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220487
Hypertherm
Introduction
Deteriorating consumable parts life is one of the first indications that something is wrong with a plasma system. Reduced parts life increases operating costs in two ways: the operator must use more electrodes and nozzles to cut the same amount of metal, and the work of cutting must stop more often to change consumables.
Proper maintenance often eliminates the problems that shorten the life of consumable parts. Since labor and overhead can account for 80% of the cost of cutting, improved productivity can reduce cutting costs dramatically.
Preventive maintenance protocol
The following protocol covers the basic elements of all Hypertherm HySpeed plasma systems.
If inspection suggests that a component is worn and might require replacement, and you would like confirmation of your decision, please contact Hypertherm's Technical Service department.
The power supply
1. With power to the power supply turned off, remove all side panels. Use compressed air to blow out any accumulation of dust and particulates.
2. Inspect wiring harnesses and connections for wear, damage or loose connections. If you see any discoloration that might indicate overheating, contact Hypertherm Technical Service.
3. Inspect the main contactor for excessive pitting on the contacts, characterized by a blackened, rough surface on any of the contacts. If this condition exists, replacement is recommended.
Cooling system
4. Inspect the coolant-circulating system’s filter element at the rear of the power supply. If the filter is a brownish color, replace it. Consult the Parts List in this manual for part numbers.
5. Perform a coolant flow test as described in this manual, then check for coolant leaks. Primary locations to inspect are these: A. The back of the power supply; B. At the ignition console; and C. At the torch main body. Also, check the coolant tank for dirt and particulates. Verify that proper Hypertherm coolant is being used. Proper Hypertherm coolant (028872) is a red liquid.
Torch main body
6. Verify that the water tube is straight and has no pitting on the end.
7. Clean all threads on the front end of the torch head with hydrogen peroxide and a cotton swab, pipe cleaner or clean cloth. Do not use alcohol. Damage to the threads usually results from not cleaning the torch and retaining cap threads properly, so that dirt and particulates accumulate in the threads.
8. Inspect the torch insulator for cracks. Replace the torch if you find cracks.
9. Inspect all o-rings on the torch body and consumables. Make sure that the correct amount of lubricant, a thin film, is applied to these o-rings. Too much lubricant may obstruct gas flows.
10. Check that the retaining or shield cap is tightened securely to the torch main body.
11. Inspect all hose fittings at the rear of the torch for wear. Damage to the fitting threads may indicate that overtightening has occurred.
12. Check that all connections between the torch and torch leads are tight, but do not overtighten. See torque specs in the Installation section of this manual. When removing consumables, always place them on a clean, dry, oil-free surface, since dirty consumables may cause the torch to malfunction.
Gas flows
13. Check each gas line from the gas supply, as follows:
A. Remove and plug the inlet gas fitting at the gas console.
B. Pressurize the O2 gas line to 8.3 bar (120 psi) and the air gas line to 7.2 bar (105 psi).
C. Close the gas supply valve at the source. Watch for a pressure drop. If the gas supply line is a hose, there may be a 0.3 to 0.5 bar (5 to 7 psi) drop due to hose-stretch.
D. Repeat for each line from a gas supply source. If any pressure continues to drop, find the leak within the system.
14. If the gas line pressures hold steady, perform a system gas leak test as specified in this manual.
15. Check for hose restrictions, as follows:
A. Check all hoses to verify that they have no kinks or sharp bends, which can restrict gas flow.
B. If the cutting table uses a power track system to support leads from the power supply to the gas console or torch, check the position of the leads in the power track to ensure the leads do not twist or kink, causing a possible restriction.
Cable connections
16. All cables should be checked for chafing or unusual wear. If the outside insulation has been cut or otherwise damaged, replace the cable.
Ignition console
17. Open the cover and use compressed air to blow out any accumulation of dust and particulates. If moisture is present, dry the inside of the console with a cloth and try to identify the source of the moisture.
18. Inspect the spark gap assembly. Ensure that the wiring connections to the spark gap assembly are secure.
19. Inspect the torch leads. Ensure that they are fastened tightly to the outside of the ignition console.
System grounding
20. Verify that all components of the system are individually grounded to a driven earth ground, as described in the Installation and Grounding sections of this manual.
A. All metal enclosures, such as the power supply, ignition console and gas console, should be connected individually to a ground point. These connections should be made with 10 mm2 (#8 AWG) wire (USA), or equivalent-size wire.
21. Check the work lead (+) connection, particularly where the work lead (+) connects to the cutting table. This must be a good, clean connection because a poor connection may cause arc-transfer problems.
22. Complete the Preventive Maintenance worksheet on the next page, for future reference.
220487 Electrode
220488 Swirl ring
220489 Nozzle
220490 Retaining cap
220491 Shield
220492 Nozzle
220525 Nozzle
220528 Electrode
220529 Swirl ring
220530 Nozzle
220532 Shield
220578 Retaining cap with IHS tab
220340 Water tube with o-ring
Hypertherm 220487 Electrode 130A For Use With HSD130 Maxpro200
Introduction
Deteriorating consumable parts life is one of the first indications that something is wrong with a plasma system. Reduced parts life increases operating costs in two ways: the operator must use more electrodes and nozzles to cut the same amount of metal, and the work of cutting must stop more often to change consumables.
Proper maintenance often eliminates the problems that shorten the life of consumable parts. Since labor and overhead can account for 80% of the cost of cutting, improved productivity can reduce cutting costs dramatically.
Preventive maintenance protocol
The following protocol covers the basic elements of all Hypertherm HySpeed plasma systems.
If inspection suggests that a component is worn and might require replacement, and you would like confirmation of your decision, please contact Hypertherm's Technical Service department.
The power supply
1. With power to the power supply turned off, remove all side panels. Use compressed air to blow out any accumulation of dust and particulates.
2. Inspect wiring harnesses and connections for wear, damage or loose connections. If you see any discoloration that might indicate overheating, contact Hypertherm Technical Service.
3. Inspect the main contactor for excessive pitting on the contacts, characterized by a blackened, rough surface on any of the contacts. If this condition exists, replacement is recommended.
Cooling system
4. Inspect the coolant-circulating system’s filter element at the rear of the power supply. If the filter is a brownish color, replace it. Consult the Parts List in this manual for part numbers.
5. Perform a coolant flow test as described in this manual, then check for coolant leaks. Primary locations to inspect are these: A. The back of the power supply; B. At the ignition console; and C. At the torch main body. Also, check the coolant tank for dirt and particulates. Verify that proper Hypertherm coolant is being used. Proper Hypertherm coolant (028872) is a red liquid.
Torch main body
6. Verify that the water tube is straight and has no pitting on the end.
7. Clean all threads on the front end of the torch head with hydrogen peroxide and a cotton swab, pipe cleaner or clean cloth. Do not use alcohol. Damage to the threads usually results from not cleaning the torch and retaining cap threads properly, so that dirt and particulates accumulate in the threads.
8. Inspect the torch insulator for cracks. Replace the torch if you find cracks.
9. Inspect all o-rings on the torch body and consumables. Make sure that the correct amount of lubricant, a thin film, is applied to these o-rings. Too much lubricant may obstruct gas flows.
10. Check that the retaining or shield cap is tightened securely to the torch main body.
11. Inspect all hose fittings at the rear of the torch for wear. Damage to the fitting threads may indicate that overtightening has occurred.
12. Check that all connections between the torch and torch leads are tight, but do not overtighten. See torque specs in the Installation section of this manual. When removing consumables, always place them on a clean, dry, oil-free surface, since dirty consumables may cause the torch to malfunction.
Gas flows
13. Check each gas line from the gas supply, as follows:
A. Remove and plug the inlet gas fitting at the gas console.
B. Pressurize the O2 gas line to 8.3 bar (120 psi) and the air gas line to 7.2 bar (105 psi).
C. Close the gas supply valve at the source. Watch for a pressure drop. If the gas supply line is a hose, there may be a 0.3 to 0.5 bar (5 to 7 psi) drop due to hose-stretch.
D. Repeat for each line from a gas supply source. If any pressure continues to drop, find the leak within the system.
14. If the gas line pressures hold steady, perform a system gas leak test as specified in this manual.
15. Check for hose restrictions, as follows:
A. Check all hoses to verify that they have no kinks or sharp bends, which can restrict gas flow.
B. If the cutting table uses a power track system to support leads from the power supply to the gas console or torch, check the position of the leads in the power track to ensure the leads do not twist or kink, causing a possible restriction.
Cable connections
16. All cables should be checked for chafing or unusual wear. If the outside insulation has been cut or otherwise damaged, replace the cable.
Ignition console
17. Open the cover and use compressed air to blow out any accumulation of dust and particulates. If moisture is present, dry the inside of the console with a cloth and try to identify the source of the moisture.
18. Inspect the spark gap assembly. Ensure that the wiring connections to the spark gap assembly are secure.
19. Inspect the torch leads. Ensure that they are fastened tightly to the outside of the ignition console.
System grounding
20. Verify that all components of the system are individually grounded to a driven earth ground, as described in the Installation and Grounding sections of this manual.
A. All metal enclosures, such as the power supply, ignition console and gas console, should be connected individually to a ground point. These connections should be made with 10 mm2 (#8 AWG) wire (USA), or equivalent-size wire.
21. Check the work lead (+) connection, particularly where the work lead (+) connects to the cutting table. This must be a good, clean connection because a poor connection may cause arc-transfer problems.
22. Complete the Preventive Maintenance worksheet on the next page, for future reference.
220487 Electrode
220488 Swirl ring
220489 Nozzle
220490 Retaining cap
220491 Shield
220492 Nozzle
220525 Nozzle
220528 Electrode
220529 Swirl ring
220530 Nozzle
220532 Shield
220578 Retaining cap with IHS tab
220340 Water tube with o-ring
Hypertherm 220487 Electrode 130A For Use With HSD130 Maxpro200