HT 2000

HyPro2000 ™ Straight Torch
HT2000 Torch Upgrade for Punch

Presses
Field Service Bulletin

807230 – Revision 1 – May 2011
HyPro2000 Straight Torch — HT2000 torch Upgrade for punch presses
DANGER
Electric Shock Can Kill
Disconnect electrical power before performing any maintenance.

All work requiring removal of the power supply cover must be
performed by a qualified technician.
See the Safety Section of the system’s Manual for more safety
precautions.
Introduction
Purpose
This document describes the steps necessary to upgrade the HT2000 with the HyPro2000 straight torch for punch
presses.
Required tools
5/16 inch, 3/8 inch, 7/16 inch, 1/2 inch, open end wrench, and 2 inch spanner wrench.
Kits
Part number Description Qty
228778 Kit: HyPro2000 straight torch retrofit with Control PCB 1
228777 Kit: HyPro2000 straigh torch retrofit 1
HT2000 control PCB

Straight torch retrofit kit
Field Service Bulletin 1

Kit - 228778 Contents (PCB included)
Note: This kit includes all the parts that are in the 228777 kit , plus the following items:
Part
Number Description Qty.
141163 PCB assembly: HT2000 control board 1
223173 Jumper wire: HyPro2000/phase loss upgrade 1
Kit - 228777 Contents (PCB not included)
Part
Number Description Qty.
024873 Hose 1
027055 Silicone lubricant: 1/4 ounce 1
044026 O-ring: 1.239 inch x 0.070 inch 2
046065 Tubing: 9/16 inch interior diameter, 76.2 mm (0.25 ft) length 1
104119 Consumable tool 1
220831 Nozzle: 200 amp O2 5
220832 Shield: 200 amp O2/air 1
220834 Swirl ring: 200 amp 1
220925 Electrode: 200 amp SilverPlus 3
220935 Shield cap: O2/air, clockwise, with IHS tab 1
220937 Electrode: 200 amp O2/air 2
220942 Torch mounting sleeve: 1-3/4 inch outside diameter 1
220943 Torch mounting sleeve: 2 inch outside diameter 1
220961 HyPro2000 straight torch 1
228567 Gauge: Plasma pressure 1
228571 Kit: Firmware upgrade 1
807230 Field service bulletin: HyPro2000, HT2000 Torch Upgrade 1
2 Field Service Bulletin

Pre-installation
Before starting this upgrade you must determine if the system is a Local High Frequency (LHF) or a Remote High
Frequency system (RHF). You need to know this information to choose the correct firmware chip.
Inspect the gas console as described below:
PLASMA DC PLASMA DC
N2/Air O2 N2/Air O2
SHIELD SHIELD
10 10 10 10
9 9 9 9
psi psi
8 8 8 8
psi psi
7 7 7 7
6 6 6 6
5 5 5 5
N2/Air N2/Air
4 4 4 4
3 3 3 3
2 2 2 2
psi psi
1 1 1 1
0 0 0 0
O2 O2
N2/Air PLASMA O2 N2/Air PLASMA O2

PreFlow Cut Flow PreFlow PreFlow Cut Flow PreFlow
Run Run
Test Test Test Test

Preflow Cutflow Preflow Cutflow
If there is a toggle switch for the If it has a knob to adjust the

plasma cutflow gas it is an RHF plasma cutflow gas it is an LHF
system system
The HySpeed off-valve assembly (129840) MUST be installed in an LHF system to continue with this upgrade. The off-
valve assembly is marked HYSPEED, as shown below.

Installation of the firmware chip

1. Access the control board (PCB2) by removing the 2 front panels.
Control board
location
Firmware chip
location
2. Inspect the control board. If it is a older model, you will have to replace the board and the firmware chip.
Older board Newer board

(replace board and chip) (replace chip)
Look for this

metal cover
on the older
board
Firmware chip
location

If you are installing a new control board skip to step 4
3. Remove and discard the old chip by using the tool included in this kit. See pictures below.
3a. Place the straight end of the chip removal tool under one corner of the chip. Only 2 opposite corners will accept
the tool.
3b. Carefully pry each of the 2 corners alternately until the chip is removed. Prying the chip out from only one corner
can damage the chip receptacle.
4. Chose the appropriate chip from firmware kit 228571 (located in the main kit box), and install it in the chip receptacle
on the control board.
Use the chip labeled 081192 for an RHF system.
Use the chip labeled 081194 for an LHF system.
NOTE: T
he chip must be oriented correctly before installation. DO NOT use the orientation of the label
to orient the chip to the chip receptacle. There is a bevel on one edge of each chip and one
corner is angled (see figure below).
Angled corner Bevel
Firmware Chip
Chip receptacle
on PCB
5. If you are installing a new control board see Installation of the new control board on the next page.
If you have installed the new chip on an existing control board see step 2 of Installation of the new control board on
the next page, before you replace the 2 front panels of the power supply and continue to torch and quick-disconnect
installation.

Installation of the new control board

1. Install the appropriate firmware chip on the new control board by following step 4 on the previous page.
Control board
location
2. Locate plug PL 2.4 in receptacle 4 on the control board. If no wires are present in sockets 1 and 2 use the jumper
wire provided in this kit to jump the 2 sockets.
Plug PL 2.4 in
receptacle 4
Wires (blue and white)

present in sockets 1 and 2

3. Label each connector before removing any connections to the old board. After labeling the connectors, remove
all connections to the control board. Any wires that are present but not connected to the board will remain
disconnected.
4. Remove the 6 screws that hold the control board in place, and remove the old control board. Save the screws for
reuse.
5. Install the new control board using the six screws from step 3.
6. Plug all the connectors into the appropriate receptacles on the new control board.
7. Replace the 2 front panels and continue to torch installation.

Torch Installation
1. Remove the existing torch and mounting sleeve from the lifter.
2. Unscrew the mounting sleeve and slide it up to expose the hose fittings.
3. Disconnect all the hoses and the pilot arc connection from the torch and remove the sleeve.
Always use 2 wrenches to loosen or tighten the fittings.
4. Inspect all hoses and wires for damage.
5. Loosen the off-valve assembly to remove the existing blue plasma hose. Hold the black
plasma hose provided in this kit with the bundled cables and hoses, and slide the new sleeve
(1-3/4 in or 2 in diameter) over the bundle. 2WRENCHES
Note 1: make sure the threaded end of the torch sleeve is closest to the torch
Black plasma
gas hose
6. Connect the green and red coolant fittings to the corresponding colored hoses.
7. Slide the clear, 3 inch long, plastic tube over the blue shield gas hose before connecting it to the torch. Slide the
clear tube over the connection when the connection is tight.
Blue shield gas hose Clear plastic tube

8. Connect the cap sense lead and the plasma gas hose to the torch fittings.
Cap sense lead
Plasma gas hose
9. Install the pressure gauge included in this kit between the plasma gas line and the off-valve assembly.
Off-valve
connection
Plasma gas hose

connection
10. Screw the torch mounting sleeve onto the torch.

Torch mounting
sleeve

11. Verify gas pressures.

11a. Turn on the power to the system and turn on the gas supplies.
11b. Adjust the gas console settings for the chosen process using the cut charts in this document.
11c. Verify the gas pressure reading on the gauge between the plasma gas line and the off-valve assembly with
the table below.
Note: Recommended incoming gas (supply gas) pressures a re 120 psi for oxygen and nitrogen and 90 psi for air.
If the incoming gas pressures are not set correctly the back pressure reading will also be incorrect.
Test pressures
Current Process Preflow pressure Cutflow pressure Pressure while cutting
(at the off-valve) (at the off-valve) (at the off-valve)
Amps Gases psi bar psi bar psi bar
50 Air/Air 49.2 3.4 31.3 2.2 63.2 4.4
50 O2/Air 54.2 4.4 24.3 1.7 71 4.9
130 O2/Air 37.5 2.6 18.4 1.3 62.8 4.3
130 Air/Air 27 1.8 50 3.4 62.5 4.3
O2/Air
200 27 1.8 49 3.4 69 4.8
(copper electrode)
O2/Air
200 32 2.2 54 3.7 75 5.1
(SilverPlus electrode)
200 Air/Air 26 1.8 36 2.5 52 3.6
200 N2/Air 38.3 2.6 48.6 3.4 63.4 4.4
12. Verify that there are no leaks at any of the connections.

13. Remove the pressure gauge that was installed in step 9. and the installation is complete.

Daily start-up
Prior to start-up, ensure that your cutting environment and that your clothing meet the safety requirements outlined in the
Safety section of the system’s instruction manual.
Check torch
WARNING
Before operating this system, you must read the Safety section thoroughly! Turn OFF the power
supply’s main disconnect switch before proceeding with the following steps.
1. Turn OFF the main disconnect switch to the power supply.

2. 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.
• Refer to Install consumables on the next page for details.
• Refer to the Cut charts to choose the correct consumables for your cutting needs.
3. Replace consumable parts. Refer to Changing consumables later in this section for details.
4. Ensure that the torch is perpendicular to the workpiece.
Shield Nozzle Nozzle Swirl ring Electrode Water tube Torch

retaining cap

Install consumables
WARNING
Always disconnect power to the power supply before inspecting or changing torch consumable parts.
Use gloves when removing consumables. The torch might be hot.
Install consumables
Check the consumable parts daily for wear before cutting. Before removing consumables, bring the torch to the edge of
the cutting table, with the torch lifter raised to its highest point to prevent the consumables from dropping into the water
of the water table.
Note: Do not overtighten parts! Only tighten until mating parts are seated.
Apply a thin film of silicone lubricant on each o-ring. Wipe the internal and external surfaces of the
The o-ring should look shiny, but there should not be any torch with a clean cloth or paper towel.
excess or built-up grease.
Tool: 104119
1. Install the 2. Install the 3. Install the 4. Install the 5. Install the
electrode swirl ring nozzle and nozzle shield onto
into the into the swirl ring into retaining cap the nozzle
torch head nozzle the nozzle onto the torch retaining
retaining cap head cap

Arc voltage
The arc voltage settings (v) shown in the cut charts may need to be adjusted to produce the correct cutting height.
Physically measuring the height after stopping the torch is preferred, but visual inspection during a cut is acceptable.
Over the life of a consumable set it will also be necessary to periodically adjust the arc voltage (v) up 1 to 2 volts at a
time to maintain the proper torch height and to achieve the maximum life from the consumables.
Cut charts
The following Cut charts show the consumable parts, cutting speeds, gas pressures, and the current settings required
for each process.
The numbers shown in the Cut charts are recommended to provide high-quality cuts with minimal dross. Because of
differences between installations and material composition, adjustments may be required to obtain desired results.
Digital remote
Hypertherm has produced a few versions of the digital remote. Some versions increase and decrease in 10 amp
increments, and some increase and decrease in 20 amp increments. If you have a digital remote that increases/
decreases by 20 amps, set the digital remote to 120 amps or 140 amps for a 130 amp process. The system will
automatically choose the 130 amp process.

Estimated kerf width compensation

The widths in the chart below are for reference. Differences between installations and material composition may cause
actual results to vary from those shown in the tables.
Metric
Process Thickness (mm)
Mild steel 3 4 6 8 10 12 15 20 25 32 38 44 50
50A O2/Air 1.2 1.4 – – – – – – – – – – –
50A Air/Air 1.4 1.5 – – – – – – – – – – –
130A O2/Air 1.5 1.6 1.8 1.9 2.0 2.2 2.3 2.3 3.1 – – – –
130A Air/Air 1.3 – 1.6 – 1.9 2.1 2.4 2.7 3.2 – – – –
200A O2/Air – – 2.0 2.1 2.1 2.4 2.6 3.0 3.2 4.3 4.9 5.1 5.3
200A Air/Air – – 2.1 – 2.6 2.9 3.2 3.8 4.2 4.6 5.2 – 5.5
Stainless steel
50A Air/Air 1.5 1.5 – – – – – – – – – – –
200A N2/Air – – 3.2 3.2 3.2 3.3 3.3 3.4 3.5 3.6 3.7 3.9 –
Aluminum
50A Air/Air 1.5 1.5 – – – – – – – – – – –
200A N2/Air – – 3.8 3.9 3.9 4.0 4.1 4.3 4.4 4.6 4.8 5.0 –
English
Process Thickness (in.)
Mild steel 0.135 0.25 0.375 0.5 0.625 0.75 1.0 1.25 1.5 2.0
50A O2/Air 0.046 0.058 – – – – – – – –
50A Air/Air 0.058 0.060 – – – – – – – –
130A O2/Air 0.061 0.070 0.078 0.088 0.090 0.092 0.121 – – –
130A Air/Air 0.053 0.062 0.074 0.082 0.095 0.107 0.128 – – –
200A O2/Air – 0.081 0.082 0.095 0.105 0.117 0.127 0.171 0.195 0.210
200A Air/Air – 0.082 0.104 0.115 0.126 0.148 0.166 0.180 0.205 0.215
Stainless steel
50A Air/Air 0.059 0.060 – – – – – – – –
200A N2/Air – – 0.125 0.126 0.131 0.137 0.139 0.143 0.148 –
Aluminum
50A Air/Air 0.060 0.061 – – – – – – – –
200A N2/Air – – 0.154 0.158 0.162 0.166 0.174 0.180 0.198 –

Mild steel Flow rates – lpm/scfh

Air
Air Plasma / Air Shield Preflow 123 / 259
50 A Cutting Cutflow 114 / 241
220532 220936 220890 220529 220528

220935
(No IHS tab)
Metric
Test Preflow Test Cutflow Material
Flowrates Flowrates Arc Torch-to-Work Cutting Pierce Delay
Thickness Initial Pierce Height
Voltage Distance Speed Time
Preflow % Plasma % Shield (psi)
Air Air Air mm Volts mm mm/m mm factor % seconds
0.5 112 1.5 9400 3.0 200 0.0
0.8 111 1.5 8510 3.0 200 0.0
1.0 111 1.5 8050 3.0 200 0.1
1.2 107 1.8 7625 3.6 200 0.1
39 27 40
1.5 108 1.8 7370 3.6 200 0.1
2.0 108 1.8 6735 3.6 200 0.1
2.5 109 2.0 5080 4.0 200 0.2
3.0 112 2.0 3760 4.0 200 0.3
4.0 116 2.3 2415 4.6 200 0.4
6.0 120 2.5 1600 5.0 200 0.5
English
Test Preflow Test Cutflow
Flowrates Flowrates Material Arc Torch-to-Work Cutting Pierce Delay
Initial Pierce Height
Thickness Voltage Distance Speed Time
Air Air Air in Volts in ipm in factor % seconds
0.018 112 0.06 375 0.12 200 0.0
0.024 112 0.06 350 0.12 200 0.0
0.030 111 0.06 340 0.12 200 0.0
0.036 110 0.06 325 0.12 200 0.1
0.048 107 0.07 300 0.14 200 0.1
39 27 40 0.060
0.075
108
108
0.07
0.07
290
275
0.14
0.14
200
200
0.1
0.1
0.105 110 0.08 180 0.16 200 0.2
0.135 114 0.08 110 0.16 200 0.3
0.188 118 0.09 75 0.18 200 0.4
0.250 121 0.10 60 0.20 200 0.5


O2 N2 Air
O2 Plasma / Air Shield Preflow 2/4 19 / 40 73 / 155
50 A Cutting Cutflow 12 / 25 73 / 155
220532 220936 220891 220529 220528

220935
(No IHS tab)
Metric
O2 N2 O2 Air mm Volts mm mm/m mm factor % seconds
0.5 98 1.5 7550 3.0 200 0.0
0.8 98 1.5 7050 3.0 200 0.0
1.0 98 1.5 6775 3.0 200 0.1
1.2 98 1.5 6600 3.0 200 0.1
35 0 21 30
1.5 98 1.5 6150 3.0 200 0.1
2.0 98 1.5 5400 3.0 200 0.1
2.5 100 1.8 4300 3.6 200 0.2
3.0 102 1.8 3650 3.6 200 0.3
4.0 104 2.0 2800 4.0 200 0.4
6.0 108 2.5 1750 4.0 200 0.5
English
O2 N2 O2 Air in Volts in ipm in factor % seconds
0.018 98 0.06 300 0.12 200 0.0
0.024 98 0.06 290 0.12 200 0.0
0.030 98 0.06 280 0.12 200 0.0
0.036 98 0.06 270 0.12 200 0.1
0.048 98 0.06 260 0.12 200 0.1
35 0 21 30 0.060
0.075
98
98
0.06
0.06
240
220
0.12
0.12
200
200
0.1
0.1
0.105 100 0.07 160 0.14 200 0.2
0.135 103 0.07 130 0.14 200 0.3
0.188 106 0.09 85 0.18 200 0.4
0.250 108 0.10 65 0.20 200 0.5


O2 N2 Air
O2 Plasma / Air Shield Preflow 16 / 33 21 / 44 86 / 183
220491 220936 220893 220488 220487

220935
(No IHS tab)
Metric
3 128 2.6 5900 5.2 200 0.1
4 129 2.7 5325 5.4 200 0.2
6 129 2.8 3925 5.6 200 0.3
10 133 3.0 2680 6.0 200 0.4
25 30 34 35
12 135 3.0 2200 6.0 200 0.5
15 139 3.6 1665 7.2 200 0.7
20 141 3.9 1195 7.8 200 1.0
25 151 4.1 685 8.2 200 1.5
32 155 4.6 515
Edge Start
38 160 4.6 310
English
O2 N2 O2 Air gage in Volts in ipm in factor % seconds
10 – 128 0.10 240 0.20 200 0.1
– 3/16 129 0.11 190 0.22 200 0.2
– 1/4 129 0.11 150 0.22 200 0.3
– 3/8 133 0.12 110 0.24 200 0.3
25 30 34 35
– 1/2 135 0.12 80 0.24 200 0.5
– 5/8 140 0.15 60 0.30 200 0.7
– 3/4 141 0.15 50 0.30 200 1.0
– 1.0 151 0.16 25 0.32 200 1.5
– 1-1/4 155 0.18 20
Edge Start
– 1-1/2 160 0.18 12


Air Air
Air Plasma / Air Shield Preflow 26 / 56 68 / 145
220536 220936 220892 220488 220487

220935
(No IHS tab)
Metric
3 139 3.0 5350 6.0 200 0.1
4 137 3.0 4630 6.0 200 0.2
6 142 3.4 3865 6.8 200 0.3
10 148 4.1 2445 8.2 200 0.5
45 77 24 12
15
149
153
4.1
4.4
2045
1445
8.2
8.8
200
200
0.5
0.8
20 159 4.6 815 10.5 230 1.2
25 167 4.6 415
Edge Start
32 174 5.1 250
English
Air Air Air gage in Volts in ipm in factor % seconds
10 – 140 0.12 220 0.24 200 0.1
– 3/16 136 0.12 160 0.24 200 0.2
– 1/4 144 0.14 150 0.28 200 0.3
– 3/8 148 0.16 100 0.32 200 0.5
45 77 24 –
–
1/2
5/8
149
154
0.16
0.18
75
50
0.32
0.36
200
200
0.5
0.8
– 3/4 158 0.18 35 0.42 230 1.2
– 1.0 167 0.18 15
Edge Start
– 1-1/4 174 0.20 10


O2 N2 Air
Copper electrode
220832 220936 220831 220834 220937

220935
(No IHS tab)
Metric
6 145 1.5 6210 3.00 200 0.30
8 154 3.4 4850 5.10 150 0.35
10 160 4.6 3735 6.90 150 0.40
12 157 3.8 3415 9.50 250 0.60
15 156 3.1 2845 7.80 250 0.70
12 38 70 53 20
25
157
163
3.0
3.2
1920
1430
7.50
8.00
250
250
0.80
1.00
32 170 3.1 805 7.80 250 1.25
38 179 4.4 570 11.0 250 1.50
44 185 4.4 395
Edge Start
50 191 4.4 270
English
1/4 147 0.075 235 0.150 200 0.30
3/8 161 0.188 150 0.280 150 0.30
1/2 156 0.140 130 0.280 200 0.30
5/8 156 0.115 105 0.280 250 0.50
3/4 157 0.115 80 0.280 250 0.60
12 38 70 53 7/8
1.0
162
163
0.125
0.125
65
55
0.312
0.312
250
250
0.70
0.80
1-1/4 170 0.125 32 0.312 250 1.25
1-1/2 179 0.175 22 0.437 250 1.50
1-3/4 185 0.175 15
Edge Start
2.0 192 0.175 10


O2 N2 Air
SilverPlus electrode
220832 220936 220831 220834 220925

220935
(No IHS tab)
Metric
6 145 1.5 6210 3.00 200 0.30
8 154 3.4 4850 5.10 150 0.35
10 160 4.6 3735 6.90 150 0.40
12 157 3.8 3415 9.50 250 0.60
15 156 3.1 2845 7.80 250 0.70
12 38 77 53 20
25
158
163
3.0
3.2
1920
1430
7.50
8.00
250
250
0.80
1.00
32 170 3.1 805 7.80 250 1.25
38 179 4.4 565 11.0 250 1.50
44 185 4.4 395
Edge Start
50 191 4.4 270
English
O2 N2 O2 Air in Volts in in in factor % seconds
1/4 147 0.075 235 0.150 200 0.30
3/8 161 0.188 150 0.280 150 0.30
1/2 156 0.140 130 0.280 200 0.30
5/8 156 0.115 105 0.280 250 0.50
3/4 157 0.115 80 0.280 250 0.60
12 38 77 53 7/8
1.0
162
163
0.125
0.125
65
55
0.312
0.312
250
250
0.70
0.80
1-1/4 170 0.125 32 0.312 250 1.25
1-1/2 179 0.175 22 0.437 250 1.50
1-3/4 185 0.175 15
Edge Start
2.0 192 0.175 10


Air Air
220832 220936 220903 220488 220937

220935
(No IHS tab)
Metric
6 145 1.0 4885 3.0 300 0.3
8 149 1.3 4515 3.9 300 0.5
10 154 2.6 2975 5.2 200 0.8
12 156 3.0 2655 6.0 200 0.9
15 163 4.3 2265 8.6 200 1.0
45 57 44 20
25
167
176
4.8
6.4
1415
940
9.6
12.8
200
200
1.1
1.2
32 183 6.4 630 12.8 200 1.8
38 185 6.4 510
44 193 6.4 320 Edge Start
50 197 6.4 215
English
1/4 146 0.040 190 0.120 300 0.3
5/16 149 0.050 180 0.150 300 0.5
3/8 154 0.100 120 0.200 200 0.8
1/2 157 0.125 100 0.250 200 0.9
5/8 165 0.188 85 0.375 200 1.0
45 57 44
3/4 166 0.188 60 0.375 200 1.1
7/8 169 0.188 50 0.375 200 1.2
1.0 177 0.250 35 0.500 200 1.2
1-1/4 183 0.250 25 0.500 200 1.8
1-1/2 185 0.250 20
1-3/4 193 0.250 12 Edge Start
2.0 198 0.250 8

Mild steel – 3 inch under water Flow rates – lpm/scfh

O2 N2 Air
Copper electrode
220832 220936 220831 220834 220937

220935
(No IHS tab)
Metric
6 142 0.7 6235 1.4 200 0.3
10 166 3.8 3460 7.6 200 0.3
12 159 2.9 3060 5.8 200 0.3
12 38 70 53 15
20
159
163
2.8
3.0
2555
1700
5.6
7.5
200
250
0.5
0.6
22 164 3.2 1545 8.0 250 0.7
25 165 3.2 1300 8.0 250 0.8
English
1/4 145 0.040 235 0.080 200 0.3
3/8 168 0.157 140 0.312 200 0.3
1/2 157 0.100 115 0.200 200 0.3
12 38 70 53 5/8
3/4
160
163
0.115
0.115
95
70
0.230
0.290
200
250
0.5
0.6
7/8 164 0.125 60 0.312 250 0.7
1.0 165 0.125 50 0.312 250 0.8

Mild steel – 3 inch under water Flow rates – lpm/scfh

O2 N2 Air
SilverPlus electrode
220832 220936 220831 220834 220925

220935
(No IHS tab)
Metric
6 142 0.7 6235 1.4 200 0.3
10 166 3.8 3460 7.6 200 0.3
12 159 2.9 3060 5.8 200 0.3
12 38 77 53 15
20
159
163
2.8
3.0
2555
1700
5.6
7.5
200
250
0.5
0.6
22 164 3.2 1545 8.0 250 0.7
25 165 3.2 1300 8.0 250 0.8
English
1/4 145 0.040 235 0.080 200 0.3
3/8 168 0.157 140 0.312 200 0.3
1/2 157 0.100 115 0.200 200 0.3
12 38 77 53 5/8
3/4
160
163
0.115
0.115
95
70
0.230
0.290
200
250
0.5
0.6
7/8 164 0.125 60 0.312 250 0.7
1.0 165 0.125 50 0.312 250 0.8

Stainless steel Flow rates – lpm/scfh

Air
220532 220936 220890 220529 220528

220935
(No IHS tab)
Metric
0.5 103 1.5 7620 3.0 200 0.0
0.8 104 1.5 6730 3.0 200 0.0
1.0 104 1.5 6350 3.0 200 0.1
1.2 105 1.8 5715 3.6 200 0.1
39 27 40
1.5 108 1.8 4830 3.6 200 0.1
2.0 110 1.8 4190 3.6 200 0.1
2.5 113 2.0 3175 4.0 200 0.2
3.0 114 2.0 2160 4.0 200 0.3
4.0 118 2.3 1400 4.6 200 0.4
6.0 122 2.5 1145 5.0 200 0.5
English
0.018 103 0.06 300 0.12 200 0.0
0.024 103 0.06 275 0.12 200 0.0
0.030 104 0.06 265 0.12 200 0.0
0.036 104 0.06 250 0.12 200 0.1
0.048 105 0.07 225 0.14 200 0.1
39 27 40 0.060
0.075
108
109
0.07
0.07
190
165
0.14
0.14
200
200
0.1
0.1
0.105 114 0.08 125 0.16 200 0.2
0.135 115 0.08 85 0.16 200 0.3
0.188 121 0.09 55 0.18 200 0.4
0.250 122 0.10 45 0.20 200 0.5


Air Air
220536 220936 220892 220488 220487

220935
(No IHS tab)
Metric
6 142 3.5 2625 7.0 200 0.3
10 149 4.1 1700 8.2 200 0.5
45 77 24 12
15
152
160
4.1
4.4
1380
900
8.2 200 0.8
Edge Start
20 165 4.6 430
English
1/4 143 0.14 100 0.28 200 0.3
3/8 148 0.16 70 0.32 200 0.5
45 77 24 1/2
5/8
153
162
0.16
0.18
50
30
0.32 200 0.8
Edge Start
3/4 164 0.18 20


Air Air
220832 220936 220903 220488 220937

220935
(No IHS tab)
Metric
4 154 2.7 5695 5.4 200 0.40
6 157 3.0 3105 6.0 200 0.40
10 155 3.2 2485 6.4 200 0.50
12 157 3.2 2245 6.4 200 0.75
45 57 44 15
20
162
172
3.8
4.9
1700
1155
7.6
9.8
200
200
0.80
1.00
25 179 5.6 670
32 190 5.6 515 Edge Start
38 199 5.6 310
English
3/16 155 0.110 230 0.22 200 0.40
1/4 158 0.120 200 0.24 200 0.40
3/8 155 0.125 160 0.25 200 0.50
1/2 158 0.125 110 0.25 200 0.75
45 57 44
5/8 164 0.157 85 0.315 200 0.80
3/4 170 0.188 60 0.375 200 1.00
7/8 176 0.210 50 0.420 200 1.20
1.0 180 0.220 40
1-1/4 190 0.220 20 Edge Start
1-1/2 200 0.220 12


N2 Air
N2 Plasma / Air Shield
Preflow 26 / 56 123 / 220
220832 220936 220903 220529 020415

220935
(No IHS tab)
Metric
N2 Air Air mm Volts mm mm/m mm factor % seconds
5 159 3.0 3505 6.0 200 0.40
6 160 3.0 3355 6.0 200 0.40
10 161 3.0 2670 6.0 200 0.50
12 163 3.0 2210 6.0 200 0.75
45 55 44
15 170 4.0 1930 8.0 200 0.80
20 172 4.8 1180 9.6 200 1.00
22 178 4.8 1035 9.6 200 1.20
25 184 6.2 890 12.4 200 1.30
32 191 6.2 610
Edge Start
38 197 6.2 380
English
N2 Air Air in Volts in ipm in factor % seconds
3/16 159 0.125 230 0.25 200 0.40
1/4 160 0.125 200 0.25 200 0.40
3/8 161 0.125 160 0.25 200 0.50
1/2 163 0.125 110 0.25 200 0.75
45 55 44
5/8 170 0.157 75 0.315 200 0.80
3/4 172 0.188 60 0.375 200 1.00
7/8 178 0.188 40 0.375 200 1.20
1.0 184 0.250 35 0.50 200 1.30
1-1/4 191 0.250 25
Edge Start
1-1/2 197 0.250 15

Aluminum Flow rates – lpm/scfh

Air
220532 220936 220890 220529 220528

220935
(No IHS tab)
Metric
0.5 110 1.5 8000 3.0 200 0.0
0.8 111 1.6 7750 3.2 200 0.0
1.0 112 1.8 7115 3.6 200 0.1
1.2 112 1.8 6350 3.6 200 0.1
39 27 40
1.5 113 1.8 5335 3.6 200 0.1
2.0 118 2.0 4200 4.0 200 0.1
2.5 121 2.0 3300 4.0 200 0.2
3.0 122 2.0 2800 4.0 200 0.3
4.0 123 2.2 2300 4.4 200 0.4
6.0 128 2.5 1400 5.0 200 0.5
English
0.018 110 0.06 325 0.12 200 0.0
0.020 110 0.06 315 0.12 200 0.0
0.024 110 0.06 305 0.12 200 0.0
0.030 111 0.06 295 0.12 200 0.1
0.036 112 0.07 280 0.14 200 0.1
39 27 40
0.048 112 0.07 230 0.14 200 0.2
0.060 113 0.07 195 0.14 200 0.2
0.075 118 0.08 160 0.16 200 0.2
0.105 121 0.08 120 0.16 200 0.3
0.125 122 0.08 100 0.16 200 0.3
3/16 124 0.09 75 0.18 200 0.4
1/4 129 0.10 50 0.20 200 0.5


Air Air
220536 220936 220892 220488 220487

220935
(No IHS tab)
Metric
6 152 2.8 2370 5.6 200 0.2
10 155 3.0 1470 6.0 200 0.3
45 77 24
12 157 3.0 1230 6.0 200 0.5
15 161 3.2 1050 6.4 200 0.8
20 164 3.6 725 7.9 220 1.3
25 172 4.0 525 Edge Start
English
1/4 152 0.11 90 0.22 200 0.2
3/8 155 0.12 60 0.24 200 0.3
45 77 24
1/2 157 0.12 45 0.24 200 0.5
5/8 162 0.13 40 0.26 200 0.8
3/4 163 0.14 30 0.31 220 1.3
1.0 173 0.16 20 Edge Start


Air Air
220832 220936 220903 220488 220937

220935
(No IHS tab)
Metric
4 155 2.2 6215 4.4 200 0.5
6 158 3.0 5195 6.0 200 0.5
10 159 3.3 3930 6.6 200 0.5
12 160 3.7 3370 7.4 200 0.5
45 57 44 15
20
156
165
4.0
4.9
2625
1625
8.0
9.8
200
200
0.8
1.0
25 175 5.6 1050
32 184 5.6 515 Edge Start
38 185 5.6 310
English
3/16 155 0.100 230 0.200 200 0.50
1/4 158 0.125 200 0.250 200 0.50
3/8 160 0.125 160 0.250 200 0.50
1/2 165 0.150 125 0.300 200 0.50
45 57 44 5/8
3/4
168
172
0.160
0.188
95
70
0.320
0.375
200
200
0.80
1.00
7/8 176 0.210 50 0.420 200 1.20
1.0 180 0.220 40
1-1/4 190 0.220 20 Edge Start
1-1/2 200 0.220 12


N2 Air
N2 Plasma / Air Shield
Preflow 26 / 56 123 / 220
220832 220936 220903 220529 020415

220935
(No IHS tab)
Metric
N2 Air Air mm Volts mm mm/m mm factor % seconds
5 168 2.2 4750 4.4 200 0.5
6 169 3.0 4345 6.0 200 0.5
10 175 3.3 3050 6.6 200 0.5
12 177 3.7 2490 7.4 200 0.5
45 55 44
15 180 4.0 2010 8.0 200 0.8
20 186 4.9 1450 9.8 200 1.0
22 190 5.6 1295 11.2 200 1.2
25 196 5.6 1040
32 206 5.6 740 Edge Start
38 210 5.6 510
English
N2 Air Air in Volts in ipm in factor % seconds
3/16 168 0.125 190 0.25 200 0.5
1/4 169 0.125 200 0.25 200 0.5
3/8 175 0.125 160 0.25 200 0.5
1/2 178 0.125 125 0.25 200 0.5
45 55 44
5/8 181 0.157 95 0.314 200 0.8
3/4 185 0.188 70 0.376 200 1.0
7/8 190 0.250 50 0.50 200 1.2
1.0 196 0.250 40
1-1/4 206 0.250 20 Edge Start
1-1/2 210 0.250 12


© 2011 Hypertherm, Inc.
All Rights Reserved
Hypertherm, HT2000, and HyPro are trademarks of Hypertherm, Inc. and may be registered in the United States and/or other countries.
hypertherm, inc. hypertherm (india) thermal

Hanover, NH 03755 USA cutting pvt. ltd.
603-643-3441 Tel Chennai, Tamil Nadu
91 0 44 2834 5361 Tel
hypertherm europe B.V.
4704 SE Roosendaal, Nederland hypertherm Brasil ltda.
31 165 596907 Tel Guarulhos, SP - Brasil
55 11 2409 2636 Tel
hypertherm (Shanghai)
trading co., ltd. hypertherm México, S.a. de c.V.
PR China 200052 México, D.F.
86-21 5258 3330 /1 Tel 52 55 5681 8109 Tel
hypertherm (S) pte ltd. hypertherm Korea Branch
Singapore 349567 Korea, 612-889
65 6 841 2489 Tel 82 51 747 0358 Tel
www.hypertherm.com

HT 2000

Uploaded by

Copyright:

Available Formats

HT 2000

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

HT 2000

Uploaded by

Copyright:

Available Formats

HyPro2000 ™ Straight Torch

HT2000 Torch Upgrade for Punch

Field Service Bulletin

Disconnect electrical power before performing any maintenance.

HT2000 control PCB

Field Service Bulletin 1

Kit - 228778 Contents (PCB included)

Kit - 228777 Contents (PCB not included)

2 Field Service Bulletin

Inspect the gas console as described below:

N2/Air PLASMA O2 N2/Air PLASMA O2

Test Test Test Test

If there is a toggle switch for the If it has a knob to adjust the

Field Service Bulletin 3

Installation of the firmware chip

Older board Newer board

Look for this

4 Field Service Bulletin

If you are installing a new control board skip to step 4

Angled corner Bevel

Field Service Bulletin 5

Installation of the new control board

Wires (blue and white)

6 Field Service Bulletin

7. Replace the 2 front panels and continue to torch installation.

Field Service Bulletin 7

Blue shield gas hose Clear plastic tube

8 Field Service Bulletin

Cap sense lead

Plasma gas hose

Plasma gas hose

10. Screw the torch mounting sleeve onto the torch.

Field Service Bulletin 9

11. Verify gas pressures.

12. Verify that there are no leaks at any of the connections.

10 Field Service Bulletin

1. Turn OFF the main disconnect switch to the power supply.

Shield Nozzle Nozzle Swirl ring Electrode Water tube Torch

Field Service Bulletin 11

12 Field Service Bulletin

Field Service Bulletin 13

Estimated kerf width compensation

14 Field Service Bulletin

Mild steel Flow rates – lpm/scfh

220532 220936 220890 220529 220528

Field Service Bulletin 15

Mild steel Flow rates – lpm/scfh

220532 220936 220891 220529 220528

16 Field Service Bulletin

Mild steel Flow rates – lpm/scfh

220491 220936 220893 220488 220487

Field Service Bulletin 17

Mild steel Flow rates – lpm/scfh

220536 220936 220892 220488 220487

18 Field Service Bulletin

Mild steel Flow rates – lpm/scfh

220832 220936 220831 220834 220937

Field Service Bulletin 19

Mild steel Flow rates – lpm/scfh

7. Replace the 2 front panels and continue to torch installation.

10. Screw the torch mounting sleeve onto the torch.

11. Verify gas pressures.

12. Verify that there are no leaks at any of the connections.

1. Turn OFF the main disconnect switch to the power supply.