HT2000 Maintenance

HT2000 maintenance

• Regular maintenance will

increase the life of the
machine, torch and
consumables.
• During regularly scheduled
maintenance go through the Disconnect power to the machine
machine in an ordered fashion before removing the panels or
to assure that everything is proceed with EXTREME caution.
checked. High voltage - high amperage DC can
• Hypertherm publishes a kill
Preventive Maintenance
Protocol booklet to guide you.
• We are going to approach
maintenance by looking at
each sub-system.

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Subsystems

Interlocks
Control power
Arc initiation
Arc power
Arc amperage control Gas
m
Gas system Cooli
ng syste

Interlocks
Cooling system
Amp ower
owe r trol p
contro Arc p Con
l

Arc
initia
tio n

Review

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Interlock system

Purpose:
To protect the machine and the operator

Basics:
A series of switches checked continuously by the processor for a closed
state.

Components:
Power distribution board
Control board
Pressure Flow Temperature
Wiring switch switch switch

Switches
Power More
distribution switches
board
Control
board
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Interlock LEDs

Green is good (older systems)

Amber is bad (newer LVD systems)
Check from top down

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Interlock subsystem maintenance

Maintaining the interlock system:

Check switch function
Check wiring connections

Door switch, 1 of 2 Thermal switch Thermal switch

in the RHF console CH130 chopper main transformer

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Interlock subsystem maintenance

Maintaining the interlock system:

Check switch function
Check wiring connections

Coolant level switch

Coolant thermal switch

Coolant reservoir
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 Interlock subsystem maintenance

Maintaining the interlock system:

Check switch function
Check wiring connections

Cap on safety
orifice and o-rings

N2 and O2 Plasma gas

Shield gas pressure switch inlet pressure switches
RHF console (12 PSI) Gas console (80 PSI)

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Interlock subsystem maintenance

Maintaining the interlock system:

Check switch function
Check wiring connections

Flow switch (.5 GPM)

Coolant compartment
Rear of the machine
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Ignition system

Purpose:
To initiate a plasma arc

Basics:
A high frequency arc and then a pilot arc are created in the torch
then a cutting arc transfers to the work.

Components:
Spark gap assembly
Surge injection circuit
Pilot arc relay
Current sensors
Arc power system
Arc control system

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Ignition subsystem maintenance

Spark gaps
• .020” gap
• Ends should be square and smooth
• Check wiring for signs of heat
• Check connections

Spark gap assembly

RHF console

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Ignition subsystem maintenance

Pilot arc relay

• Check contacts for pitting
• Remove any metallic dust from the
permanent magnet below the flapper
• Check wiring for signs of heat
• Check connections

Pilot arc relay

Rear interior wall, left side

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Gas system

Purpose:
To control gas flow in order to maintain and shape the arc

Basics:
Metering valves and flow tubes on the gas console control and measure plasma
gas flow and a back-pressure gauge measures shield gas flow.

Components:
Gas console
Lead set
Motor control valve
OFF valve assembly
Torch and consumables

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Gas system maintenance

Inlet pressure
Plasma switch
1. Power up the machine (no interlocks)
2. Set the test switch to “Test Cut”
3. Set Plasma switch to O2
4. Check the O2 inlet pressure 120 PSI
(flowing) at the inlet regulator
5. Set Plasma switch to N2/Air
6. Check the N2 (or air) inlet pressure
120PSI (flowing) at the inlet regulator
7. Return switches to original positions

Test switch

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Gas system maintenance

Leak test
1. Power up the machine (no
interlocks) Motor Valve Console
2. Set the test switch to “Test
Cut”
3. Set Plasma switch to O2
4. O2 inlet pressure 120 PSI
(flowing)
5. Disconnect Off Valve control
Off valve control cable
cable from Motor Valve
Console

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Gas system maintenance

Leak test (cont.)

6. Observe flow tube balls drop
and rest on the bottom of the O2 system pressure gauge
tube
7. Allow five minutes for the
system to accommodate the
added pressure
8. Shut off the O2 source
9. Monitor the O2 system
pressure for 20 minutes
10. If the pressure loss is greater
than 5 PSI repair leaks

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Gas system maintenance

Leak test (cont.) N2 system pressure gauge

11. Return the system to its
original setup
12. If desired use the above
steps to check for N2/Air
plasma leaks (with Plasma
switch set to N2/Air)
13. If desired use the above
steps to check for Pre-Flow
gas system leaks (with the
test switch set to Pre-flow)
Alternately:
• Modify a nozzle by brazing or soldering the nozzle orifice closed
• Install an O-ring above the threads
• Leave the Off Valve control cable connected
This will check the gas connections inside the torch sleeve

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Control power system

Purpose:
To provide power to the control and support
devices in the machine.

Basics:
Transformed AC voltages
240 VAC
Components: Two legs of the incoming
three phase AC 120 VAC
Power distribution board
Control transformer 24 VAC

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Control power system

Wiring
Check every plug and receptacle for
complete mating
Check every wiring connection for
tightness

Devices
Check all fans for operation
Check power indicators (ON button, DC
light, etc) for function

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Arc power system

Purpose:
Provides constant current DC to power the arc.

Basics:
A constant current output, AC to DC power conversion
system

Components:
Main contactor
Power transformer
Chopper (Rectifier and IGBT) Inductor Load
Inductor
Load

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Arc power system maintenance

Main contactor
• Inspect the wiring
connections
• Check the contacts for wear
• Look for signs of heat

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Arc power system maintenance

High current connections

At the table and at the machine
• Check for tightness
• Check for corrosion
• Check for signs of arcing or heat

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Arc amperage control system

Purpose:
To control the amperage output of the plasma arc power circuit.

Basics:
A feedback controlled, constant current, DC power supply

Components: DC current
Machine
Current sensors logic
Source

Power and control boards

Chopper or inverter control circuitry

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Arc amperage control system maintenance

Shunts
• Check the high current connections
•For tightness
•For signs of arcing or heat

• Check the sense lines

•For tightness

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Coolant system

Purpose:
To move heat away from the torch and consumables.

Basics:
A closed loop liquid cooling system.

Components:
Reservoir
Pump
Lead set
Torch
Heat exchanger
Flow meter
Filter

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Coolant system

General:
• Check the coolant level in
the reservoir
• Check for coolant
contamination
• Check for fan function at the
heat exchanger
• Check for tightness of all
fittings
• Check the system, including
the torch and leads for signs
of leakage

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Coolant system

Flow test:
Consumable and torch life can be
affected by low coolant flow
1. Turn off the power coming to the
machine at the disconnect box
2. Disconnect the coolant return line
3. Turn on the power at the disconnect
4. Press and hold the ON button to
force the pump to operate
5. Check for 1GPM+ at the return line

Coolant return line

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Review

1. How do you perform a gas leak test?

2. How do you perform a coolant flow test?
3. How are contactor function and chopper life related?
4. To be satisfied what state should the interlock switches be in?
5. Why would a loose work lead cause poor cut quality?
6. What are the dangers of “jumping out” interlocks?
7. Is it safe to be in the machine if the disconnect is closed?
8. How does arc shape relate to gas velocity and pressure at the nozzle
orifice?

Page 28
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