Hypertherm HT4400 HySpeed Plasma Arc Cutting System - Manual (Page 12)

HT4400 Instruction Manual v
TABLE OF CONTENTS
Leak Tests .......................................................................................................................................................4-6
Daily Startup....................................................................................................................................................4-8
Common Cutting Faults ................................................................................................................................4-12
Performance and Process Data ....................................................................................................................4-13
Cut Chart and Consumable Parts Index .......................................................................................................4-14
Cut Charts .....................................................................................................................................................4-15
Changing Consumable Parts ........................................................................................................................4-23
Remove Consumables .........................................................................................................................4-23
Inspect Consumables ...........................................................................................................................4-24
Inspect Torch ........................................................................................................................................4-25
Inspect Electrode Pit Depth ..................................................................................................................4-26
Install Consumables .............................................................................................................................4-27
Replace Torch Water Tube............................................................................................................................4-28
Cutting Techniques........................................................................................................................................4-29
How to Get Better Cut Quality ..............................................................................................................4-29
How to Get Longer Consumable Life ...................................................................................................4-30
How to Get Better Pierces ....................................................................................................................4-32
How to Increase Cutting Speed............................................................................................................4-32
Section 5 Maintenance ..............................................................................................................................5-1
Introduction .....................................................................................................................................................5-2
Routine Maintenance ......................................................................................................................................5-2
Replacing the Cooler Filter..............................................................................................................................5-3
Pump Strainer Cleaning ..................................................................................................................................5-3
Torch Coolant Draining....................................................................................................................................5-4
Cooler Draining ...............................................................................................................................................5-4
HT4400 Startup Sequence..............................................................................................................................5-5
HT4400 Plasma START Sequence.................................................................................................................5-6
HT4400 Plasma RUN Sequence ....................................................................................................................5-7
Error Code Troubleshooting - 1 of 3................................................................................................................5-8
Error Code Troubleshooting - 2 of 3................................................................................................................5-9
Error Code Troubleshooting - 3 of 3..............................................................................................................5-10
System Troubleshooting - 1 of 4....................................................................................................................5-11
System Troubleshooting - 2 of 4 ...................................................................................................................5-12
System Troubleshooting - 3 of 4 ...................................................................................................................5-13
System Troubleshooting - 4 of 4 ...................................................................................................................5-14
Initial Checks.................................................................................................................................................5-15
Power Measurement Location - All Voltages.................................................................................................5-16
Power Distribution PCB1 - Status Indicators.................................................................................................5-17
Microprocessor Control Board PCB2 - Status Indicators ..............................................................................5-18
Analog Board PCB3 - Status Indicators ........................................................................................................5-19
Current Sense Test .......................................................................................................................................5-20
Relay Board PCB4 - Status Indicators ..........................................................................................................5-21
Serial I/O Board PCB5 - Status Indicators ....................................................................................................5-24
Start Circuit Board PCB14 - Status Indicators and Operation.......................................................................5-29
Pilot Arc Current Levels ........................................................................................................................5-29
Start Circuit Functional Schematic .......................................................................................................5-30
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