gases needed, gas quality requirements and maximum flow rate and
inlet pressure.

Gas Panel
This unit houses metering and solenoid valves, pressure readout LEDs and gas selection switches to choose, set
and monitor plasma and shield gases. The gas console must be located within 50 ft (15.3 m) of the valve cluster.

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SPECIFICATIONS

System Requirements

Gas Requirements:
Plasma Gas Types Oxygen, Nitrogen
Shield Gas Types Air; Nitrogen
Gas Quality:
Oxygen 99.5% pure (liquid gas recommended)
Nitrogen 99.995% pure (liquid gas recommended)
Air 99.995% pure (liquid gas recommended)
Maximum Gas Flow Rates and Inlet Pressures:
Oxygen 140 scfh (3965 sclh) @ 120 psi +/- 10 psi (8.3 bar +/- 0.7 bar)
Nitrogen 250 scfh (7080 sclh) @ 120 psi +/- 10 psi (8.3 bar +/- 0.7 bar)
Air 250 scfh (5664 sclh) @ 120 psi +/- 10 psi (8.3 bar +/- 0.7 bar)

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 SPECIFICATIONS

Gas Panel – 077044

Dimensions and Weight:

Width ................................................9" (228 mm)

Height ..............................................34" (864 mm)
Depth ................................................6" (150 mm)
Weight ..............................................20 lbs (9 kg)

Gas Panel - Mounting Dimensionsl

0.203 ø (5 mm)
- 12 places

33.625" (853 mm) 34" (864 mm)

26.975" (685 mm)

20.325" (516 mm)

13.675" (347 mm)

7.025" (178 mm)

0.375" (9.5 mm) 8.625" (219 mm)

0 0.375" (9.5 mm)

0 9" (229 mm)

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SPECIFICATIONS

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 Section 2

INSTALLATION

See HT4400 instruction manual 803580 Installation section for system requirements,
component placement and safety information.
Use the diagrams on the following pages to make Titan system interconnections. See Installation section of
the system’s main instruction manual for specific information on each cable, hose or connection.

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INSTALLATION

Gas Panel Connections

3X2


O2 In

 Green
N2 In Red
Green
Red


Green

Air In
10a

Red

Green

 3X1

 Gas Panel to Power Supply

 Gas Panel to Power Supply

 Hoses - Gas Panel to Valve Cluster

 Oxygen Hose - Gas Panel to Gas Supply

 Nitrogen Hose - Gas Panel to Gas Supply

10a Air Hose - Gas Panel to Gas Supply

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 INSTALLATION

Post-Installation
HT4400 Initial Startup
After installation is complete, perform the following procedure to ensure the proper performance of the
HT4400 system before moving on to the Operation section of this manual. The gas panel will display error code
FS (flow switch error) on initial startup until: all air is out of the torch coolant loop; the reservoir in the water
cooler has an adequate supply of fluid. Follow the procedure below to satisfy the flow switch.

Status Display
1. Verify that all installation requirements are met and that all
connections are made as outlined in this section and the
Installation section of manual 803580.

2. Verify that consumables are installed properly in the torch

(see Daily Startup in the Operation section, if necessary).

Valve Select 3. Verify that the torch coolant has been added to the water
(S2) cooler (see Installation section of manual 803580).

4. Position the valve select switch (S2) on the gas panel to

either Leak Test 1 or Leak Test 2.

5. Switch the Control Power switch on the power supply

ON (I).

6. Allow coolant to flow through the system. If the coolant is

flowing properly, propellers on the flow switch (FS1) will be
spinning rapidly.

Note: When propellers are spinning, the individual paddles

cannot be seen.

If coolant stops flowing and FS is still displayed on the gas

panel, turn valve select switch to RUN, and then back to
Leak Test 1 or Leak Test 2. This action allows the pump to
run for 30 seconds. Check coolant level.

7. After 5 minutes, switch the Control Power switch on the

power supply OFF (O).
Check coolant
level
8. Position the valve select switch (S2) on the gas panel to
RUN.

9. Switch Control Power switch on the power supply ON (I).

The coolant pump should continue to run and OK should

be displayed on the gas panel status display.

If FS or any other error code is displayed on the gas panel

other than OK, the system has a problem that needs to be
fixed before daily operations can begin. See Section 5,
Maintenance, of manual 803580 to troubleshoot.

Flow switch (FS1)

propellers

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INSTALLATION

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 Section 3

OPERATION

In this section:

Gas Panel .......................................................................................................................................................3-2

Gas Panel Controls and Indicators.........................................................................................................3-3
Status Display Messages on the Gas Panel ..........................................................................................3-4
Leak Tests .......................................................................................................................................................3-5
Gas Schematic................................................................................................................................................3-6
Daily Startup....................................................................................................................................................3-7

NOTE: All cut chart information can be found in HT4400 manual 803580

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OPERATION

Gas Panel
Status Display

PG1 PG2

Valve Select S1
S2

Gas Select 1

MV1 MV5

MV2

Gas Select 2

MV3 MV6

MV4 MV7

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 OPERATION

Gas Panel Controls and Indicators

PG1 Indicates the plasma gas pressure. Settings for the plasma gas pressures are specified in the
Cut Charts in manual 803580, Operation section.

S1 Selects the use of either nitrogen or oxygen as the plasma cutting gas.

Status Displays a 2 character code to report the condition of the HT4400 system. See Status
Display Display Messages on the Gas Console in operation section of manual 803580. See also Error
Code Troubleshooting in Section 5.

PG2 Indicates the shield gas pressure. Settings for the shield gas pressures are specified in the
Cut Charts (manual 803580).

MV1 Adjusts the plasma gas cutflow pressure. MV1 and cutflow plasma pressures are specified in
the Cut Charts.

MV2 Adjusts one of the plasma gas preflow pressures. MV2 and preflow plasma pressures are
specified in the Cut Charts. .

MV3 Adjusts one of the shield gas cutflow pressures. MV3 and cutflow shield pressures are
specified in the Cut Charts.

MV4 Adjusts one of the shield gas preflow pressures. MV4 and preflow shield pressures are
specified in the Cut Charts. .

MV5 Adjusts one of the plasma gas preflow pressures. MV5 and preflow plasma pressures are
specified in the Cut Charts. .

MV6 Adjusts one of the shield gas cutflow pressures. MV6 and cutflow shield pressures are
specified in the Cut Charts.

MV7 Adjusts one of the shield gas preflow pressures. MV7 and preflow shield pressures are
specified in the Cut Charts.

Gas Select 1 Selects the plasma cutting gas (Gas 1). When the shield gas is a mixture of 2 gases, this
setting represents the plasma portion of the mixture.

Gas Select 2 Selects the shield gas (Gas 2). When the shield gas is a mixture of 2 gases, this setting
represents the non-plasma portion of the mixture.

Valve Select Chooses the active valve to adjust. Also selects Leak Test 1, Leak Test 2, Test Preflow,
S2 and Test Cutflow.

Leak Test 1 See Gas Console Valve Select Detail in Section 5 (manual 803580).

Leak Test 2 See Gas Console Valve Select Detail in Section 5.

Test Preflow See Gas Console Valve Select Detail in Section 5.

Test Cutflow See Gas Console Valve Select Detail in Section 5.

Run In this mode, all valves are OFF initially. The valve select switch must be positioned to
RUN before sending the START command to the plasma system.

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OPERATION

Status Display Messages on the Gas Panel

The list of error codes that may appear in the Status display are explained in the maintenance Section of manual
803580.

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 OPERATION

Leak Tests

WARNING
CUTTING WITH OXYGEN CAN CAUSE FIRE OR EXPLOSION

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.
After installing the system and before adjusting plasma and shield gas levels, perform the following leak tests.

Leak Test 1

1. Open all gas panel valves, MV1-MV7.

2. Set the Gas Select 1 lever on the gas panel to the proper plasma gas.

3. Set the Gas Select 2 lever on the gas panel to the proper shield gas.
Note: If the shield gas is a mixture, set Gas Select 2 to the non-plasma portion of the mixture.

4. Choose Leak Test 1 on the valve select thumb-wheel switch.

5. Turn the supply gases on.

6. Turn on the power supply by positioning the CONTROL POWER circuit breaker on the rear of the power
supply to the UP (I) position.

7. When the system is pressurized, turn off the supply gases and view the supply gas pressure gauge. If the
system is losing pressure, troubleshoot by using the gas schematic on page 3-6.

Leak Test 2

1. Open all gas panel valves, MV1-MV7.

2. Set the Gas Select 1 lever on the gas panel to the proper plasma gas.

3. Set the Gas Select 2 lever on the gas panel to the proper shield gas.
Note: If the shield gas is a mixture, set Gas Select 2 to the non-plasma portion of the mixture.

4. Choose Leak Test 2 from the valve select thumb-wheel switch.

5. Turn the supply gases on.

6. Turn on the power supply by positioning the POWER circuit breaker on the rear of the power supply to the
UP (I) position.

7. When the system is pressurized, turn off the supply gases and view the supply gas pressure gauge. If the
system is losing pressure, troubleshoot by using the gas schematic on page 3-6.

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OPERATION

Gas Schematic

Gas Console

MV-1 SV-1

MV-2 SV-2 Plasma Cutflow

Rotary Selector Switch #1
Plasma Preflow

SV-13
MV-3 SV-3
Shield Cutflow
Plug
Shield Preflow
SV-8 SV-9 SV-10 SV-11 SV-12
FL2
MV-4 SV-4
O2 SVC

PRESSURE FEEDBACK
Plug PG-2
PRESSURE FEEDBACK
PG-1
FL4 MV-5 SV-5

N2
Valve Cluster
Rotary Selector Switch #2
FL3 MV-6 SV-6
Air
Plug

MV-7 SV-7

Note: In Leak Test 1, valves 1-7 are ON (open), and valves 8-12 are OFF (closed).
In Leak Test 2, valves 8-12 are ON (open), and valves 1-7 are OFF (closed).

Valve Select

Gas Select 1

Gas Select 2

Gas Panel

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 OPERATION

Daily Startup
Prior to startup, ensure that your cutting environment and that your clothing meet the safety requirements outlined
in the Safety section of HT4400 manual 803580. See Post-installation in Section 2 of this manual if you are
switching the power supply on for the first time.

WARNING

Before operating this system, you must read the Safety section in manual 803580 thoroughly! Turn
main disconnect switch to the power supply OFF before proceeding with the following steps.

1. Check Torch and Consumables

1. Remove the consumables from the torch and check for worn or damaged parts. See Changing
Consumable Parts in Operation section of manual 803580. 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
.040 inch (1 mm). A gauge for measuring electrode pit depth can be purchased through Hypertherm.
See Section 6 Parts List in this manual. See also Inspect Electrode Pit Depth in Operation section of
manual 803580.

• Wipe the current ring in the torch with a clean paper towel or cotton swab.

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

2. Replace consumable parts. Refer to Changing Consumable Parts in Operation section of manual
803580 for detailed information on replacing consumables.

3. Ensure that the torch is perpendicular to the material. Refer to Operation section of manual 803580 for
the torch alignment procedure.

Retaining Cap Nozzle Swirl Ring Electrode Current Ring Torch

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OPERATION

2. Turn Gases On
1. Turn the supply gases on.
S1
2. Set S1 toggle switch on the gas panel to plasma gas O2, or
Valve N2.
Select
S2 3. Set the Gas Select 1 lever on the gas panel to the proper
plasma gas.
Gas
Select 1 4. Set the Gas Select 2 lever on the gas panel to the proper
shield gas. Note: If the shield gas is a mixture, set Gas
Select 2 to the non-plasma portion of the mixture.(e.g., If the
plasma gas is O2 and the shield gas is Air, set Gas Select 2
switch to Air.)

5. Set the Valve Select thumb-wheel switch (S2) to Run.

Note: See the Cut Charts (manual 803580) to set the plasma
and shield gas pressures.
Gas
Select 2

3. Turn Power Supply On and Adjust Current & Voltage

1. Turn the main disconnect switch ON.

2. Turn on the power supply by positioning the CONTROL

POWER circuit breaker on the rear of the power supply to the
UP position. The system will automatically purge gases and
then display OK in the gas panel status display window.

3. Set the current from the machine computer interface or the

remote current control panel. Set the voltage from the
machine computer interface or torch-height control system.
Select the arc current and arc voltage numbers from the Cut
Charts for the type and thickness of metal to cut.

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 OPERATION

4. Adjust Cutflow and Preflow Gases

1. Set the Valve Select thumb-wheel switch (S2) to MV1.

2. Turn the MV1 valve to the plasma pressure detailed in the Cut Charts. The pressure reading appears
in the gas panel PG1 Plasma window.

3. Set the Valve Select thumb-wheel switch (S2) to MV2.

4. Turn the MV2 valve to the plasma pressure detailed in the Cut Charts. The pressure reading appears
in the gas panel PG1 Plasma window.

5. Repeat this procedure to set metering valves M3-M7. Note that the readings for shield gas
adjustments appear in gas panel PG2 Shield window.

PG1 PG2

Valve Select
S2

MV1 MV5
(Plasma cutflow) (Plasma preflow)

MV2
(Plasma preflow)

MV3 MV6
(Shield cutflow) (Shield cutflow)

MV4 MV7
(Shield preflow) (Shield preflow)

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OPERATION

PG2
5. Verify Test Preflow
1. Set the Valve Select thumb-wheel switch (S2) to Test
Preflow.
PG1
2. Observe pressure readings on PG1 (plasma) and PG2
(shield). Verify that the readings are within +/- 3.0 psi (0.21
bar) of the PG1 and PG2 Test Preflow Verify rates specified
Valve Select in the Cut Charts.
S2
3. If readings are not within +/- 3.0 psi (0.21 bar), repeat the
preflow gas adjustments of steps 4.

6. Verify Test Cutflow

1. Set the Valve Select thumb-wheel switch (S2) to Test
Cutflow.

2. Observe pressure readings on PG1 (plasma) and PG2

(shield). Verify that the readings are within +/- 3.0 psi (0.21
bar) of the PG1 and PG2 Test Cutflow Verify rates specified
in the Cut Charts.

3. If readings are not within +/- 3.0 psi (0.21 bar), repeat the
cutflow gas adjustments of steps 4.

7. Begin Cutting

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 Cutflow for one minute.

1. Set any additional cutting parameters as outlined in the Cut Charts (manual 803580).

2. Set Valve Select switch to Run after the test preflow and test cutflow rates have been verified.

3. The system is now ready to operate. Press the START command from the machine interface to begin the
cutting sequence.

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 Section 4

PARTS LIST

This section provides part numbers for the the HT4400 with Titan Ignition panel.

• See Installation Section in the systems main manual for part numbers of hoses and interconnecting cables.

• See HT4400 instruction manual 803580 for consumable parts kits, power supply breakdown and parts for
other HT4400 options.

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PARTS LIST

Gas Panel

 





PG1


PG2

Part
Item Number Description Designator Qty.
1 077044 HT4400 Gas Panel
2 005156 Toggle switch: SP 10A On/Off/On S1 1
3 008106 Nut: Toggle Switch, Dress 1
4 128512 Kit: Pressure Switch Replacement PG2 1
5 128511 Kit: Pressure Switch Replacement PG1 1
6 015330 Filter: 10 Micron 2
7 041638 PCB Assy: LED Display Board PCB11 1
8 129607 Thumb-wheel Assembly S2 1

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