HySpeed Plasma

HSD130
™

Remote High Frequency (RHF)

Instruction Manual
805510 – Revision 1
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 HySpeed HSD130
Remote High Frequency (RHF)

Instruction Manual

(P/N 805510)

Revision 1 – April, 2011

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

© Copyright 2011 Hypertherm, Inc.

All Rights Reserved

Hypertherm, HySpeed, and HSD130 are trademarks of Hypertherm, Inc.

and may be registered in the United States and/or other countries
Hypertherm, Inc. Hypertherm Europe B.V.
Etna Road, P.O. Box 5010 Vaartveld 9
Hanover, NH 03755 USA 4704 SE
603-643-3441 Tel (Main Office) Roosendaal, Nederland
603-643-5352 Fax (All Departments) 31 165 596907 Tel
[email protected] (Main Office Email) 31 165 596901 Fax
800-643-9878 Tel (Technical Service) 31 165 596908 Tel (Marketing)
[email protected] (Technical Service Email) 31 165 596900 Tel (Technical Service)
800-737-2978 Tel (Customer Service) 00 800 4973 7843 Tel (Technical Service)
[email protected] (Customer Service Email)
Hypertherm Japan Ltd.
Hypertherm Automation Level 9, Edobori Center Building
5 Technology Drive, Suite 300 2-1-1 Edobori, Nishi-ku
West Lebanon, NH 03784 USA Osaka 550-0002 Japan
603-298-7970 Tel 81 6 6225 1183 Tel
603-298-7977 Fax 81 6 6225 1184 Fax

Hypertherm Plasmatechnik GmbH Hypertherm Brasil Ltda.

Technologiepark Hanau Avenida Doutor Renato de
Rodenbacher Chaussee 6 Andrade Maia 350
D-63457 Hanau-Wolfgang, Deutschland Parque Renato Maia
49 6181 58 2100 Tel CEP 07114-000
49 6181 58 2134 Fax Guarulhos, SP Brasil
49 6181 58 2123 (Technical Service) 55 11 2409 2636 Tel
55 11 2408 0462 Fax
Hypertherm (S) Pte Ltd.
82 Genting Lane Hypertherm México, S.A. de C.V.
Media Centre Avenida Toluca No. 444, Anexo 1,
Annexe Block #A01-01 Colonia Olivar de los Padres
Singapore 349567, Republic of Singapore Delegación Álvaro Obregón
65 6841 2489 Tel México, D.F. C.P. 01780
65 6841 2490 Fax 52 55 5681 8109 Tel
65 6841 2489 (Technical Service) 52 55 5683 2127 Fax

Hypertherm (Shanghai) Trading Co., Ltd. Hypertherm Korea Branch

Unit A, 5th Floor, Careri Building #3904 Centum Leaders Mark B/D,
432 West Huai Hai Road 1514 Woo-dong, Haeundae-gu, Busan
Shanghai, 200052 Korea, 612-889
PR China 82 51 747 0358 Tel
86-21 5258 3330/1 Tel 82 51 701 0358 Fax
86-21 5258 3332 Fax

03/08/11
 ELECTROMAGNETIC COMPATIBILITY (EMC)

Introduction a. Other supply cables, control cables, signaling and

telephone cables; above, below and adjacent to the
Hypertherm’s CE-marked equipment is built in cutting equipment.
compliance with standard EN60974-10. The equipment
should be installed and used in accordance with b. Radio and television transmitters and receivers.
the information below to achieve electromagnetic
compatibility. c. Computer and other control equipment.

The limits required by EN60974-10 may not be d. Safety critical equipment, for example guarding of
adequate to completely eliminate interference when the industrial equipment.
affected equipment is in close proximity or has a high
degree of sensitivity. In such cases it may be necessary e. Health of the people around, for example the use of
to use other measures to further reduce interference. pacemakers and hearing aids.

This cutting equipment is designed for use only in an f. Equipment used for calibration or measurement.
industrial environment.
g. Immunity of other equipment in the environment. User
Installation and use shall ensure that other equipment being used in the
environment is compatible. This may require additional
The user is responsible for installing and using the protection measures.
plasma equipment according to the manufacturer’s
instructions. h. Time of day that cutting or other activities are to be
carried out.
If electromagnetic disturbances are detected then it shall
be the responsibility of the user to resolve the situation The size of the surrounding area to be considered
with the technical assistance of the manufacturer. In will depend on the structure of the building and other
some cases this remedial action may be as simple activities that are taking place. The surrounding area
as earthing the cutting circuit, see Earthing of the may extend beyond the boundaries of the premises.
work piece. In other cases, it could involve constructing
an electromagnetic screen enclosing the power source
and the work complete with associated input filters. In all Methods of reducing emissions
cases, electromagnetic disturbances must be reduced to Mains supply
the point where they are no longer troublesome.
Cutting equipment must be connected to the
mains supply according to the manufacturer’s
Assessment of area recommendations. If interference occurs, it may be
Before installing the equipment, the user shall make an necessary to take additional precautions such as filtering
assessment of potential electromagnetic problems in of the mains supply.
the surrounding area. The following shall be taken into
account:

Compliance Information EMC-1

7/10
ELECTROMAGNETIC COMPATIBILITY

Consideration should be given to shielding the supply Earthing of the workpiece

cable of permanently installed cutting equipment,
in metallic conduit or equivalent. Shielding should Where the workpiece is not bonded to earth for
be electrically continuous throughout its length. The electrical safety, nor connected to earth because of its
shielding should be connected to the cutting mains size and position, for example, ship’s hull or building
supply so that good electrical contact is maintained steel work, a connection bonding the workpiece to earth
between the conduit and the cutting power source may reduce emissions in some, but not all instances.
enclosure. Care should be taken to prevent the earthing of the
workpiece increasing the risk of injury to users, or
damage to other electrical equipment. Where necessary,
Maintenance of cutting equipment the connection of the workpiece to earth should be
The cutting equipment must be routinely maintained made by a direct connection to the workpiece, but
according to the manufacturer’s recommendations. All in some countries where direct connection is not
access and service doors and covers should be closed permitted, the bonding should be achieved by suitable
and properly fastened when the cutting equipment is in capacitances selected according to national regulations.
operation. The cutting equipment should not be modified
in any way, except as set forth in and in accordance with Note: The cutting circuit may or may not be earthed for
the manufacturer’s written instructions. For example, safety reasons. Changing the earthing arrangements
the spark gaps of arc striking and stabilizing devices should only be authorized by a person who is competent
should be adjusted and maintained according to the to assess whether the changes will in crease the risk of
manufacturer’s recommendations. injury, for example, by allowing parallel cutting current
return paths which may damage the earth circuits of
other equipment. Further guidance is provided in
Cutting cables IEC 60974-9, Arc Welding Equipment, Part 9:
The cutting cables should be kept as short as possible Installation and Use.
and should be positioned close together, running at or
close to the floor level. Screening and shielding
Selective screening and shielding of other cables
Equipotential bonding and equipment in the surrounding area may alleviate
Bonding of all metallic components in the cutting problems of interference. Screening of the entire plasma
installation and adjacent to it should be considered. cutting installation may be considered for special
applications.
However, metallic components bonded to the workpiece
will increase the risk that the operator could receive a
shock by touching these metallic components and the
electrode (nozzle for laser heads) at the same time.

The operator should be insulated from all such bonded

metallic components.

EMC-2 Compliance Information

7/10
 WARRANTY

Attention Hypertherm provides repair, replacement or adjustment

of the Product as the sole and exclusive remedy, if
Genuine Hypertherm parts are the factory- and only if the warranty set forth herein properly is
recommended replacement parts for your Hypertherm invoked and applies. Hypertherm, at its sole option,
system. Any damage or injury caused by the use of other shall repair, replace, or adjust, free of charge, any
than genuine Hypertherm parts may not be covered by defective Products covered by this warranty which
the Hypertherm warranty, and will constitute misuse of shall be returned with Hypertherm’s prior authorization
the Hypertherm Product. (which shall not be unreasonably withheld), properly
packed, to Hypertherm’s place of business in Hanover,
You are solely responsible for the safe use of the New Hampshire, or to an authorized Hypertherm repair
Product. Hypertherm does not and cannot make any facility, all costs, insurance and freight pre paid by the
guarantee or warranty regarding the safe use of the customer. Hypertherm shall not be liable for any repairs,
product in your environment. replacement, or adjustments of Products covered by this
warranty, except those made pursuant to this paragraph
General and with Hypertherm’s prior written consent.
Hypertherm, Inc. warrants that its Products shall be The warranty set forth above is exclusive and is in
free from defects in materials and workmanship for the lieu of all other warranties, express, implied, statutory,
specific periods of time set forth herein and as follows: or otherwise with respect to the Products or as to
if Hypertherm is notified of a defect (i) with respect to the results which may be obtained therefrom, and
the power supply within a period of two (2) years from all implied warranties or conditions of quality or of
the date of its delivery to you, with the exception of merchantability or fitness for a particular purpose or
Powermax brand power supplies, which shall be within against infringement. The foregoing shall constitute the
a period of three (3) years from the date of delivery to sole and exclusive remedy for any breach by Hypertherm
you, and (ii) with respect to the torch and leads within of its warranty.
a period of one (1) year from its date of delivery to you,
and with respect to torch lifter assemblies within a Distributors/OEMs may offer different or additional
period of one (1) year from its date of delivery to you, warranties, but Distributors/OEMs are not authorized to
and with respect to laser heads within a period of one give any additional warranty protection to you or make
(1) year from its date of delivery to you, and with respect any representation to you purporting to be binding upon
to Automation products one (1) year from its date of Hypertherm.
delivery to you, with the exception of the EDGE Pro
CNC and ArcGlide THC, which shall be within a period
of two (2) years from the date of delivery to you.

This warranty shall not apply to any Powermax brand

power supplies that have been used with phase
converters. In addition, Hypertherm does not warranty
systems that have been damaged as a result of poor
power quality, whether from phase converters or
incoming line power. This warranty shall not apply to any
Product which has been incorrectly installed, modified,
or otherwise damaged.

Compliance Information W-1

9/10
ELECTROMAGNETIC COMPATIBILITY

Consideration should be given to shielding the supply Earthing of the workpiece

cable of permanently installed cutting equipment,
in metallic conduit or equivalent. Shielding should Where the workpiece is not bonded to earth for
be electrically continuous throughout its length. The electrical safety, nor connected to earth because of its
shielding should be connected to the cutting mains size and position, for example, ship’s hull or building
supply so that good electrical contact is maintained steel work, a connection bonding the workpiece to earth
between the conduit and the cutting power source may reduce emissions in some, but not all instances.
enclosure. Care should be taken to prevent the earthing of the
workpiece increasing the risk of injury to users, or
damage to other electrical equipment. Where necessary,
Maintenance of cutting equipment the connection of the workpiece to earth should be
The cutting equipment must be routinely maintained made by a direct connection to the workpiece, but
according to the manufacturer’s recommendations. All in some countries where direct connection is not
access and service doors and covers should be closed permitted, the bonding should be achieved by suitable
and properly fastened when the cutting equipment is in capacitances selected according to national regulations.
operation. The cutting equipment should not be modified
in any way, except as set forth in and in accordance with Note: The cutting circuit may or may not be earthed for
the manufacturer’s written instructions. For example, safety reasons. Changing the earthing arrangements
the spark gaps of arc striking and stabilizing devices should only be authorized by a person who is competent
should be adjusted and maintained according to the to assess whether the changes will in crease the risk of
manufacturer’s recommendations. injury, for example, by allowing parallel cutting current
return paths which may damage the earth circuits of
other equipment. Further guidance is provided in
Cutting cables IEC 60974-9, Arc Welding Equipment, Part 9:
The cutting cables should be kept as short as possible Installation and Use.
and should be positioned close together, running at or
close to the floor level. Screening and shielding
Selective screening and shielding of other cables
Equipotential bonding and equipment in the surrounding area may alleviate
Bonding of all metallic components in the cutting problems of interference. Screening of the entire plasma
installation and adjacent to it should be considered. cutting installation may be considered for special
applications.
However, metallic components bonded to the workpiece
will increase the risk that the operator could receive a
shock by touching these metallic components and the
electrode (nozzle for laser heads) at the same time.

The operator should be insulated from all such bonded

metallic components.

EMC-2 Compliance Information

7/10
 Table of Contents

Electromagnetic compatibility (EMC)..............................................................................................................................................EMC-1

Warranty.....................................................................................................................................................................................................W-1

Section 1   Safety.................................................................................................................................................................1-1

Recognize safety information...................................................................................................................................................................1-2
Follow safety instructions..........................................................................................................................................................................1-2
Electrical hazards........................................................................................................................................................................................1-2
Electric shock can kill.................................................................................................................................................................................1-3
Cutting can cause fire or explosion........................................................................................................................................................1-4
Toxic fumes can cause injury or death...................................................................................................................................................1-5
Grounding safety........................................................................................................................................................................................1-6
Static electricity can damage circuit boards........................................................................................................................................1-6
Compressed gas equipment safety........................................................................................................................................................1-6
Gas cylinders can explode if damaged..................................................................................................................................................1-6
A plasma arc can cause injury and burns..............................................................................................................................................1-7
Arc rays can burn eyes and skin..............................................................................................................................................................1-7
Pacemaker and hearing aid operation...................................................................................................................................................1-8
Noise can damage hearing.......................................................................................................................................................................1-8
A plasma arc can damage frozen pipes................................................................................................................................................1-8
Dry dust collection information................................................................................................................................................................1-9
Laser radiation.......................................................................................................................................................................................... 1-10
Symbols and marks................................................................................................................................................................................. 1-11
Additional safety information................................................................................................................................................................. 1-11
Warning labels.......................................................................................................................................................................................... 1-12

Section 1a   Sécurité....................................................................................................................................................... 1a-1

Identifier les consignes de sécurité..................................................................................................................................................... 1a-2
Suivre les instructions de sécurité....................................................................................................................................................... 1a-2
Risques électriques................................................................................................................................................................................. 1a-2
Les chocs électriques peuvent être fatals.......................................................................................................................................... 1a-3
Le coupage peut provoquer un incendie ou une explosion........................................................................................................... 1a-4
Les vapeurs toxiques peuvent provoquer des blessures ou la mort............................................................................................ 1a-5
Mise à la masse et à la terre.................................................................................................................................................................. 1a-6
L’électricité statique peut endommager les cartes de circuits imprimés.................................................................................... 1a-6
Sécurité des bouteilles de gaz comprimé.......................................................................................................................................... 1a-6
Les bouteilles de gaz comprimé peuvent exploser en cas de dommages................................................................................. 1a-6
L’arc plasma peut provoquer des blessures ou des brûlures........................................................................................................ 1a-7
Les rayons de l’arc peuvent brûler les yeux et la peau.................................................................................................................... 1a-7
Pacemakers et prothèses auditives..................................................................................................................................................... 1a-8
Le bruit peut provoquer des problèmes auditifs............................................................................................................................... 1a-8
Un arc plasma peut endommager les tuyaux gelés......................................................................................................................... 1a-8
Information sur le dépoussièrage......................................................................................................................................................... 1a-9
Radiation au laser..................................................................................................................................................................................1a-10
Symboles et marquage.........................................................................................................................................................................1a-11
Étiquettes de sécurité...........................................................................................................................................................................1a-12

HySpeed HSD130 RHF Instruction Manual i

Table of Contents

Section 1b   Seguridad................................................................................................................................................... 1b-1

Reconocimiento de información de seguridad................................................................................................................................. 1b-2
Cumplimiento de instrucciones de seguridad.................................................................................................................................. 1b-2
Riesgos de electrocución...................................................................................................................................................................... 1b-2
Las descargas eléctricas pueden matar............................................................................................................................................. 1b-3
Los cortes pueden producir incendios o explosiones..................................................................................................................... 1b-4
Los vapores tóxicos pueden producir lesiones o la muerte........................................................................................................... 1b-5
Seguridad de toma a tierra.................................................................................................................................................................... 1b-6
La electricidad estática puede dañar las placas de circuitos........................................................................................................ 1b-6
Seguridad de equipos de gas comprimido....................................................................................................................................... 1b-6
Los cilindros de gas pueden explotar si están dañados................................................................................................................. 1b-6
El arco de plasma puede producir lesiones y quemaduras........................................................................................................... 1b-7
Los rayos del arco pueden quemar los ojos y la piel....................................................................................................................... 1b-7
Funcionamiento de marcapasos y audífonos.................................................................................................................................... 1b-8
Los ruidos pueden dañar la audición.................................................................................................................................................. 1b-8
El arco de plasma puede dañar las tuberías congeladas............................................................................................................... 1b-8
Información acerca de la recolección de polvo seco...................................................................................................................... 1b-9
Radiación láser.......................................................................................................................................................................................1b-10
Símbolos y marcas................................................................................................................................................................................1b-11
Etiquetas de advertencia......................................................................................................................................................................1b-12

Section 2   Specifications..............................................................................................................................................2-1

System description.....................................................................................................................................................................................2-2
General...............................................................................................................................................................................................2-2
Power supply ...................................................................................................................................................................................2-2
Ignition console.................................................................................................................................................................................2-2
Fuel-gas console..............................................................................................................................................................................2-2
Off-valve.............................................................................................................................................................................................2-2
Torch...................................................................................................................................................................................................2-2
System diagram 1 — without a fuel gas console......................................................................................................................2-3
System diagram 2 — with a fuel-gas console...........................................................................................................................2-4
Specifications..............................................................................................................................................................................................2-5
System gas requirements...............................................................................................................................................................2-5
Noise levels........................................................................................................................................................................................2-6
Power supply.....................................................................................................................................................................................2-7
Fuel gas console — 078201.........................................................................................................................................................2-8
Ignition console — 078172...........................................................................................................................................................2-9
Standard off-valve — 229105.................................................................................................................................................... 2-10
Fuel-gas off-valve — 229130..................................................................................................................................................... 2-11
Torch – 228144............................................................................................................................................................................ 2-12

Section 3   Installation....................................................................................................................................................3-1

Upon receipt................................................................................................................................................................................................3-3
Claims............................................................................................................................................................................................................3-3
Installation requirements...........................................................................................................................................................................3-3
Placement of system components..........................................................................................................................................................3-3
Torque specifications......................................................................................................................................................................3-3

ii HySpeed HSD130 RHF Instruction Manual

 Table of Contents

Installation requirements  –  standard system......................................................................................................................................3-4

System components........................................................................................................................................................................3-5
Cables and hoses............................................................................................................................................................................3-5
Customer-supplied power cable..................................................................................................................................................3-5
Supply gas hoses.............................................................................................................................................................................3-5
Installation requirements — system with optional fuel gas console................................................................................................3-6
System components........................................................................................................................................................................3-7
Cables and hoses............................................................................................................................................................................3-7
Customer-supplied power cable..................................................................................................................................................3-7
Supply gas hoses.............................................................................................................................................................................3-7
System integration diagram......................................................................................................................................................................3-8
Components......................................................................................................................................................................................3-9
Recommended grounding and shielding practices......................................................................................................................... 3-10
Introduction............................................................................................................................................................................................... 3-10
Types of grounding....................................................................................................................................................................... 3-10
Steps to take.................................................................................................................................................................................. 3-11
Grounding diagram....................................................................................................................................................................... 3-14
Placement of the power supply............................................................................................................................................................ 3-15
Install the ignition console...................................................................................................................................................................... 3-16
Install the off-valve................................................................................................................................................................................... 3-18
Torch mounting and alignment............................................................................................................................................................. 3-19
Mounting the torch........................................................................................................................................................................ 3-19
Torch alignment............................................................................................................................................................................. 3-19
Torch lifter requirement................................................................................................................................................................ 3-19
Install the fuel-gas console (optional component)........................................................................................................................... 3-20
Cable and hose assembly from power supply to off-valve............................................................................................................ 3-21
Power supply to off-valve connections.................................................................................................................................... 3-22
Fuel-gas console to off-valve connections........................................................................................................................................ 3-23
Fuel-gas console to power supply connections............................................................................................................................... 3-24
Power supply to ignition console leads.............................................................................................................................................. 3-26
Ignition console power cable...................................................................................................................................................... 3-28
Ignition console coolant hoses................................................................................................................................................... 3-29
Torch lead assembly............................................................................................................................................................................... 3-30
Connect the torch to the torch lead assembly....................................................................................................................... 3-31
Work lead.................................................................................................................................................................................................. 3-34
Arc voltage connection........................................................................................................................................................................... 3-35
Power supply to CNC interface cable................................................................................................................................................ 3-36
Notes to CNC interface cable run list...................................................................................................................................... 3-37
Examples of output circuits......................................................................................................................................................... 3-38
Examples of input circuits............................................................................................................................................................ 3-40
Power requirements................................................................................................................................................................................ 3-41
General............................................................................................................................................................................................ 3-41
Line disconnect switch................................................................................................................................................................ 3-42
Power cable.................................................................................................................................................................................... 3-42
Connect the power.................................................................................................................................................................................. 3-43
Torch coolant requirements................................................................................................................................................................... 3-44

HySpeed HSD130 RHF Instruction Manual iii

Table of Contents

Premixed coolant for standard operating temperatures....................................................................................................... 3-44

Custom coolant mix for cold operating temperatures........................................................................................................... 3-45
Custom coolant mix hot operating temperatures................................................................................................................... 3-46
Water purity requirements........................................................................................................................................................... 3-46
Fill the power supply with coolant........................................................................................................................................................ 3-47
Gas requirements.................................................................................................................................................................................... 3-48
Setting the supply regulators...................................................................................................................................................... 3-48
Gas regulators............................................................................................................................................................................... 3-49
Supply gas plumbing.............................................................................................................................................................................. 3-50
Connect the supply gases..................................................................................................................................................................... 3-51
Standard system............................................................................................................................................................................ 3-51
Fuel-gas system............................................................................................................................................................................. 3-51
Supply gas hoses.................................................................................................................................................................................... 3-52

Section 4   operation.........................................................................................................................................................4-1

Controls and indicators.............................................................................................................................................................................4-2
Main power switch . ........................................................................................................................................................................4-2
Daily start-up................................................................................................................................................................................................4-3
Check torch.......................................................................................................................................................................................4-3
System operation........................................................................................................................................................................................4-4
Amps display.....................................................................................................................................................................................4-4
Fuel-gas console operation......................................................................................................................................................................4-5
Consumable selection...............................................................................................................................................................................4-6
Mild steel............................................................................................................................................................................................4-6
Stainless steel...................................................................................................................................................................................4-6
Aluminum............................................................................................................................................................................................4-7
IInstall and Inspect consumables............................................................................................................................................................4-8
Torch maintenance.................................................................................................................................................................................. 4-10
Torch connections......................................................................................................................................................................... 4-10
Replace torch water tube....................................................................................................................................................................... 4-11
Common cutting faults........................................................................................................................................................................... 4-12
How to optimize cut quality................................................................................................................................................................... 4-13
Tips for table and torch................................................................................................................................................................ 4-13
Plasma set-up tips........................................................................................................................................................................ 4-13
Maximize the life of consumable parts...................................................................................................................................... 4-13
Additional factors of cut quality.................................................................................................................................................. 4-14
Additional improvements............................................................................................................................................................. 4-15
Estimated kerf width compensation.................................................................................................................................................... 4-16
Cut charts.................................................................................................................................................................................................. 4-18

Section 5   maintenance...................................................................................................................................................5-1

Introduction..................................................................................................................................................................................................5-3
Routine maintenance.................................................................................................................................................................................5-3
System description.....................................................................................................................................................................................5-4
Control and signal cables...............................................................................................................................................................5-4
Sequence of operation..............................................................................................................................................................................5-5
Gas system purge cycle............................................................................................................................................................................5-6

iv HySpeed HSD130 RHF Instruction Manual

 Table of Contents

Gas system valve usage............................................................................................................................................................................5-6

Systems without a fuel-gas console............................................................................................................................................5-6
Systems with a fuel-gas console..................................................................................................................................................5-7
PCB block diagram....................................................................................................................................................................................5-8
Error codes...................................................................................................................................................................................................5-9
Error code troubleshooting – Error codes 000 to 024........................................................................................................ 5-10
Error code troubleshooting – Error codes 026 to 042........................................................................................................ 5-11
Error code troubleshooting – Error codes 043 to 047........................................................................................................ 5-12
Error code troubleshooting – Error codes 050 to 063........................................................................................................ 5-13
Error code troubleshooting – Error codes 065 to 075........................................................................................................ 5-14
Error code troubleshooting – Error codes 093 to 103........................................................................................................ 5-15
Error code troubleshooting – Error codes 195 to 116........................................................................................................ 5-16
Error code troubleshooting – Error codes 134 to 157........................................................................................................ 5-17
Power supply states................................................................................................................................................................................ 5-18
Plasma system operation with pump timeout.................................................................................................................................... 5-19
CNC operation with pump timeout...................................................................................................................................................... 5-20
Initial checks.............................................................................................................................................................................................. 5-21
Automated diagnostic tests................................................................................................................................................................... 5-22
Power measurement............................................................................................................................................................................... 5-23
Power supply coolant system servicing.............................................................................................................................................. 5-24
Draining the coolant system........................................................................................................................................................ 5-24
Coolant system filter replacement....................................................................................................................................................... 5-25
Air filter replacement............................................................................................................................................................................... 5-26
Coolant flow test procedure.................................................................................................................................................................. 5-27
Testing the flow switch................................................................................................................................................................ 5-28
Gas leak test procedure......................................................................................................................................................................... 5-29
PCB4: Power supply control board.................................................................................................................................................... 5-30
PCB3: Power supply power distribution board................................................................................................................................ 5-31
PCB2: Start circuit.................................................................................................................................................................................. 5-32
Operation........................................................................................................................................................................................ 5-32
Start-circuit functional schematic.............................................................................................................................................. 5-32
Start-circuit troubleshooting....................................................................................................................................................... 5-32
Pilot arc current levels.................................................................................................................................................................. 5-34
PCB2: Fuel-gas console control board.............................................................................................................................................. 5-35
PCB1: Fuel-gas console power distribution board......................................................................................................................... 5-36
PCB3: Fuel-gas console AC valve-driver board.............................................................................................................................. 5-37
Chopper tests........................................................................................................................................................................................... 5-38
Phase-loss detection test...................................................................................................................................................................... 5-42
Torch lead test.......................................................................................................................................................................................... 5-44
Preventive maintenance.......................................................................................................................................................................... 5-45

Section 6   parts list.........................................................................................................................................................6-1

Power supply...............................................................................................................................................................................................6-2
RHF Ignition console ................................................................................................................................................................................6-8
Fuel-gas console.........................................................................................................................................................................................6-9
Off-valve (standard)................................................................................................................................................................................. 6-10

HySpeed HSD130 RHF Instruction Manual v

Table of Contents

Off-valve (fuel-gas).................................................................................................................................................................................. 6-10

HySpeed torch......................................................................................................................................................................................... 6-11
Torch assembly.............................................................................................................................................................................. 6-11
Torch leads..................................................................................................................................................................................... 6-11
Mild steel consumable parts kit............................................................................................................................................................ 6-12
Stainless steel / Aluminum consumable parts kit............................................................................................................................. 6-13
Recommended spare parts................................................................................................................................................................... 6-14

Section 7   Wiring Diagrams..........................................................................................................................................7-1

Introduction..................................................................................................................................................................................................7-1
Wiring diagrams..........................................................................................................................................................................................7-5

Appendix A   Hypertherm torch coolant Safety Data.............................................................................. a-1

Section   1   Chemical Product and Company Identification...........................................................................................................a-2
Section   2   Information on Ingredients................................................................................................................................................a-2
Section   3   Hazards Identification........................................................................................................................................................a-2
Section   4   First Aid Measures.............................................................................................................................................................a-3
Section   5   Fire Fighting Measures......................................................................................................................................................a-3
Section   6   Accidental Release Measures.........................................................................................................................................a-3
Section   7   Handling and Storage.......................................................................................................................................................a-3
Section   8   Exposure Controls / Personal Protection.....................................................................................................................a-4
Section   9   Physical and Chemical Properties..................................................................................................................................a-4
Section 10   Stability and Reactivity......................................................................................................................................................a-4
Section 11   Toxicological Information..................................................................................................................................................a-4
Section 12   Ecological Information.......................................................................................................................................................a-5
Section 13   Disposal Considerations..................................................................................................................................................a-5
Section 14   Transport Information........................................................................................................................................................a-5
Section 15   Regulatory Information......................................................................................................................................................a-5
Section 16   Other Information...............................................................................................................................................................a-5

vi HySpeed HSD130 RHF Instruction Manual

 Section 1

SAFETY

In this section:

Recognize safety information...................................................................................................................................................................1-2

Follow safety instructions..........................................................................................................................................................................1-2
Electrical hazards........................................................................................................................................................................................1-2
Electric shock can kill.................................................................................................................................................................................1-3
Cutting can cause fire or explosion........................................................................................................................................................1-4
Toxic fumes can cause injury or death...................................................................................................................................................1-5
Grounding safety........................................................................................................................................................................................1-6
Static electricity can damage circuit boards........................................................................................................................................1-6
Compressed gas equipment safety........................................................................................................................................................1-6
Gas cylinders can explode if damaged..................................................................................................................................................1-6
A plasma arc can cause injury and burns..............................................................................................................................................1-7
Arc rays can burn eyes and skin..............................................................................................................................................................1-7
Pacemaker and hearing aid operation...................................................................................................................................................1-8
Noise can damage hearing.......................................................................................................................................................................1-8
A plasma arc can damage frozen pipes................................................................................................................................................1-8
Dry dust collection information................................................................................................................................................................1-9
Laser radiation.......................................................................................................................................................................................... 1-10
Symbols and marks................................................................................................................................................................................. 1-11
Additional safety information................................................................................................................................................................. 1-11
Warning labels.......................................................................................................................................................................................... 1-12

Hypertherm 1-1
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SAFETY

RECOGNIZE SAFETY DANGER    WARNING    CAUTION

INFORMATION Hypertherm uses American National Standards Institute
The symbols shown in this section are used to identify guidelines for safety signal words and symbols. A signal
potential hazards. When you see a safety symbol in this word DANGER or WARNING is used with a safety
manual or on your machine, understand the potential symbol. DANGER identifies the most serious hazards.
for personal injury, and follow the related instructions to
avoid the hazard. • DANGER and WARNING safety labels are located on
your machine near specific hazards.

• DANGER safety messages precede related

FOLLOW SAFETY instructions in the manual that will result in serious
INSTRUCTIONS injury or death if not followed correctly.

Read carefully all safety messages in this manual and • WARNING safety messages precede related
safety labels on your machine. instructions in this manual that may result in injury
• Keep the safety labels on your machine in good or death if not followed correctly.
condition. Replace missing or damaged labels
• CAUTION safety messages precede related
immediately.
instructions in this manual that may result in
• Learn how to operate the machine and how to use minor injury or damage to equipment if not
the controls properly. Do not let anyone operate it followed correctly.
without instruction.
• Keep your machine in proper working condition.
Unauthorized modifications to the machine may affect
safety and machine service life.

ELECTRICAL HAZARDS
• Only trained and authorized personnel may open this • The enclosure shall be closed and the proper earth
equipment. ground continuity to the enclosure verified prior to
operating the equipment after moving, opening, or
• If the equipment is permanently connected, turn it off, servicing.
and lock out/tag out power before the enclosure is
opened. • Always follow these instructions for disconnecting
power before inspecting or changing torch
• If power is supplied to the equipment with a cord, consumable parts.
unplug the unit before the enclosure is opened.
• Lockable disconnects or lockable plug covers must be
provided by others.
• Wait 5 minutes after removal of power before entering
the enclosure to allow stored energy to discharge.
• If the equipment must have power when the enclosure
is open for servicing, arc flash explosion hazards may
exist. Follow ALL local requirements (NFPA 70E in
the USA) for safe work practices and for Personal
Protective Equipment when servicing energized
equipment.

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 SAFETY

ELECTRIC SHOCK CAN KILL

Touching live electrical parts can cause a fatal shock or • Install and ground this equipment according to the
severe burn. instruction manual and in accordance with national
• Operating the plasma system completes an electrical and local codes.
circuit between the torch and the workpiece. The • Inspect the input power cord frequently for damage or
workpiece and anything touching the workpiece are cracking of the cover. Replace a damaged power cord
part of the electrical circuit. immediately. Bare wiring can kill.
• Never touch the torch body, workpiece or the water in • Inspect and replace any worn or damaged torch leads.
a water table when the plasma system is operating.
• Do not pick up the workpiece, including the waste
cutoff, while you cut. Leave the workpiece in place or
Electric shock prevention
on the workbench with the work cable attached during
All Hypertherm plasma systems use high voltage the cutting process.
in the cutting process (200 to 400 VDC are • Before checking, cleaning or changing torch parts,
common). Take the following precautions when disconnect the main power or unplug the power
operating this system: supply.
• Wear insulated gloves and boots, and keep your body • Never bypass or shortcut the safety interlocks.
and clothing dry.
• Before removing any power supply or system
• Do not stand, sit or lie on – or touch – any wet surface enclosure cover, disconnect electrical input power.
when using the plasma system. Wait 5 minutes after disconnecting the main power
• Insulate yourself from work and ground using dry to allow capacitors to discharge.
insulating mats or covers big enough to prevent any • Never operate the plasma system unless the power
physical contact with the work or ground. If you must supply covers are in place. Exposed power supply
work in or near a damp area, use extreme caution. connections present a severe electrical hazard.
• Provide a disconnect switch close to the power • When making input connections, attach proper
supply with properly sized fuses. This switch allows grounding conductor first.
the operator to turn off the power supply quickly in
an emergency situation. • Each Hypertherm plasma system is designed to be
used only with specific Hypertherm torches. Do not
• When using a water table, be sure that it is correctly substitute other torches which could overheat and
connected to earth ground. present a safety hazard.

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SAFETY

CUTTING CAN CAUSE FIRE OR EXPLOSION

Fire prevention WARNING

• Be sure the area is safe before doing any cutting. Explosion Hazard
Keep a fire extinguisher nearby. Argon-Hydrogen and Methane
• Remove all flammables within 35 feet (10 m) of the Hydrogen and methane are flammable gases that
cutting area. present an explosion hazard. Keep flames away from
• Quench hot metal or allow it to cool before handling cylinders and hoses that contain methane or hydrogen
or before letting it touch combustible materials. mixtures. Keep flames and sparks away from the torch
• Never cut containers with potentially flammable when using methane or argon-hydrogen plasma.
materials inside – they must be emptied and
properly cleaned first.
• Ventilate potentially flammable atmospheres
before cutting.
WARNING
• When cutting with oxygen as the plasma gas, an
Explosion Hazard
exhaust ventilation system is required.
Underwater Cutting with Fuel Gases
Explosion prevention
• Do not cut aluminum underwater or with water
• Do not use the plasma system if explosive dust or touching the underside of the aluminum.
vapors may be present.
• Do not cut pressurized cylinders, pipes, or any • Cutting aluminum underwater or with the water
closed container. touching the underside of the aluminum can result
in an explosive condition that can detonate during
• Do not cut containers that have held combustible
plasma cutting operations.
materials.

WARNING
Hydrogen Detonation with
Aluminum Cutting

• Do not cut under water with fuel gases containing

hydrogen.
• Cutting under water with fuel gases containing
hydrogen can result in an explosive condition that can
detonate during plasma cutting operations.

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 SAFETY

TOXIC FUMES CAN CAUSE INJURY OR DEATH

The plasma arc by itself is the heat source used for • Size, air volume, ventilation and filtration of the
cutting. Accordingly, although the plasma arc has not work area.
been identified as a source of toxic fumes, the material • Personal protective equipment.
being cut can be a source of toxic fumes or gases that
deplete oxygen. • Number of welding and cutting systems in operation.
• Other site processes that may produce fumes.
Fumes produced vary depending on the metal that is
cut. Metals that may release toxic fumes include, but If the workplace must conform to national or local
are not limited to, stainless steel, carbon steel, zinc regulations, only monitoring or testing done at the
(galvanized), and copper. site can determine whether the site is above or below
allowable levels.
In some cases, the metal may be coated with a substance
To reduce the risk of exposure to fumes:
that could release toxic fumes. Toxic coatings include,
but are not limited to, lead (in some paints), cadmium • Remove all coatings and solvents from the metal
(in some paints and fillers), and beryllium. before cutting.
• Use local exhaust ventilation to remove fumes from
Gases produced by plasma cutting vary based on the the air.
material to be cut and the method of cutting, but may
• Do not inhale fumes. Wear an air-supplied respirator
include ozone, oxides of nitrogen, hexavalent chromium,
when cutting any metal coated with, containing, or
hydrogen, and other substances if such are contained
suspected to contain toxic elements.
in or released by the material being cut.
• Assure that those using welding or cutting equipment,
Caution should be taken to minimize exposure to fumes as well as air-supplied respiration devices, are
produced by any industrial process. Depending upon qualified and trained in the proper use of such
the chemical composition and concentration of the equipment.
fumes (as well as other factors, such as ventilation), • Never cut containers with potentially toxic materials
there may be a risk of physical illness, such as birth inside. Empty and properly clean the container first.
defects or cancer.
• Monitor or test the air quality at the site as needed.
It is the responsibility of the equipment and site owner • Consult with a local expert to implement a site plan
to test the air quality in the area where the equipment is to ensure safe air quality.
used and to ensure that the air quality in the workplace
meets all local and national standards and regulations.

The air quality level in any relevant workplace depends

on site-specific variables such as:
• Table design (wet, dry, underwater).
• Material composition, surface finish, and composition
of coatings.
• Volume of material removed.
• Duration of cutting or gouging.

Hypertherm 1-5
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SAFETY

GROUNDING SAFETY

Work cable  Attach the work cable securely to the • If installation of the plasma system involves connecting
workpiece or the work table with good metal-to-metal the power cord to the power supply, be sure to
contact. Do not connect it to the piece that will fall away connect the power cord ground wire properly.
when the cut is complete. • Place the power cord’s ground wire on the stud first,
then place any other ground wires on top of the power
Work table  Connect the work table to an earth cord ground. Fasten the retaining nut tightly.
ground, in accordance with appropriate national and
local electrical codes. • Tighten all electrical connections to avoid excessive
heating.
Input power
• Be sure to connect the power cord ground wire to the
ground in the disconnect box.

STATIC ELECTRICITY CAN DAMAGE CIRCUIT BOARDS

Use proper precautions when handling printed circuit boards:
• Store PC boards in anti-static containers.
• Wear a grounded wrist strap when handling PC boards.

COMPRESSED GAS EQUIPMENT GAS CYLINDERS CAN

SAFETY EXPLODE IF DAMAGED
• Never lubricate cylinder valves or regulators with oil Gas cylinders contain gas under high pressure.
or grease. If damaged, a cylinder can explode.

• Use only correct gas cylinders, regulators, hoses and • Handle and use compressed gas cylinders in
fittings designed for the specific application. accordance with applicable national and local codes.

• Maintain all compressed gas equipment and • Never use a cylinder that is not upright and secured
associated parts in good condition. in place.

• Label and color-code all gas hoses to identify the type • Keep the protective cap in place over valve except
of gas in each hose. Consult applicable national and when the cylinder is in use or connected for use.
local codes.
• Never allow electrical contact between the plasma arc
and a cylinder.

• Never expose cylinders to excessive heat, sparks, slag

or open flame.

• Never use a hammer, wrench or other tool to open a

stuck cylinder valve.

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 SAFETY

A PLASMA ARC CAN CAUSE INJURY AND BURNS

Instant-on torches The plasma arc will cut quickly through gloves and skin.
Plasma arc comes on immediately when the torch • Keep away from the torch tip.
switch is activated. • Do not hold metal near the cutting path.
• Never point the torch toward yourself or others.

ARC RAYS CAN BURN EYES AND SKIN

Eye protection  Plasma arc rays produce intense visible and invisible (ultraviolet and infrared) rays that can
burn eyes and skin.
• Use eye protection in accordance with applicable national and local codes.
• Wear eye protection (safety glasses or goggles with side shields, and a welding helmet) with appropriate
lens shading to protect your eyes from the arc’s ultraviolet and infrared rays.

Skin protection  Wear protective clothing to protect against burns caused by ultraviolet light, sparks, and
hot metal.
• Gauntlet gloves, safety shoes and hat.
• Flame-retardant clothing to cover all exposed areas.
• Cuffless trousers to prevent entry of sparks and slag.
• Remove any combustibles, such as a butane lighter or matches, from your pockets before cutting.

Cutting area  Prepare the cutting area to reduce reflection and transmission of ultraviolet light:
• Paint walls and other surfaces with dark colors to reduce reflection.
• Use protective screens or barriers to protect others from flash and glare.
• Warn others not to watch the arc. Use placards or signs.

Minimum protective Suggested shade

Arc current OSHA 29CFR Europe
shade number number for comfort
(amps) 1910.133(a)(5) EN168:2002
(ANSI Z49.1:2005) (ANSI Z49.1:2005)
Less than 40 A 5 5 8 9
41 to 60 A 6 6 8 9
61 to 80 A 8 8 8 9
81 to 125 A 8 9 8 9
126 to 150 A 8 9 8 10
151 to 175 A 8 9 8 11
176 to 250 A 8 9 8 12
251 to 300 A 8 9 8 13
301 to 400 A 9 12 9 13
401 to 800 A 10 14 10

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SAFETY

PACEMAKER AND HEARING AID OPERATION

Pacemaker and hearing aid operation can be affected by • Do not wrap or drape the torch lead or work cable
magnetic fields from high currents. around your body.
Pacemaker and hearing aid wearers should consult a • Keep as far away from the power supply as possible.
doctor before going near any plasma arc cutting and
gouging operations.
To reduce magnetic field hazards:
• Keep both the work cable and the torch lead to one
side, away from your body.
• Route the torch leads as close as possible to the
work cable.

NOISE CAN DAMAGE HEARING

Cutting with a plasma arc can exceed acceptable noise Use ear protectors if the noise is disruptive or if there
levels as defined by local codes in many applications. is a risk of hearing damage after all other engineering
Prolonged exposure to excessive noise can damage and administrative controls have been implemented.
hearing. Always wear proper ear protection when cutting If hearing protection is required, wear only approved
or gouging, unless sound pressure level measurements personal protective devices such as ear muffs or ear
taken at the installed site have verified personal hearing plugs with a noise reduction rating appropriate for the
protection is not necessary per relevant international, situation. Warn others in the area of possible noise
regional, and local codes. hazards. In addition, ear protection can prevent hot
splatter from entering the ear.
Significant noise reduction can be obtained by adding
simple engineering controls to cutting tables such as
barriers or curtains positioned between the plasma arc
and the workstation; and/or locating the workstation
away from the plasma arc. Implement administrative
controls in the workplace to restrict access, limit
operator exposure time, screen off noisy working areas
and/or take measures to reduce reverberation in working
areas by putting up noise absorbers.

A PLASMA ARC CAN DAMAGE FROZEN PIPES

Frozen pipes may be damaged or can burst if you attempt to thaw them with a plasma torch.

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SAFETY Safety

DRY DUST COLLECTION INFORMATION

At some sites, dry dust can represent a potential Note 1 – Hypertherm’s interpretation of these new
explosion hazard. requirements is that unless a site-specific evaluation has
been completed to determine that all dust generated is
The U.S. National Fire Protection Association’s 2007
not combustible, the 2007 edition of NFPA 68 requires
edition of NFPA standard 68, “Explosion Protection by
the use of explosion vents designed to the worst-case
Deflagration Venting,” provides requirements for the
Kst value (see annex F) that could be generated from
design, location, installation, maintenance, and use of
dust so that the explosion vent size and type can be
devices and systems to vent combustion gases and
designed. NFPA 68 does not specifically identify plasma
pressures after any deflagration event. Consult with
cutting or other thermal cutting processes as requiring
the manufacturer or installer of any dry dust collection
deflagration venting systems, but it does apply these
system for applicable requirements before you install
new requirements to all dry dust collection systems.
a new dry dust collection system or make significant
changes in the process or materials used with an Note 2 – Users of Hypertherm manuals should consult
existing dry dust collection system. and comply with all applicable federal, state, and local
laws and regulations. Hypertherm does not, by the
Consult your local “Authority Having Jurisdiction” (AHJ)
publication of any Hypertherm manual, intend to urge
to determine whether any edition of NFPA 68 has been
action that is not in compliance with all applicable
“adopted by reference” in your local building codes.
regulations and standards, and this manual may never
Refer to NFPA68 for definitions and explanations of be construed as doing so.
regulatory terms such as deflagration, AHJ, adopted by
reference, the Kst value, deflagration index, and other
terms.

Hypertherm 1-9
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Safety SAFETY

LASER RADIATION
Exposure to the laser output can result in serious eye injury. Avoid direct eye exposure.

For your convenience and safety, on Hypertherm products that use a laser, one of the following laser radiation
labels has been applied on the product near where the laser beam exits the enclosure. The maximum output (mV),
wavelength emitted (nM) and, if appropriate, the pulse duration is also provided.

Additional laser safety instructions:

• Consult with an expert on local laser regulations. Laser • Modifying the laser or product in any way can increase
safety training may be required. the risk of laser radiation.
• Do not allow untrained persons to operate the laser. • Use of adjustments or performance of procedures
Lasers can be dangerous in the hands of untrained other than those specified in this manual may result in
users. hazardous laser radiation exposure.
• Do not look into the laser aperture or beam at any • Do not operate in explosive atmospheres, such as in
time. the presence of flammable liquids, gases, or dust.
• Position the laser as instructed to avoid unintentional • Use only laser parts and accessories that are
eye contact. recommended or provided by the manufacturer for
• Do not use the laser on reflective workpieces. your model.
• Do not use optical tools to view or reflect the laser • Repairs and servicing MUST be performed by
beam. qualified personnel.
• Do not disassemble or remove the laser or aperture • Do not remove or deface the laser safety label.
cover.

1-10 Hypertherm
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 SAFETY

SYMBOLS AND MARKS

Your Hypertherm product may have one or more of the following markings on or near the data plate. Due to differences
and conflicts in national regulations, not all marks are applied to every version of a product.

S mark symbol
The S mark symbol indicates that the power supply and torch are suit­able for operations carried out in en­vi­
ron­ments with in­creased hazard of elec­tri­cal shock per IEC 60974-1.

CSA mark
Hypertherm products with a CSA mark meet the United States and Canadian regulations for product safety.
The products were evaluated, tested, and certified by CSA-International. Alternatively the product may have
a mark by one of the other Nationally Recognized Testing Laboratories (NRTL) accredited in both the United
States and Canada, such as Underwriters Laboratories, Incorporated (UL) or TÜV.

CE marking
 he CE marking signifies the manufacturer’s declaration of conformity to applicable European directives
T
and standards. Only those versions of Hypertherm products with a CE marking located on or near the
data plate have been tested for compliance with the European Low Voltage Directive and the European
Electromagnetic Compatibility (EMC) Directive. EMC filters needed to comply with the European EMC
Directive are incorporated within versions of the product with a CE marking.

GOST-R mark
CE versions of Hypertherm products that include a GOST-R mark of conformity meet the product safety
and EMC requirements for export to the Russian Federation.

c-Tick mark
 E versions of Hypertherm products with a c-Tick mark comply with the EMC regulations required for sale
C
in Australia and New Zealand.

CCC mark
The China Compulsory Certification (CCC) mark indicates that the product has been tested and found
compliant with product safety regulations required for sale in China.

ADDITIONAL SAFETY INFORMATION

1. ANSI Standard Z49.1, Safety in Welding and Cutting, American 6. CGA Pamphlet P-1, Safe Handling of Compressed Gases in Cylinders,
Welding Society, 550 LeJeune Road Compressed Gas Association
P.O. Box 351020, Miami, FL 33135 1235 Jefferson Davis Highway, Arlington, VA 22202
2. ANSI Standard Z49.2, Fire Prevention in the Use of Cutting and 7. CSA Standard W117.2, Code for Safety in Welding and Cutting,
Welding Processes, American National Standards Institute Canadian Standards Association Standard Sales
1430 Broadway, New York, NY 10018 178 Rexdale Boulevard, Rexdale, Ontario M9W 1R3, Canada
3. ANSI Standard Z87.1, Safe Practices for Occupation and 8. NFPA Standard 51B, Cutting and Welding Processes, National Fire
Educational Eye and Face Protection, American National Standards Protection Association
Institute, 1430 Broadway, New York, NY 10018 470 Atlantic Avenue, Boston, MA 02210
4. AWS F4.1, Recommended Safe Practices for the Preparation for 9. NFPA Standard 70–1978, National Electrical Code, National Fire
Welding and Cutting of Containers and Piping That Have Held Protection Association, 470 Atlantic Avenue, Boston, MA 02210
Hazardous Substances, American Welding Society
10. OSHA, Safety and Health Standards, 29FR 1910
550 LeJeune Road, P.O. Box 351040, Miami, FL 33135
U.S. Government Printing Office, Washington, D.C. 20402
5. AWS F5.2, Recommended Safe Practices for Plasma Arc
11. AWS Safety and Health Fact Sheets, American Welding Society 550
Cutting, American Welding Society
LeJeune Road, P.O. Box 351040, Miami, FL 33135
550 LeJeune Road, P.O. Box 351040, Miami, FL 33135
www.aws.org/technical/facts/

Hypertherm 1-11
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SAFETY

WARNING LABELS
This warning label is affixed to some power supplies. It is important that the operator and maintenance technician
understand the intent of these warning symbols as described.

Read and follow these instructions, employer safety

practices, and material safety data sheets. Refer to WARNING AVERTISSEMENT
ANS Z49.1, “Safety in Welding, Cutting and Allied
Processes” from American Welding Society Plasma cutting can be injurious to operator and persons Le coupage plasma peut être préjudiciable pour l’opérateur et les personnes qui se
(http://www.aws.org) and OSHA Safety and Health in the work area. Consult manual before operating. Failure trouvent sur les lieux de travail. Consulter le manuel avant de faire fonctionner. Le
Standards, 29 CFR 1910 (http://www.osha.gov). to follow all these safety instructions can result in death. non respect des ces instructions de sécurité peut entraîner la mort.

1. Cutting sparks can cause explosion or fire. 1. Les étincelles de coupage peuvent provoquer une explosion
1.1 Do not cut near flammables. ou un incendie.
1.2 Have a fire extinguisher nearby and ready to use. 1.1 Ne pas couper près des matières inflammables.
1.3 Do not use a drum or other closed container as a cutting table. 1.2 Un extincteur doit être à proximité et prêt à être utilisé.
1.3 Ne pas utiliser un fût ou un autre contenant fermé comme table de coupage.
2. Plasma arc can injure and burn; point the nozzle away 2. L’arc plasma peut blesser et brûler; éloigner la buse de soi.
from yourself. Arc starts instantly when triggered. Il s’allume instantanément quand on l’amorce;
2.1 Turn off power before disassembling torch. 2.1 Couper l’alimentation avant de démonter la torche.
2.2 Do not grip the workpiece near the cutting path. 2.2 Ne pas saisir la pièce à couper de la trajectoire de coupage.
2.3 Wear complete body protection. 2.3 Se protéger entièrement le corps.

3. Hazardous voltage. Risk of electric shock or burn. 3. Tension dangereuse. Risque de choc électrique ou de brûlure.
3.1 Wear insulating gloves. Replace gloves when wet or damaged. 3.1 Porter des gants isolants. Remplacer les gants quand ils sont humides ou
3.2 Protect from shock by insulating yourself from work and ground. endommagés.
3.3 Disconnect power before servicing. Do not touch live parts. 3.2 Se protéger contre les chocs en s’isolant de la pièce et de la terre.
3.3 Couper l’alimentation avant l’entretien. Ne pas toucher les pièces sous tension.

4. Plasma fumes can be hazardous. 4. Les fumées plasma peuvent être dangereuses.
4.1 Do not inhale fumes. 4.1 Ne pas inhaler les fumées
4.2 Use forced ventilation or local exhaust to remove the fumes. 4.2 Utiliser une ventilation forcée ou un extracteur local pour dissiper les fumées.
4.3 Do not operate in closed spaces. Remove fumes with ventilation. 4.3 Ne pas couper dans des espaces clos. Chasser les fumées par ventilation.

5. Arc rays can burn eyes and injure skin. 5. Les rayons d’arc peuvent brûler les yeux et blesser la peau.
5.1 Wear correct and appropriate protective equipment to protect 5.1 Porter un bon équipement de protection pour se protéger la tête, les yeux, les
head, eyes, ears, hands, and body. Button shirt collar. Protect ears oreilles, les mains et le corps. Boutonner le col de la chemise. Protéger les oreilles
from noise. Use welding helmet with the correct shade of filter. contre le bruit. Utiliser un masque de soudeur avec un filtre de nuance appropriée.

6. Become trained. Only qualified personnel should operate this 6. Suivre une formation. Seul le personnel qualifié a le droit de faire
equipment. Use torches specified in the manual. Keep non-qualified fonctionner cet équipement. Utiliser exclusivement les torches indiquées dans le
personnel and children away. manual. Le personnel non qualifié et les enfants doivent se tenir à l’écart.
7. Do not remove, destroy, or cover this label. 7. Ne pas enlever, détruire ni couvrir cette étiquette.
Replace if it is missing, damaged, or worn (PN 110584 Rev C). La remplacer si elle est absente, endommagée ou usée (PN 110584 Rev C).

1-12 Hypertherm
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 SAFETY

Warning LabelS 1. C
 utting sparks can cause explosion
or fire.
This warning label is affixed to some power supplies. It is important
that the operator and maintenance technician understand the intent of 1.1 Do not cut near flammables.
these warning symbols as described. The numbered text corresponds 1.2 Have a fire extinguisher nearby and
to the numbered boxes on the label. ready to use.
1.3 Do not use a drum or other closed
container as a cutting table.
2. P
 lasma arc can injure and burn; point
the nozzle away from yourself. Arc starts
instantly when triggered.
2.1 Turn off power before disassembling
torch.
2.2 Do not grip the workpiece near the
cutting path.
2.3 Wear complete body protection.
3. H
 azardous voltage. Risk of electric
shock or burn.
3.1 Wear insulating gloves. Replace gloves
when wet or damaged.
3.2 Protect from shock by insulating yourself
from work and ground.
3.3 Disconnect power before servicing.
Do not touch live parts.
4. Plasma fumes can be hazardous.
4.1 Do not inhale fumes.
4.2 Use forced ventilation or local exhaust to
remove the fumes.
4.3 Do not operate in closed spaces.
Remove fumes with ventilation.
5. Arc rays can burn eyes and injure skin.
5.1 Wear correct and appropriate protective
equipment to protect head, eyes, ears,
hands, and body. Button shirt collar.
Protect ears from noise. Use welding
helmet with the correct shade of filter.
6. B
 ecome trained. Only qualified
personnel should operate this
equipment. Use torches specified in the
manual. Keep non-qualified personnel
and children away.
7. D
 o not remove, destroy, or cover this
label. Replace if it is missing, damaged,
or worn.

Hypertherm 1-13
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SAFETY

1-14 Hypertherm
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 Section 1a

SÉCURITÉ

Sommaire de cette section :

Identifier les consignes de sécurité........................................................................................................................................................1-2

Suivre les instructions de sécurité..........................................................................................................................................................1-2
Risques électriques....................................................................................................................................................................................1-2
Les chocs électriques peuvent être fatals.............................................................................................................................................1-3
Le coupage peut provoquer un incendie ou une explosion..............................................................................................................1-4
Les vapeurs toxiques peuvent provoquer des blessures ou la mort...............................................................................................1-5
Mise à la masse et à la terre.....................................................................................................................................................................1-6
L’électricité statique peut endommager les cartes de circuits imprimés.......................................................................................1-6
Sécurité des bouteilles de gaz comprimé.............................................................................................................................................1-6
Les bouteilles de gaz comprimé peuvent exploser en cas de dommages....................................................................................1-6
L’arc plasma peut provoquer des blessures ou des brûlures...........................................................................................................1-7
Les rayons de l’arc peuvent brûler les yeux et la peau.......................................................................................................................1-7
Pacemakers et prothèses auditives........................................................................................................................................................1-8
Le bruit peut provoquer des problèmes auditifs..................................................................................................................................1-8
Un arc plasma peut endommager les tuyaux gelés............................................................................................................................1-8
Information sur le dépoussièrage............................................................................................................................................................1-9
Radiation au laser.................................................................................................................................................................................... 1-10
Symboles et marquage........................................................................................................................................................................... 1-11
Étiquettes de sécurité............................................................................................................................................................................. 1-12

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IDENTIFIER LES DANGER   AVERTISSEMENT   ATTENTION

CONSIGNES DE SÉCURITÉ Hypertherm adopte les lignes directrices de l’American
Les symboles indiqués dans cette section sont utilisés National Standards Institute relativement aux termes
pour identifier les risques éventuels. Si vous trouvez un et aux symboles de la signalisation de sécurité. Les
symbole de sécurité, que ce soit dans ce manuel ou sur signaux DANGER ou AVERTISSEMENT sont utilisés
l’équipement, soyez conscient des risques de blessures avec un symbole de sécurité. DANGER correspond aux
et suivez les instructions correspondantes afin d’éviter risques les plus sérieux.
ces risques.
• Les étiquettes de sécurité DANGER et
AVERTISSEMENT sont placées sur l’équipement
SUIVRE LES INSTRUCTIONS pour situer certains dangers spécifiques.
DE SÉCURITÉ • Les messages de sécurité DANGER précèdent
Lire attentivement toutes les consignes de sécurité dans les directives correspondantes dans le manuel
le présent manuel et sur les étiquettes de sécurité se qui, si elles ne sont pas suivies scrupuleusement,
trouvant sur l’équipement. entraînent des blessures graves, voire mortelles.
• Les étiquettes de sécurité sur l’équipement doivent • Les messages d’AVERTISSEMENT précèdent les
rester lisibles. Remplacer immédiatement les étiquettes instructions d’utilisation présentées dans ce manuel
manquantes ou abîmées. qui, si elles ne sont pas suivies scrupuleusement,
• Il est important d’apprendre à faire fonctionner peuvent entraîner des blessures graves, voire
l’équipement et à utiliser correctement les commandes. mortelles.
Ne laisser personne utiliser l’équipement sans
connaître son fonctionnement. • Les messages de sécurité ATTENTION précèdent
les directives associées dans le manuel qui, si elles
• Garder l’équipement en bon état. Des modifications
ne sont pas suivies scrupuleusement, peuvent
non autorisées sur l’équipement peuvent entraîner des
entraîner des blessures mineures ou endommager
problèmes de sécurité et raccourcir la durée de vie
l’équipement.
utile de l’équipement.

RISQUES ÉLECTRIQUES
• Seul le personnel formé et autorisé peut ouvrir cet • Vérifier que le boîtier est bien fermé et que la mise
équipement. à la terre est bien effectuée avant de faire fonctionner
l’équipement après l’avoir déplacé, ouvert ou après
• Si l’équipement est branché en permanence, mettez-le
avoir effectué un entretien.
hors tension, puis coupez l’alimentation avant d’ouvrir
le boîtier. • Toujours suivre ces instructions concernant le
débranchement de la source de courant avant
• Si l’équipement est mis sous tension à l’aide d’un
d’inspecter ou de remplacer des consommables
cordon, débranchez-le avant d’ouvrir le boîtier.
de la torche.
• Dans un cas autre, des raccords ou des capots
d’obturateurs verrouillables doivent être fournis.
• Attendre ensuite 5 minutes après la coupure de
l’alimentation électrique avant l’ouverture du capot
pour que l’énergie stockée se décharge.
• Si l’équipement doit être sous tension lorsque le
capot est ouvert pour l’entretien, le coup d’arc peut
se produire. Respecter TOUTES les exigences locales
(NFPA 70E aux États-Unis) relatives aux pratiques
de travail sécuritaires et à l’équipement de protection
individuelle lors de l’entretien de l’équipement électrique.

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LES CHOCS ÉLECTRIQUES PEUVENT ÊTRE FATALS

Le contact avec les pièces électriques sous tension • Installer et mettre à la terre l’équipement selon les
peut entraîner une électrocution ou de brûlures graves, instructions du présent manuel et conformément
voire la mort. aux codes locaux et nationaux.
• L’utilisation d’un système plasma complète un circuit • Inspecter fréquemment le cordon de puissance
électrique entre la torche et la pièce à couper. d’entrée pour vérifier qu’il n’est pas endommagé
La pièce ainsi que tout autre élément la touchant ni fendu. Remplacer immédiatement un cordon
font partie du circuit électrique. d’alimentation endommagé. Un câble dénudé
• Ne jamais toucher le corps de la torche, la pièce peut causer la mort.
à couper ou l’eau de la table à eau lorsque • Inspecter et remplacer les câbles de la torche qui
le système plasma fonctionne. sont usés ou endommagés.
• Ne pas saisir la pièce à couper, ni les débris lors du
Prévention des chocs électriques coupage. Laisser la pièce à couper en place ou sur
Tous les systèmes plasma Hypertherm la table de travail et le câble de retour connecté lors
fonctionnent à haute tension pour le coupage du coupage.
(souvent de 200 à 400 V c.c.). Prendre les • Avant de vérifier, de nettoyer ou de remplacer
précautions suivantes lors de l’utilisation les pièces de la torche, couper l’alimentation ou
du système : débrancher la source de courant.
• Porter des bottes et des gants isolants et garder • Ne jamais contourner ou court-circuiter les verrous
le corps et les vêtements au sec. de sécurité.
• Ne pas se tenir, s’asseoir ou se coucher sur une • Avant d’enlever le capot du système ou de la
surface mouillée, ni la toucher pendant l’utilisation source de courant, couper la puissance d’entrée
du système plasma. électrique. Attendre ensuite 5 minutes pour que
• S’isoler de la surface de travail et du sol en utilisant les condensateurs se déchargent.
des tapis isolants ou des couvertures assez grandes • Ne jamais faire fonctionner le système plasma sans
pour éviter tout contact physique avec le matériel de que les capots de la source de courant ne soient en
travail ou le sol. S’il s’avère nécessaire de travailler place. Les raccords exposés de la source de courant
dans ou près d’un endroit humide, procéder avec sont extrêmement dangereux.
extrême prudence. • Lors de l’installation des connexions, attacher tout
• Installer un sectionneur avec fusibles appropriés, d’abord la prise de terre appropriée.
à proximité de la source de courant. Ce sectionneur • Chaque système plasma Hypertherm est conçu pour
permet à l’opérateur d’éteindre rapidement la source être utilisé uniquement avec des torches Hypertherm
de courant en cas d’urgence. spécifiques. Ne pas utiliser des torches inappropriées
• En cas d’utilisation d’une table à eau, s’assurer qui pourraient surchauffer et présenter des risques
que cette dernière est correctement mise à la terre. pour la sécurité.

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LE COUPAGE PEUT PROVOQUER UN INCENDIE

OU UNE EXPLOSION

Prévention des incendies AVERTISSEMENT

• Avant de commencer, vérifier que la zone de coupage Risque d’explosion
ne présente aucun danger. Conserver un extincteur Argon-hydrogène et méthane
à proximité. L’hydrogène et le méthane sont des gaz inflammables
• Éloigner toute matière inflammable à une distance et potentiellement explosifs. Conserver à l’écart de toute
d’au moins 10 m du poste de coupage. flamme les bouteilles et tuyaux contenant des mélanges
• Tremper le métal chaud ou le laisser refroidir avant à base d’hydrogène ou de méthane. Maintenir toute
de le manipuler ou avant de le mettre en contact flamme et étincelle à l’écart de la torche lors de l’utilisation
avec des matériaux combustibles. d’un plasma d’argon-hydrogène ou de méthane.
• Ne jamais couper des récipients pouvant contenir
des matières inflammables avant de les avoir vidés
et nettoyés correctement.
• Aérer toute atmosphère potentiellement inflammable AVERTISSEMENT
avant de commencer le coupage. Risque d’explosion
Sous l’eau lors du coupage
• Lors de l’utilisation d’oxygène comme gaz plasma, un
avec gaz combustibles
système de ventilation par extraction est nécessaire.
• Ne pas couper l’aluminium sous l’eau ou lorsque
Prévention des explosions celle-ci touche la partie inférieure de la pièce
• Ne pas utiliser le système plasma en présence d’aluminium.
possible de poussière ou de vapeurs. • Le coupage de l’aluminium sous l’eau, ou l’eau qui
• Ne pas couper de bouteilles, de tuyaux ou autres touche la partie inférieure de la pièce d’aluminium peut
récipients fermés et pressurisés. rassembler les conditions propices à une explosion
• Ne pas couper de récipients qui ont servi à contenir causant une détonation lors du coupage plasma.
des matières combustibles.

AVERTISSEMENT
Détonation de l’hydrogène
lors du coupage de l’aluminium
• Ne pas couper la pièce sous l’eau avec des gaz
combustibles contenant de l’hydrogène.
• Cela peut entraîner une explosion suivie d’une
détonation lors du coupage plasma.

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LES VAPEURS TOXIQUES PEUVENT PROVOQUER

DES BLESSURES OU LA MORT
L’arc plasma constitue la source de chaleur utilisée • Dimensions, volume d’air, ventilation et filtration
pour le coupage. Par conséquent, bien que l’arc plasma de la zone de travail.
n’ait pas été reconnu comme une source de vapeurs • Équipement de protection individuelle.
toxiques, le matériau coupé peut être une source de
vapeurs ou de gaz toxiques qui épuisent l’oxygène. • Nombre de systèmes de soudage et de coupage
en fonctionnement.
Les vapeurs produites varient selon le métal coupé. • Autres procédés du site qui peuvent produire
Les métaux qui peuvent dégager des vapeurs toxiques des vapeurs.
comprennent, entre autres, l’acier inoxydable, l’acier
au carbone, le zinc (galvanisé) et le cuivre. Si les lieux de travail doivent être conformes aux
réglementations nationales ou locales, seuls les
Dans certains cas, le métal peut être revêtu d’une contrôles ou les essais effectués au site peuvent
substance susceptible de dégager des vapeurs déterminer si celui-ci se situe au-dessus ou
toxiques. Les revêtements toxiques comprennent entre au-dessous des niveaux admissibles.
autres, le plomb (dans certaines peintures), le cadmium
Pour réduire le risque d’exposition aux vapeurs :
(dans certaines peintures et enduits) et le béryllium.
• Éliminer tout revêtement et solvant du métal avant
Les gaz produits par le coupage plasma varient selon le coupage.
le matériau à couper et la méthode de coupage, mais • Utiliser la ventilation par extraction locale pour éliminer
ils peuvent comprendre l’ozone, les oxydes d’azote, les vapeurs de l’air.
le chrome hexavalent, l’hydrogène et autres substances
• Ne pas inhaler les vapeurs. Porter un respirateur
présentes dans le matériau coupé ou en émanent.
à adduction d’air lors du coupage des métaux revêtus
d’éléments toxiques ou qui en contiennent ou sont
Certaines précautions s’imposent pour réduire au
susceptibles d’en contenir.
minimum l’exposition aux vapeurs produites par tout
processus industriel. Selon la composition chimique et • S’assurer que les personnes qui utilisent un
la concentration des vapeurs (ainsi que d’autres facteurs équipement de soudage ou de coupage ainsi que
comme la ventilation), celles-ci risquent de causer une les dispositifs de respiration par adduction d’air sont
maladie physique, comme des déficiences de naissance qualifiées et formées pour utiliser adéquatement cet
ou le cancer. équipement.
• Ne jamais couper les contenants dans lesquels il peut
Il incombe au propriétaire du matériel et du site de y avoir des matériaux toxiques. En premier lieu, vider
vérifier la qualité de l’air dans le secteur où le matériel et nettoyer correctement le contenant.
est utilisé et de s’assurer que la qualité de l’air sur les
• Contrôler ou éprouver la qualité de l’air du site au
lieux de travail répond aux normes et réglementations
besoin.
locales et nationales.
• Consulter un expert local pour mettre en œuvre
Le niveau de qualité de l’air dans tout lieu de travail un plan du site afin d’assurer la qualité de l’air.
dépend des variables propres au site comme :
• Type de table (humide, sèche, sous l’eau).
• Composition du matériau, fini de la surface et
composition des revêtements.
• Volume de matériau enlevé.
• Durée du coupage ou du gougeage.

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MISE À LA MASSE ET À LA TERRE

Câble de retour  Bien fixer le câble de retour • S’il est nécessaire de brancher le cordon d’alimentation
(ou de masse) à la pièce à couper ou à la table de à la source de courant lors de l’installation du système,
travail de façon à assurer un bon contact métal à métal. vérifier que le fil de terre est correctement branché.
Ne pas fixer le câble de retour à la partie de la pièce qui • Placer tout d’abord le fil de terre du cordon
doit se détacher. d’alimentation sur le plot de mise à la terre, puis placer
les autres fils de terre par-dessus. Bien serrer l’écrou
Table de travail  Raccorder la table de travail à la de retenue.
terre, conformément aux codes de sécurité locaux
ou nationaux appropriés. • Vérifier que toutes les connexions sont bien serrées
pour éviter une surchauffe.
Puissance d’entrée
• S’assurer que le fil de terre du cordon d’alimentation
est connecté à la terre dans le coffret du sectionneur.

L’ÉLECTRICITÉ STATIQUE PEUT ENDOMMAGER

LES CARTES DE CIRCUITS IMPRIMÉS
Les précautions qui s’imposent doivent être respectées lors de la manipulation des circuits imprimés :
• Les cartes de circuits imprimés doivent être rangées dans des contenants antistatiques.
• L’utilisateur doit porter un bracelet antistatique lors de la manipulation des cartes de circuits imprimés.

SÉCURITÉ DES BOUTEILLES LES BOUTEILLES DE GAZ

DE GAZ COMPRIMÉ COMPRIMÉ PEUVENT
• Ne jamais lubrifier les robinets des bouteilles EXPLOSER EN CAS DE
ou les régulateurs avec de l’huile ou de la graisse. DOMMAGES
• Utiliser uniquement les bouteilles, régulateurs, tuyaux Les bouteilles de gaz contiennent du gaz à haute pression.
et accessoires appropriés et conçus pour chaque Si une bouteille est endommagée, elle peut exploser.
application spécifique.
• Manipuler et utiliser les bouteilles de gaz comprimé
• Entretenir l’équipement et les pièces d’équipement conformément aux codes locaux ou nationaux.
à gaz comprimé afin de les garder en bon état.
• Ne jamais utiliser une bouteille qui n’est pas placée
• Étiqueter et coder avec des couleurs tous les à la verticale et bien assujettie.
tuyaux de gaz afin d’identifier le type de gaz contenu
dans chaque tuyau. Consulter les codes locaux • Le capuchon de protection doit être placé sur le robinet
ou nationaux en vigueur. sauf si la bouteille est en cours d’utilisation ou connectée
pour utilisation.

• Éviter à tout prix le contact électrique entre l’arc plasma

et une bouteille.

•  Ne jamais exposer des bouteilles à une chaleur excessive,

aux étincelles, aux scories ou aux flammes nues.

• Ne jamais utiliser des marteaux, des clés ou d’autres

outils pour débloquer le robinet des bouteilles.

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L’ARC PLASMA PEUT PROVOQUER DES BLESSURES

OU DES BRÛLURES

Torches à allumage instantané L’arc plasma coupe facilement les gants et la peau.
L’arc plasma s’allume immédiatement après que • Rester éloigné de l’extrémité de la torche.
la torche est activée. • Ne pas tenir de métal près de la trajectoire de coupe.
• Ne jamais pointer la torche vers soi ou d’autres personnes.

LES RAYONS DE L’ARC PEUVENT BRÛLER

LES YEUX ET LA PEAU
Protection des yeux  Les rayons de l’arc plasma produisent de puissants rayons visibles et invisibles (ultraviolets
et infrarouges) qui peuvent brûler les yeux et la peau.
• Utiliser des lunettes de sécurité conformément aux codes locaux ou nationaux en vigueur.
• Porter des lunettes de protection (des lunettes ou masque muni d’écrans latéraux et un masque de soudure)
avec des verres teintés appropriés pour protéger les yeux des rayons ultraviolets et infrarouges de l’arc.

Protection de la peau  Porter des vêtements de sécurité pour se protéger contre les brûlures que peuvent causer
les rayons ultraviolets, les étincelles et le métal brûlant :
• Gants à crispin, chaussures et casque de sécurité.
• Vêtements ignifuges couvrant toutes les parties exposées du corps.
• Pantalon sans revers pour éviter que des étincelles ou des scories puissent s’y loger.
• Avant le coupage, retirer de ses poches tout objet combustible comme les briquets au butane ou les allumettes.

Zone de coupage  Préparer la zone de coupage afin de réduire la réverbération et la transmission de la lumière
ultraviolette :
• Peindre les murs et autres surfaces d’une couleur sombre pour réduire la réflexion de la lumière.
• Utiliser des écrans et autres dispositifs de protection afin de protéger les autres personnes de la lumière
et de la réverbération.
• Prévenir les autres personnes de ne pas regarder l’arc. Utiliser des affiches ou des panneaux.

Indice de protection
Indice de protection
Courant de l’arc suggéré pour OSHA 29CFR Europe
minimum
(A) assurer le confort 1910.133(a)(5) EN168:2002
(ANSI Z49.1:2005)
(ANSI Z49.1:2005)
Moins de 40 A 5 5 8 9
41 à 60 A 6 6 8 9
61 à 80 A 8 8 8 9
81 à 125 A 8 9 8 9
126 à 150 A 8 9 8 10
151 à 175 A 8 9 8 11
176 à 250 A 8 9 8 12
251 à 300 A 8 9 8 13
301 à 400 A 9 12 9 13
401 à 800 A 10 14 10

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PACEMAKERS ET PROTHÈSES AUDITIVES

Les champs magnétiques produits par les courants • Faire passer le faisceau de torche le plus près
à haute tension peuvent affecter le fonctionnement possible du câble de retour.
des prothèses auditives et des pacemakers.
• Ne pas s’enrouler le faisceau de torche ou le câble
Les personnes portant ce type d’appareil doivent de retour autour du corps.
consulter un médecin avant de s’approcher d’un lieu
• Se tenir le plus loin possible de la source de courant.
où s’effectue le coupage ou le gougeage d’arc plasma.
Pour réduire les risques associés aux champs
magnétiques :
• Garder loin de soi et du même côté du corps le câble
de retour et le faisceau de torche.

LE BRUIT PEUT PROVOQUER DES PROBLÈMES AUDITIFS

Le coupage avec l’arc plasma peut dépasser les niveaux de l’opérateur, délimiter les zones bruyantes à l’aide
de bruits acceptables conformément aux codes locaux d’une paroi et/ou instaurer des mesures préventives
relatifs à de nombreuses applications. Une exposition visant à réduire la réverbération sur le lieu de travail
prolongée à un bruit excessif peut provoquer des en installant des dispositifs antibruits.
problèmes auditifs. Toujours porter un dispositif de
Utiliser des protecteurs d’oreille si le bruit est toujours
protection antibruit adéquat lors du coupage ou du
dérangeant ou si des problèmes auditifs peuvent
gougeage, sauf si les mesures de niveau de bruits prises
survenir après l’installation des dispositifs de sécurité
sur le site d’installation certifient que les prothèses
intégrés et l’instauration des mesures préventives.
auditives ne sont pas nécessaires, telles que spécifiées
Si des protecteurs d’oreilles s’avèrent être nécessaires,
par les codes internationaux, régionaux et locaux.
porter uniquement des articles de protection
Les bruits peuvent être considérablement réduits en personnelle approuvés, tels que des oreillères ou des
ajoutant de simples dispositifs de sécurité intégrés bouchons d’oreille avec un coefficient de réduction de
aux tables de coupe, telles que des barrières ou des bruits approprié pour la situation sur le lieu de travail.
rideaux placés entre l’arc plasma et le poste de travail; Prévenir les personnes aux alentours des risques
et/ou en éloignant le poste de travail de l’arc plasma. encourus en cas d’exposition au bruit. En outre,
Mettre sur pied des mesures administratives sur le site la protection des oreilles sert également de munition
de travail afin de limiter l’accès et la durée d’exposition contre les projections chaudes.

UN ARC PLASMA PEUT ENDOMMAGER LES TUYAUX GELÉS

Tenter de dégeler les tuyaux gelés avec une torche plasma peut les endommager ou les faire éclater.

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INFORMATION SUR LE DÉPOUSSIÈRAGE

À certains endroits, la poussière peut représenter Note 1 – L’interprétation d’Hypertherm de ces nouvelles
un risque d’explosion potentiel. exigences est que, sauf évaluation particulière du site,
pour déterminer que toute la poussière produite n’est
La norme NFPA 68 de la National Fire Protection
pas combustible, l’édition 2007 de la NFPA 68 exige
Association des É.-U. (édition 2007) « Explosion
l’utilisation d’évents d’explosion conçus pour l’indice Kst
Protection by Deflagration Venting » établit les
dans le pire des cas (voir annexe F) qui pourrait provenir
exigences relatives à la conception, à l’emplacement,
de la poussière de sorte que l’on puisse concevoir la
à l’installation, à l’entretien et à l’utilisation de dispositifs
dimension et le type d’évent d’explosion. La NFPA 68
et de systèmes pour évacuer à l’air libre les gaz de
ne stipule pas particulièrement le procédé de coupage
combustion et les pressions après une déflagration.
plasma ou d’autres procédés de coupage thermique,
Communiquer avec le fabricant ou avec l’installateur
mais elle prescrit ces nouveaux règlements à tous les
de tout système de dépoussiérage afin de connaître
systèmes de dépoussiérage.
les exigences applicables avant d’installer un tel système
neuf ou d’apporter des modifications importantes aux Note 2 – Les utilisateurs des manuels d’Hypertherm
procédés ou aux matériaux utilisés par un système doivent consulter tous les règlements et lois fédéraux
de dépoussiérage existant. et locaux applicables et s’y conformer. Hypertherm n’a
pas l’intention, en publiant un manuel d’Hypertherm, de
Consultez l’autorité compétente locale pour déterminer
demander des mesures qui ne sont pas conformes aux
si une édition de la NFPA 68 a été adoptée en référence
règlements et normes applicables et ce manuel ne peut
dans vos codes du bâtiment locaux.
jamais être interprété dans ce sens.
Voir le document NFPA 68 pour obtenir des définitions
et des explications des termes réglementaires tels que
« déflagration, autorité compétente, adopté en référence,
indice Kst, indice de déflagration » et autres termes.

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RADIATION AU LASER
L’exposition à une sortie laser peut provoquer des problèmes visuels graves. Éviter un contact
direct avec les yeux.

Pour votre aisance et votre sécurité, l’une des étiquettes de radiation au laser suivantes a été installée sur les
produits Hypertherm près de la sortie du faisceau laser du boîtier. Ont également été fournies la sortie maximale
(mV), la longueur d’onde émise (nM) et au besoin, la durée d’impulsion.

Autres consignes de sécurité relatives au laser :

• Consulter un expert local pour les réglementations • Toute modification du laser ou du produit peut
locales sur le laser. Une formation sur la sécurité accroître le risque de radiation au laser.
relative au laser peut être nécessaire. • L’utilisation des réglages ou le suivi des procédures
• Ne pas autoriser le personnel non formé à faire autres que celles spécifiées dans ce manuel peut
fonctionner le laser. Il peut s’avérer dangereux pour entraîner un risque de radiation au laser.
ce personnel. • Ne pas faire fonctionner l’appareil en présence
• Ne jamais regarder l’intérieur ou le faisceau du laser. d’explosifs tels que des liquides et des gaz
• Positionner le laser selon les instructions afin d’éviter inflammables ou la poussière.
un éventuel contact avec les yeux. • Utiliser uniquement les pièces et accessoires laser
• Ne pas utiliser le laser sur des pièces à couper recommandés ou fournis par le fabricant pour votre
réflectives. modèle.
• Ne pas utiliser des outils optiques pour visualiser • Les travaux de réparation et d’entretien DOIVENT
le faisceau du laser. être effectués par un personnel qualifié.
• Ne pas démonter ou retirer le laser ou son capot. • Ne pas retirer ou détruire l’étiquette de sécurité
du laser.

1a-10 Hypertherm
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 Sécurité

SYMBOLES ET MARQUAGE
Votre produit Hypertherm peut comporter une ou plusieurs des marques suivantes sur sa plaque signalétique ou
à proximité. En raison des différends et des conflits relatifs aux règlements nationaux, toutes les marques ne sont
pas appliquées à chaque version d’un produit.

Symbole de marque S
Le symbole de marque S indique que la source de courant et la torche conviennent pour les travaux
effectués dans les milieux à risque accru de choc électrique selon l’IEC 60974-1.

Marque CSA
Les produits Hypertherm portant la marque CSA sont conformes aux réglementations des États-Unis et du
Canada pour la sécurité des produits. Les produits ont été évalués, testés et certifiés par CSA-International.
Le produit peut autrement porter la marque d’autres laboratoires d’essais reconnus à l’échelle nationale
(NRTL) agréés à la fois aux États-Unis et au Canada, par exemple : Underwriters Laboratories, Incorporated
(UL) ou TÜV.

Marque CE
 e marquage CE signifie : déclaration de conformité du fabricant aux directives et normes européennes
L
applicables. Seules les versions des produits Hypertherm portant la marque CE située sur ou à proximité
de la plaque signalétique ont été testées pour conformité à la directive européenne « basse tension »
et la directive européenne « compatibilité électromagnétique » (CEM). Les filtres CEM devant être
en conformité avec la directive européenne CEM sont intégrés dans les produits portant la marque CE.

Marque GOST-R
Les versions CE des produits Hypertherm qui portent la marque de conformité GOST-R répondent aux
exigences de sécurité du produit et de CEM en vue de l’exportation à la Fédération russe.

Marque c-Tick
 es versions CE des produits Hypertherm portant la marque c-Tick sont conformes aux règlements CEM
L
prescrits pour la vente en Australie et en Nouvelle-Zélande.

Marque CCC
La marque de certification obligatoire en Chine (CCC) indique que le produit a été mis à l’essai et déclaré
conforme aux règlements de sécurité du produit prescrits pour la vente en Chine.

Hypertherm 1a-11
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Sécurité

ÉTIQUETTES DE SÉCURTITÉ
Cette étiquette est affichée sur certaines sources de courant. Il est important que l’opérateur et le technicien
d’entretien comprennent la signification des symboles de sécurité.

Read and follow these instructions, employer safety

practices, and material safety data sheets. Refer to WARNING AVERTISSEMENT
ANS Z49.1, “Safety in Welding, Cutting and Allied
Processes” from American Welding Society Plasma cutting can be injurious to operator and persons Le coupage plasma peut être préjudiciable pour l’opérateur et les personnes qui se
(http://www.aws.org) and OSHA Safety and Health in the work area. Consult manual before operating. Failure trouvent sur les lieux de travail. Consulter le manuel avant de faire fonctionner. Le
Standards, 29 CFR 1910 (http://www.osha.gov). to follow all these safety instructions can result in death. non respect des ces instructions de sécurité peut entraîner la mort.

1. Cutting sparks can cause explosion or fire. 1. Les étincelles de coupage peuvent provoquer une explosion
1.1 Do not cut near flammables. ou un incendie.
1.2 Have a fire extinguisher nearby and ready to use. 1.1 Ne pas couper près des matières inflammables.
1.3 Do not use a drum or other closed container as a cutting table. 1.2 Un extincteur doit être à proximité et prêt à être utilisé.
1.3 Ne pas utiliser un fût ou un autre contenant fermé comme table de coupage.
2. Plasma arc can injure and burn; point the nozzle away 2. L’arc plasma peut blesser et brûler; éloigner la buse de soi.
from yourself. Arc starts instantly when triggered. Il s’allume instantanément quand on l’amorce;
2.1 Turn off power before disassembling torch. 2.1 Couper l’alimentation avant de démonter la torche.
2.2 Do not grip the workpiece near the cutting path. 2.2 Ne pas saisir la pièce à couper de la trajectoire de coupage.
2.3 Wear complete body protection. 2.3 Se protéger entièrement le corps.

3. Hazardous voltage. Risk of electric shock or burn. 3. Tension dangereuse. Risque de choc électrique ou de brûlure.
3.1 Wear insulating gloves. Replace gloves when wet or damaged. 3.1 Porter des gants isolants. Remplacer les gants quand ils sont humides ou
3.2 Protect from shock by insulating yourself from work and ground. endommagés.
3.3 Disconnect power before servicing. Do not touch live parts. 3.2 Se protéger contre les chocs en s’isolant de la pièce et de la terre.
3.3 Couper l’alimentation avant l’entretien. Ne pas toucher les pièces sous tension.

4. Plasma fumes can be hazardous. 4. Les fumées plasma peuvent être dangereuses.
4.1 Do not inhale fumes. 4.1 Ne pas inhaler les fumées
4.2 Use forced ventilation or local exhaust to remove the fumes. 4.2 Utiliser une ventilation forcée ou un extracteur local pour dissiper les fumées.
4.3 Do not operate in closed spaces. Remove fumes with ventilation. 4.3 Ne pas couper dans des espaces clos. Chasser les fumées par ventilation.

5. Arc rays can burn eyes and injure skin. 5. Les rayons d’arc peuvent brûler les yeux et blesser la peau.
5.1 Wear correct and appropriate protective equipment to protect 5.1 Porter un bon équipement de protection pour se protéger la tête, les yeux, les
head, eyes, ears, hands, and body. Button shirt collar. Protect ears oreilles, les mains et le corps. Boutonner le col de la chemise. Protéger les oreilles
from noise. Use welding helmet with the correct shade of filter. contre le bruit. Utiliser un masque de soudeur avec un filtre de nuance appropriée.

6. Become trained. Only qualified personnel should operate this 6. Suivre une formation. Seul le personnel qualifié a le droit de faire
equipment. Use torches specified in the manual. Keep non-qualified fonctionner cet équipement. Utiliser exclusivement les torches indiquées dans le
personnel and children away. manual. Le personnel non qualifié et les enfants doivent se tenir à l’écart.
7. Do not remove, destroy, or cover this label. 7. Ne pas enlever, détruire ni couvrir cette étiquette.
Replace if it is missing, damaged, or worn (PN 110584 Rev C). La remplacer si elle est absente, endommagée ou usée (PN 110584 Rev C).

1a-12 Hypertherm
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 Sécurité

ÉTIQUETTE DE SÉCURITÉ 1. L  es étincelles de coupage peuvent

provoquer une explosion ou un incendie.
Cette étiquette est affichée sur certaines sources de courant. Il est
important que l’opérateur et le technicien d’entretien comprennent 1.1 Ne pas couper près des matières
la signification des symboles de sécurité. Les numéros de la liste inflammables.
correspondent aux numéros des images. 1.2 Un extincteur doit se trouver sur les lieux
et être prêt à être utilisé.
1.3 Ne pas utiliser un fût ou un autre
contenant fermé comme table de coupe.
2. L’arc plasma peut blesser et brûler;
ne jamais pointer la buse vers soi.
L’arc s’amorce instantanément quand
on  appuie sur la gâchette.
2.1 Couper l’alimentation avant de démonter
la torche.
2.2 Ne pas saisir la pièce à couper près
de la trajectoire de coupage.
2.3 Se protéger entièrement le corps.
3. Tension dangereuse. Risque de choc
électrique ou de brûlure.
3.1 Porter des gants isolants. Remplacer les
gants s’ils sont humides ou endommagés.
3.2 Se protéger contre les chocs en s’isolant
de la pièce et de la terre.
3.3 Couper l’alimentation avant de procéder
à l’entretien. Ne pas toucher les pièces
sous tension.
4. Les fumées du plasma peuvent être
dangereuses.
4.1 Ne pas inhaler les fumées.
4.2 Utiliser une ventilation forcée ou par
extraction locale pour éliminer les fumées.
4.3 Ne pas utiliser dans des espaces clos.
Éliminer les fumées avec la ventilation.
5. Les rayons d’arc peuvent brûler les yeux
et blesser la peau.
5.1 Porter un bon équipement de protection
pour se protéger la tête, les yeux, les
oreilles, les mains et le corps. Boutonner
le col de la chemise. Protéger les oreilles
contre le bruit. Utiliser le masque de
soudage avec le filtre ayant le bon indice
de protection.
6. Suivre une formation. Seul le personnel
qualifié doit faire fonctionner cet
équipement. Utiliser les torches prescrites
dans le manuel. Tenir le personnel non
qualifié et les enfants à l’écart.
7. Ne pas enlever, détruire ou couvrir
cette étiquette. La remplacer si elle
est manquante, endommagée ou usée.

Hypertherm 1a-13
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Sécurité

1a-14 Hypertherm
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 Sección 1b

SEGURIDAD

En esta sección:

Reconocimiento de información de seguridad....................................................................................................................................1-2

Cumplimiento de instrucciones de seguridad.....................................................................................................................................1-2
Riesgos de electrocución.........................................................................................................................................................................1-2
Las descargas eléctricas pueden matar................................................................................................................................................1-3
Los cortes pueden producir incendios o explosiones........................................................................................................................1-4
Los vapores tóxicos pueden producir lesiones o la muerte..............................................................................................................1-5
Seguridad de toma a tierra.......................................................................................................................................................................1-6
La electricidad estática puede dañar las placas de circuitos...........................................................................................................1-6
Seguridad de equipos de gas comprimido..........................................................................................................................................1-6
Los cilindros de gas pueden explotar si están dañados...................................................................................................................1-6
El arco de plasma puede producir lesiones y quemaduras..............................................................................................................1-7
Los rayos del arco pueden quemar los ojos y la piel..........................................................................................................................1-7
Funcionamiento de marcapasos y audífonos.......................................................................................................................................1-8
Los ruidos pueden dañar la audición.....................................................................................................................................................1-8
El arco de plasma puede dañar las tuberías congeladas..................................................................................................................1-8
Información acerca de la recolección de polvo seco.........................................................................................................................1-9
Radiación láser......................................................................................................................................................................................... 1-10
Símbolos y marcas.................................................................................................................................................................................. 1-11
Etiquetas de advertencia........................................................................................................................................................................ 1-12

Hypertherm 1b-1
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Seguridad

RECONOCIMIENTO PELIGRO   ADVERTENCIA   PRECAUCIÓN

DE INFORMACIÓN Hypertherm utiliza las pautas del American National
DE SEGURIDAD Standards Institute en relación con los símbolos y las
palabras de aviso de seguridad. Junto a los símbolos de
Los símbolos incluidos en esta sección se usan para seguridad, aparecen palabras de aviso como PELIGRO
identificar posibles peligros. Cuando vea un símbolo de o ADVERTENCIA. La palabra PELIGRO identifica a los
seguridad en este manual o en la máquina, debe tomar riesgos más graves.
conciencia del riesgo de lesiones personales y seguir
las instrucciones relacionadas para evitar ese riesgo. • Las etiquetas de seguridad de PELIGRO
y ADVERTENCIA están colocadas cerca de
CUMPLIMIENTO los riesgos específicos que presenta la máquina.
DE INSTRUCCIONES • Los mensajes de seguridad de PELIGRO aparecen
DE SEGURIDAD en este manual antes de las instrucciones
Lea cuidadosamente todos los mensajes de seguridad relacionadas a procesos que pueden producir
de este manual y todas las etiquetas de seguridad de lesiones o la muerte si no se siguen correctamente.
la máquina.
• Los mensajes de seguridad de ADVERTENCIA
• Mantenga las etiquetas de seguridad de la máquina aparecen en este manual antes de las instrucciones
en buen estado. Reponga de inmediato las etiquetas relacionadas a procesos que pueden producir
dañadas o faltantes. lesiones o la muerte si no se siguen correctamente.
• Aprenda a operar la máquina y usar los controles de
manera adecuada. No permita que nadie la opere sin • Los mensajes de seguridad de PRECAUCIÓN
las instrucciones correspondientes. aparecen en este manual antes de las instrucciones
relacionadas a procesos que pueden producir
• Asegúrese de que la máquina esté en buenas condiciones
lesiones menores o daños en los equipos si no
operativas. Las modificaciones no autorizadas pueden
se siguen correctamente.
afectar la seguridad y la vida útil de la máquina.

RIESGOS DE ELECTROCUCIÓN
• Si no se puede cortar el suministro de energía del
• Sólo el personal capacitado y autorizado puede abrir equipo mientras se abre el armazón para realizar
este equipo. reparaciones, es posible que se produzcan peligros
• Si el equipo está conectado en forma permanente, de explosión de arco eléctrico. Siga TODOS los
apáguelo e implemente un cierre “con llave y etiqueta” requisitos locales (NFPA 70E en los EE. UU.) en
de la energía antes de abrir el armazón. relación con las practicas de trabajo seguro y con el
equipo de protección personal al realizar reparaciones
• Si el suministro de energía se realiza a través de un en equipos energizados.
cable, desenchufe la unidad antes de abrir el armazón.
• El armazón debe permanecer cerrado y se debe
• Otras personas deberán suministrar las cubiertas para verificar que la continuidad a tierra física al armazón
enchufes bloqueables y los elementos de desconexión sea la adecuada antes de operar el equipo y luego
bloqueables. de moverlo, abrirlo o realizarle reparaciones.
• Espere 5 minutos luego de cortar la energía y antes • Siempre siga estas instrucciones para desconectar
de ingresar en el armazón, a fin de permitir que la energía antes de inspeccionar o cambiar las piezas
la energía almacenada se descargue. consumibles de la antorcha.

1b-2 Hypertherm
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 Seguridad

LAS DESCARGAS ELÉCTRICAS PUEDEN MATAR

El contacto con piezas eléctricas con corriente puede • Instale y ponga a tierra el equipo respetando el manual
causar una descarga mortal o quemaduras graves. de instrucciones y los códigos nacionales y locales.
• Cuando el sistema de plasma está en funcionamiento, • Inspeccione con frecuencia el cable de potencia
se completa un circuito eléctrico entre la antorcha y la de alimentación para detectar daños o rajaduras
pieza a cortar. La pieza a cortar y cualquier objeto que en la cubierta. Reemplace los cables dañados
la esté tocando pasan a formar parte de este circuito. de inmediato. Los cables pelados pueden ser
• Nunca toque el cuerpo de antorcha, la pieza a cortar mortales.
ni el agua de la mesa de agua cuando el sistema • Inspeccione las mangueras de la antorcha y reemplace
de plasma esté en funcionamiento. las que estén dañadas.
• No levante la pieza a cortar ni los residuos de corte
Prevención de descargas eléctricas
durante la tarea. Deje la pieza a cortar en su lugar
Todos los sistemas de plasma Hypertherm o en la mesa de trabajo con el cable de trabajo
usan voltajes altos en el proceso de corte colocado durante el proceso de corte.
(suelen ser de 200 a 400 VCD). Tome las • Antes de controlar, limpiar o reemplazar piezas de
siguientes precauciones al operar el sistema: la antorcha, desconecte la alimentación principal
• Use botas y guantes aislados, y mantenga su cuerpo o desenchufe la fuente de energía.
y su vestimenta secos. • Nunca anule ni puentee los bloqueos de seguridad.
• Asegúrese de que ninguna parte de su cuerpo esté • Antes de quitarle la cubierta a una fuente de energía
en contacto con una superficie mojada mientras usa o recinto del sistema, desconecte la potencia
el sistema de plasma. de alimentación eléctrica. Espere 5 minutos antes
• Aíslese de la pieza de trabajo y la tierra con una de desconectar la alimentación principal, para permitir
alfombra o cubierta aislante de tamaño suficiente la descarga de los condensadores.
para prevenir cualquier contacto físico con la pieza • Nunca opere el sistema de plasma sin las cubiertas
de trabajo o la tierra. Tenga mucha precaución si de la fuente de energía en su lugar. Si las conexiones
el lugar de trabajo o los alrededores están húmedos. de la fuente de energía están expuestas, presentan
• Instale un interruptor de desconexión con fusibles un alto riesgo de electrocución.
de tamaño apropiado cerca de la fuente de energía. • Al hacer las conexiones de entrada, una primero
Este interruptor permitirá al operador cortar la fuente el conductor de puesta a tierra correspondiente.
de energía rápidamente ante una emergencia.
• Cada sistema de plasma Hypertherm está diseñado
• Al usar una mesa de agua, asegúrese de que esté para usarse únicamente con antorchas Hypertherm
bien puesta a tierra. específicas. No utilice otras antorchas, ya que
podrían sobrecalentarse y presentar un riesgo para
la seguridad.

Hypertherm 1b-3
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Seguridad

LOS CORTES PUEDEN PRODUCIR INCENDIOS

O EXPLOSIONES

Prevención de incendios ADVERTENCIA

• Compruebe la seguridad del lugar antes de realizar Peligro de explosión
cortes. Tenga disponible un extintor de incendios Argón-hidrógeno y metano
cerca del lugar. El hidrógeno y el metano son gases inflamables que
• Mantenga todas las sustancias inflamables a 10 m presentan un riesgo de explosión. Mantenga las llamas
de distancia del área de corte. alejadas de los cilindros y las mangueras con metano
• Temple o deje enfriar el metal caliente antes de o mezclas de hidrógeno. Evite que las llamas y las
manipularlo o que entre en contacto con materiales chispas se acerquen a la antorcha cuando use plasma
combustibles. de metano o argón-hidrógeno.
• Nunca corte envases que contengan materiales
potencialmente inflamables; primero deben vaciarse
y limpiarse bien.
• Ventile las atmósferas que puedan ser inflamables ADVERTENCIA
antes de realizar cortes. Peligro de explosión
Cortes bajo el agua con
• Al cortar con oxígeno como gas plasma, es obligatorio
gases combustibles
el uso de un sistema de ventilación de escape.
• No corte aluminio bajo el agua o cuando el agua esté
Prevención de explosiones en contacto con la parte inferior del aluminio.
• No use el sistema de plasma si puede haber polvo • Cortar aluminio bajo el agua o cuando el agua esté
o vapores explosivos. en contacto con la parte inferior del aluminio puede
• No corte cilindros presurizados, tuberías ni envases provocar una situación explosiva que podría detonarse
cerrados. durante las operaciones de corte por plasma.
• No corte envases que tenían materiales combustibles.

ADVERTENCIA
Explosión de hidrógeno
al cortar aluminio
• No realice cortes bajo el agua con gases
combustibles que contengan hidrógeno.
• Realizar cortes bajo el agua con gases combustibles
que contienen hidrógeno puede provocar una situación
explosiva que podría detonarse durante operaciones
de corte por plasma.

1b-4 Hypertherm
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 Seguridad

LOS VAPORES TÓXICOS PUEDEN PRODUCIR LESIONES

O LA MUERTE
El arco de plasma es la fuente de calor usada para el • Tamaño, volumen de aire, ventilación y filtración
corte. Por lo tanto, aunque el arco de plasma mismo no del área de trabajo.
sea fuente de vapores tóxicos, el material que se corta • Equipos de protección personal.
puede producir estos vapores o gases que agotan
el oxígeno. • Cantidad de sistemas de soldadura y corte en
funcionamiento.
Los vapores producidos varían según el metal que se • Otros procesos del lugar que pueden producir
corte. Algunos de los metales que pueden producir vapores.
vapores tóxicos son, entre otros, el acero inoxidable,
el acero al carbono, el zinc (galvanizado) y el cobre. Si el lugar de trabajo debe cumplir con reglamentaciones
nacionales o locales, sólo los controles o pruebas
En algunos casos, el metal puede estar recubierto por realizados en el lugar pueden determinar si los niveles
una sustancia que podría producir vapores tóxicos. se encuentran dentro de lo permitido.
Los revestimientos tóxicos incluyen, entre otros, el plomo
Para reducir el riesgo de exposición a vapores:
(de algunas pinturas), el cadmio (de algunas pinturas
y tapaporos) y el berilio. • Quite todos los revestimientos y solventes del metal
antes de cortar.
Los gases producidos por el corte por plasma varían • Use la ventilación de escape local para eliminar los
según el material y el método de corte, pero pueden vapores del aire.
incluir ozono, óxidos de nitrógeno, cromo hexavalente,
• No inhale los vapores. Use un respirador con suministro
hidrógeno y otras sustancias contenidas o liberadas
de aire al cortar metales que contienen o pueden
por el material de corte.
contener elementos tóxicos, o están recubiertos con
estos elementos.
Se deben tomar precauciones para minimizar la
exposición a los vapores producidos en cualquier • Asegúrese de que las personas que usen equipos
proceso industrial. Según la composición química de soldadura o corte, y respiradores con suministro
y la concentración de los vapores (junto con otros de aire estén calificadas y capacitadas en el uso
factores, como la ventilación), puede haber riesgo adecuado de estos equipos.
de contraer enfermedades físicas, como defectos • Nunca corte envases que contengan materiales
congénitos o cáncer. potencialmente tóxicos. Vacíe y limpie bien el envase
antes de cortarlo.
El propietario del equipo y las instalaciones debe
• Realice controles o pruebas de la calidad del aire del
analizar la calidad del aire del lugar donde se usa
lugar, según sea necesario.
el equipo, para asegurarse de que cumpla con todas
las normas y reglamentaciones locales y nacionales. • Consulte a un experto local sobre la implementación
de un plan para asegurarse de que la calidad del aire
La calidad del aire de cualquier lugar de trabajo sea segura.
depende de variables específicas del lugar, como:
• Diseño de la mesa (con agua, en seco, bajo el agua).
• Composición del material, acabado de la superficie
y composición de los revestimientos.
• Volumen de material descartado.
• Duración del corte o ranurado.

Hypertherm 1b-5
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Seguridad

SEGURIDAD DE TOMA A TIERRA

Cable de trabajo  Sujete el cable de trabajo firmemente • Si la instalación del sistema de plasma implica
a la pieza a cortar o la mesa de trabajo, estableciendo un la conexión del cable de alimentación a la fuente
buen contacto metal con metal. No lo conecte a la pieza de energía, asegúrese de conectar adecuadamente
que se caerá cuando se termine el corte. el conductor de puesta a tierra del cable de
alimentación.
Mesa de trabajo  Ponga a tierra la mesa de trabajo, • Coloque el conductor de puesta a tierra del cable
en cumplimiento con los códigos eléctricos locales de alimentación en el borne antes que los demás;
y nacionales. los otros conductores de puesta a tierra deben ir
encima del conductor del cable de alimentación.
Potencia de alimentación (entrada) Ajuste bien la tuerca de retención.
• Asegúrese de conectar el conductor de puesta • Ajuste todas las conexiones eléctricas para evitar
a tierra del cable de alimentación con la puesta el calentamiento excesivo.
a tierra de la caja de desconexión.

LA ELECTRICIDAD ESTÁTICA PUEDE DAÑAR LAS PLACAS

DE CIRCUITOS
Tome las precauciones necesarias para manipular placas de circuito impreso:
• Guarde las placas de PC en recipientes antiestáticos.
• Use una cinta de muñeca puesta a tierra para manipular las placas de PC.

SEGURIDAD DE EQUIPOS LOS CILINDROS DE GAS

DE GAS COMPRIMIDO PUEDEN EXPLOTAR SI
• Nunca lubrique los reguladores o las válvulas ESTÁN DAÑADOS
de cilindros con aceite o grasa. Los cilindros de gas tienen gas bajo alta presión. Si se
dañan, pueden explotar.
• Use únicamente los cilindros de gas, los reguladores,
las mangueras y los accesorios diseñados • Los cilindros de gas comprimido deben manipularse
específicamente para esa aplicación. y usarse respetando los códigos nacionales y locales.
• Mantenga todos los equipos de gas comprimido • Use únicamente cilindros que estén en posición
y las piezas relacionadas en buen estado. vertical y bien sujetos en su lugar.
• Etiquete e identifique con colores todas las • Mantenga la tapa protectora colocada en la válvula,
mangueras de gas, para saber el tipo de gas que a menos que el cilindro esté conectado o en uso.
transporta cada manguera. Consulte los códigos
nacionales y locales correspondientes. • Nunca permita que haya contacto eléctrico entre
el arco de plasma y un cilindro.

• Nunca exponga los cilindros al calor excesivo,

las chispas, la escoria ni la llama directa.

• Nunca use un martillo, llave ni otra herramienta para

abrir una válvula de cilindro atascada.

1b-6 Hypertherm
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 Seguridad

EL ARCO DE PLASMA PUEDE PRODUCIR LESIONES

Y QUEMADURAS
Antorchas de encendido inmediato El arco de plasma puede cortar los guantes y la piel
El arco de plasma se enciende de inmediato al activar rápidamente.
el interruptor de la antorcha. • Evite el contacto con la punta de la antorcha.
• No ponga piezas de metal cerca de la ruta de corte.
• Nunca apunte la antorcha en dirección a usted
o a otras personas.

LOS RAYOS DEL ARCO PUEDEN QUEMAR

LOS OJOS Y LA PIEL
Protección ocular  El arco de plasma produce rayos visibles e invisibles (ultravioletas e infrarrojos) que pueden
quemar los ojos y la piel.
• Use la protección ocular que exigen los códigos nacionales y locales.
• Las lentes de la protección ocular (anteojos o gafas de seguridad con protección lateral, y careta de soldador)
deben contar con el sombreado adecuado para proteger los ojos de los rayos ultravioletas e infrarrojos del arco.

Protección cutánea  Use vestimenta de protección para evitar las quemaduras producidas por la luz ultravioleta,
las chispas y el metal caliente.
• Guantes de seguridad, calzado de seguridad y casco.
• Vestimenta ignífuga para cubrir todas las áreas expuestas.
• Pantalones sin dobladillo, para evitar el ingreso de chispas y escoria.
• Antes del corte, sáquese de los bolsillos todo material combustible, como los encendedores con butano o los fósforos.

Área de corte  Prepare el área de corte para reducir el reflejo y la emisión de luz ultravioleta:
• Pinte las paredes y otras superficies de colores oscuros, para reducir el reflejo.
• Use pantallas o barreras protectoras para resguardar a los demás del centelleo y el resplandor.
• Advierta a las demás personas que no deben mirar el arco. Coloque carteles o anuncios.
Número mínimo Número de sombra
Corriente
de sombra de sugerido para OSHA 29CFR Europa
del arco
protección confort (ANSI 1910.133(a)(5) EN168:2002
(amperios)
(ANSI Z49.1:2005) Z49.1:2005)
Inferior a 40 A 5 5 8 9
41 a 60 A 6 6 8 9
61 a 80 A 8 8 8 9
81 a 125 A 8 9 8 9
126 a 150 A 8 9 8 10
151 a 175 A 8 9 8 11
176 a 250 A 8 9 8 12
251 a 300 A 8 9 8 13
301 a 400 A 9 12 9 13
401 a 800 A 10 14 10

Hypertherm 1b-7
03/10
Seguridad

FUNCIONAMIENTO DE MARCAPASOS Y AUDÍFONOS

El funcionamiento de marcapasos y audífonos puede • Haga pasar las mangueras de la antorcha lo más
verse afectado por los campos magnéticos de las altas cerca posible del cable de trabajo.
corrientes.
• No se enrosque ni apoye los conductos de antorcha
Las personas que usan marcapasos o audífonos deben ni el cable de trabajo en el cuerpo.
consultar a un médico antes de acercarse a una operación
• Manténgase lo más alejado de la fuente de energía
de corte o ranurado por arco de plasma.
como sea posible.
Para reducir el riesgo que presentan los campos
magnéticos:
• Mantenga el cable de trabajo y los conductos
de antorcha a un costado, alejados del cuerpo.

LOS RUIDOS PUEDEN DAÑAR LA AUDICIÓN

Realizar cortes con un arco de plasma puede superar administrativos en el lugar de trabajo para restringir
los niveles de ruido aceptables, según se definen el acceso, limitar el tiempo de exposición del operador,
en los códigos locales en muchas aplicaciones. La cubrir áreas de trabajo ruidosas o tomar las medidas
exposición prolongada a ruidos excesivos puede dañar necesarias para reducir la reverberación en áreas de
la audición. Siempre use una protección apropiada para trabajo al colocar mecanismos de absorción de ruidos.
los oídos al realizar cortes o ranurados, a menos que
Se debe utilizar una protección auditiva si el ruido es
se haya verificado que, en función de las mediciones
perjudicial o si existe el riesgo de que se produzcan
de los niveles de presión de sonido tomadas en el sitio
daños a la audición una vez implementados todos los
instalado, no sea necesario utilizar protección auditiva
demás controles administrativos y de ingeniería. Si es
personal, de acuerdo con los códigos internacionales,
necesario utilizar una protección auditiva, utilice sólo los
regionales y locales correspondientes.
dispositivos de protección personal aprobados, como
Se puede obtener una reducción significativa de protectores para las orejas o tapones para los oídos
los ruidos mediante la incorporación de controles con una calificación de reducción de ruidos adecuada
de ingeniería simples a las mesas de corte, como para la situación. Advierta a las demás personas que
barreras o cortinas ubicadas entre el arco de trabajan en el área sobre los posibles riesgos que
plasma y la estación de trabajo; además, se puede presentan los ruidos. Además, la protección para los
ubicar la estación de trabajo en un lugar alejado oídos puede evitar que salpicaduras calientes ingresen
del arco de plasma. Se deben implementar controles en la oreja.

EL ARCO DE PLASMA PUEDE DAÑAR LAS TUBERÍAS

CONGELADAS
Las tuberías pueden dañarse o reventar si se intenta descongelarlas con una antorcha de plasma.

1b-8 Hypertherm
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 Seguridad

INFORMACIÓN ACERCA DE LA RECOLECCIÓN DE POLVO SECO

En algunos sitios, el polvo seco puede presentar un Nota 1 – La interpretación por parte de Hypertherm de
posible riesgo de explosión. estos nuevos requisitos implica que, a menos que se
haya realizado una evaluación específica del lugar para
La edición 2007 de la norma 68 NFPA de la U.S. National
determinar que el polvo generado no es combustible,
Fire Protection Association, “Explosion Protection by
la edición 2007 de NFPA 68 requiere el uso de
Deflagration Venting” (Protección contra explosiones
ventilaciones de explosión diseñadas para el peor valor
mediante ventilación en caso de deflagración)
Kst (consulte el anexo F) que se podría generar a causa
proporciona los requisitos para el diseño, la ubicación,
del polvo, de manera que se puedan diseñar el tipo y el
la instalación, el mantenimiento y el uso de dispositivos
tamaño de ventilación de explosión. La norma NFPA 68
y sistemas para ventilar presiones y gases de combustión
no identifica específicamente que el corte por plasma
después de un evento de deflagración. Consulte al
ni otros procesos de corte térmico requieran sistemas
fabricante o instalador de sistemas de recolección de
de ventilación en caso de deflagración; sin embargo,
polvo seco acerca de los requisitos aplicables antes
sí aplica estos nuevos requisitos a todos los sistemas
de instalar un nuevo sistema de recolección de polvo
de recolección de polvo seco.
seco o de realizar cambios significativos en los materiales
o procesos utilizados con un sistema de recolección Nota 2 – Los usuarios de los manuales de Hypertherm
de polvo seco existente. deben consultar y cumplir todas las regulaciones
y leyes federales, estatales y locales correspondientes.
Consulte la “Autoridad con jurisdicción” (AHJ, Authority
Mediante la publicación de sus manuales, Hypertherm
Having Jurisdiction) para determinar si la edición de la
no pretende instar la implementación de acciones
norma 68 de la NFPA se ha “adoptado por referencia”
que no cumplen los estándares y las regulaciones
en los códigos de construcción locales.
aplicables; asimismo, no se debe interpretar que este
Consulte la norma NFPA68 para conocer las manual persigue dicho fin.
definiciones y explicaciones de los términos aprobados
como deflagración, AHJ, adoptado por referencia, valor
Kst, índice de deflagración y otros términos.

Hypertherm 1b-9
03/10
Seguridad

RADIACIÓN LÁSER
La exposición a la salida del láser puede provocar graves daños oculares. Evite la exposición
ocular directa.

Para su conveniencia y seguridad, en todos los productos Hypertherm que usan un láser, se ha aplicado una
de las siguientes etiquetas de radiación láser en el producto, cerca de lugar donde el haz láser sale del bastidor.
También se proporcionan los valores de salida máxima (mV), la longitud de onda emitida (nM) y, si corresponde,
la duración de pulso.

Instrucciones de seguridad adicionales sobre

la utilización de productos con láser:
• Consulte a un experto para conocer las regulaciones • Las modificaciones realizadas al láser o al producto
locales sobre la utilización de láser. Es posible que pueden aumentar el riesgo de que se produzca
se exija una capacitación de seguridad para el uso radiación láser.
de láser. • El uso de ajustes o la implementación de
• No permita que el personal no capacitado opere procedimientos que no sean aquellos especificados
el láser. El láser puede ser peligroso si es utilizado en este manual pueden provocar una exposición
por personal no capacitado. peligrosa a la radiación láser.
• No mire el haz o la apertura del láser en ningún • No opere el producto en atmósferas explosivas, como
momento. en presencia de polvo, gases o líquidos inflamables.
• Ubique el láser como se indica, a fin de evitar • Sólo utilice los accesorios y las piezas del láser que
contacto ocular no deseado. el fabricante suministra o recomienda para su modelo.
• No utilice el láser en piezas a cortar reflectantes. • Las reparaciones y el mantenimiento SE DEBEN
• No utilice herramientas ópticas para visualizar llevar a cabo por personal calificado.
o reflectar el haz del láser. • No extraiga ni mutile la etiqueta de seguridad
• No desarme ni extraiga el láser ni la cubierta del láser.
de apertura.

1b-10 Hypertherm
03/10
 Seguridad

SÍMBOLOS Y MARCAS
Su producto Hypertherm puede contener alguna de las siguientes marcas en la placa de datos o cerca de ella. Debido
a las diferencias y los conflictos con las regulaciones nacionales, no todas las marcas se aplican a todas las versiones
de un producto.

Marca símbolo S
La marca símbolo S indica que la fuente de energía y la antorcha son aptas para operaciones llevadas a cabo
en entornos en los que existe un alto peligro de descargas eléctricas, de acuerdo con la norma IEC 60974-1.

Marca CSA
Los productos de Hypertherm que tienen la marca CSA cumplen con los reglamentos de seguridad de los
productos de los Estados Unidos y Canadá. Estos productos han sido evaluados, probados y certificados
por CSA-International. De manera alternativa, es posible que el producto tenga una marca colocada por otro
Laboratorio de pruebas reconocido a nivel nacional (NRTL, por sus siglas en inglés) autorizado en los Estados
Unidos y en Canadá, por ejemplo, Underwriters Laboratories, Incorporated (UL) o TÜV.

Marca CE
 a marca CE indica la declaración de cumplimiento del fabricante con las normas y las directivas europeas
L
aplicables. Sólo se considerarán probadas para cumplimiento con las Directivas europeas de baja tensión
y con las Directivas europeas de compatibilidad electromagnética (EMC) aquellas versiones de los productos
Hypertherm que tengan la marca CE colocada sobre la placa de datos o cerca de ésta. Aquellos filtros de
EMC que deban cumplir con las Directivas europeas de EMC se han incorporado a las versiones de los
productos con la marca CE.

Marca GOST-R
Las versiones CE de los productos de Hypertherm que incluyen una marca de conformidad GOST-R cumplen
los requisitos de compatibilidad electromagnética (EMC) y de seguridad del producto para exportación
a la Federación Rusa.

Marca c-Tick
 as versiones CE de los productos de Hypertherm que incluyen una marca c-Tick cumplen las regulaciones
L
de EMC para la venta del producto en Australia y Nueva Zelanda.

Marca CCC
La marca China Compulsory Certification (CCC) indica que se ha evaluado el producto y que este cumple
las regulaciones de seguridad del producto requeridas para su venta en China.

Hypertherm 1b-11
03/10
Seguridad

ETIQUETAS DE ADVERTENCIA
Esta etiqueta de advertencia se coloca en ciertas fuentes de energía. Es importante que el operador y el técnico
de mantenimiento entiendan las ideas que transmiten estos símbolos de advertencia.

Read and follow these instructions, employer safety

practices, and material safety data sheets. Refer to WARNING AVERTISSEMENT
ANS Z49.1, “Safety in Welding, Cutting and Allied
Processes” from American Welding Society Plasma cutting can be injurious to operator and persons Le coupage plasma peut être préjudiciable pour l’opérateur et les personnes qui se
(http://www.aws.org) and OSHA Safety and Health in the work area. Consult manual before operating. Failure trouvent sur les lieux de travail. Consulter le manuel avant de faire fonctionner. Le
Standards, 29 CFR 1910 (http://www.osha.gov). to follow all these safety instructions can result in death. non respect des ces instructions de sécurité peut entraîner la mort.

1. Cutting sparks can cause explosion or fire. 1. Les étincelles de coupage peuvent provoquer une explosion
1.1 Do not cut near flammables. ou un incendie.
1.2 Have a fire extinguisher nearby and ready to use. 1.1 Ne pas couper près des matières inflammables.
1.3 Do not use a drum or other closed container as a cutting table. 1.2 Un extincteur doit être à proximité et prêt à être utilisé.
1.3 Ne pas utiliser un fût ou un autre contenant fermé comme table de coupage.
2. Plasma arc can injure and burn; point the nozzle away 2. L’arc plasma peut blesser et brûler; éloigner la buse de soi.
from yourself. Arc starts instantly when triggered. Il s’allume instantanément quand on l’amorce;
2.1 Turn off power before disassembling torch. 2.1 Couper l’alimentation avant de démonter la torche.
2.2 Do not grip the workpiece near the cutting path. 2.2 Ne pas saisir la pièce à couper de la trajectoire de coupage.
2.3 Wear complete body protection. 2.3 Se protéger entièrement le corps.

3. Hazardous voltage. Risk of electric shock or burn. 3. Tension dangereuse. Risque de choc électrique ou de brûlure.
3.1 Wear insulating gloves. Replace gloves when wet or damaged. 3.1 Porter des gants isolants. Remplacer les gants quand ils sont humides ou
3.2 Protect from shock by insulating yourself from work and ground. endommagés.
3.3 Disconnect power before servicing. Do not touch live parts. 3.2 Se protéger contre les chocs en s’isolant de la pièce et de la terre.
3.3 Couper l’alimentation avant l’entretien. Ne pas toucher les pièces sous tension.

4. Plasma fumes can be hazardous. 4. Les fumées plasma peuvent être dangereuses.
4.1 Do not inhale fumes. 4.1 Ne pas inhaler les fumées
4.2 Use forced ventilation or local exhaust to remove the fumes. 4.2 Utiliser une ventilation forcée ou un extracteur local pour dissiper les fumées.
4.3 Do not operate in closed spaces. Remove fumes with ventilation. 4.3 Ne pas couper dans des espaces clos. Chasser les fumées par ventilation.

5. Arc rays can burn eyes and injure skin. 5. Les rayons d’arc peuvent brûler les yeux et blesser la peau.
5.1 Wear correct and appropriate protective equipment to protect 5.1 Porter un bon équipement de protection pour se protéger la tête, les yeux, les
head, eyes, ears, hands, and body. Button shirt collar. Protect ears oreilles, les mains et le corps. Boutonner le col de la chemise. Protéger les oreilles
from noise. Use welding helmet with the correct shade of filter. contre le bruit. Utiliser un masque de soudeur avec un filtre de nuance appropriée.

6. Become trained. Only qualified personnel should operate this 6. Suivre une formation. Seul le personnel qualifié a le droit de faire
equipment. Use torches specified in the manual. Keep non-qualified fonctionner cet équipement. Utiliser exclusivement les torches indiquées dans le
personnel and children away. manual. Le personnel non qualifié et les enfants doivent se tenir à l’écart.
7. Do not remove, destroy, or cover this label. 7. Ne pas enlever, détruire ni couvrir cette étiquette.
Replace if it is missing, damaged, or worn (PN 110584 Rev C). La remplacer si elle est absente, endommagée ou usée (PN 110584 Rev C).

1b-12 Hypertherm
03/10
 Seguridad

Etiquetas de advertencia 1. L  as chispas de corte pueden producir

explosiones o incendios.
Esta etiqueta de advertencia se coloca en ciertas fuentes de energía.
1.1 No corte cerca de sustancias inflamables.
Es importante que el operador y el técnico de mantenimiento
entiendan las ideas que transmiten estos símbolos de advertencia. 1.2 Tenga disponible un extintor de incendios
Los textos numerados corresponden a los cuadros numerados cerca del lugar y listo para usar.
de la etiqueta. 1.3 No use tambores ni otros envases
cerrados como mesa de corte.
2. El arco de plasma puede producir
lesiones y quemaduras; mantenga
la boquilla alejada del cuerpo. El arco
arranca instantáneamente al apretar
el gatillo.
2.1 Corte la fuente de energía antes
de desarmar la antorcha.
2.2 No agarre la pieza a cortar cerca
de la ruta de corte.
2.3 Use protección corporal completa.
3. Voltaje peligroso. Riesgo de descargas
o quemaduras eléctricas.
3.1 Use guantes aislantes. Reemplácelos
cuando estén húmedos o dañados.
3.2 Protéjase de las descargas aislándose
de la pieza de trabajo y la tierra.
3.3 Desconecte la corriente antes de realizar
reparaciones. No toque las piezas con
corriente.
4. Los vapores de plasma pueden ser
peligrosos.
4.1 No inhale los vapores.
4.2 Use ventilación forzada o la ventilación
de escape local para eliminar los vapores.
4.3 No opere el sistema en espacios
cerrados. Elimine los vapores con
ventilación.
5. Los rayos del arco pueden quemar
los ojos y lesionar la piel.
5.1 Use el equipo de protección correcto
y adecuado para proteger la cabeza,
los ojos, los oídos, las manos y el cuerpo.
Abróchese el cuello de la camisa.
Protéjase los oídos del ruido. Use una
careta de soldador con el sombreado
o filtro adecuado.
6. Capacítese. Sólo personal calificado
debe operar este equipo. Use las
antorchas especificadas en el manual.
Mantenga al personal no calificado
y a los niños alejados del área de trabajo.
7. No quite, destruya, ni cubra esta etiqueta.
Reemplácela si falta o si está dañada
o gastada.
Hypertherm 1b-13
03/10
Seguridad

1b-14 Hypertherm
03/10
 Section 2

SPECIFICATIONS

In this section:

System description ....................................................................................................................................................................................2-2

General...............................................................................................................................................................................................2-2
Power supply ...................................................................................................................................................................................2-2
Ignition console ................................................................................................................................................................................2-2
Fuel-gas console ..............................................................................................................................................................................2-2
Off-valve .............................................................................................................................................................................................2-2
Torch ...................................................................................................................................................................................................2-2
System diagram 1 — without a fuel-gas console ......................................................................................................................2-3
System diagram 2 — with a fuel-gas console ............................................................................................................................2-4
Specifications..............................................................................................................................................................................................2-5
System gas requirements ..............................................................................................................................................................2-5
Noise levels .......................................................................................................................................................................................2-6
Power supply.....................................................................................................................................................................................2-7
Fuel-gas console — 078201 ..........................................................................................................................................................2-8
Ignition console — 078172.............................................................................................................................................................2-9
Standard off-valve — 229105 .....................................................................................................................................................2-10
Fuel-gas off-valve — 229130 ......................................................................................................................................................2-11
Torch – 228144.............................................................................................................................................................................2-12

HySpeed HSD130 RHF Instruction Manual 2-1

SPECIFICATIONS

System description
General
The HySpeed HSD130 plasma system is designed to cut a wide range of thicknesses of mild steel, stainless steel
and aluminum.

Power supply
The power supply is a 130-amp, 150-VDC constant-current supply. It contains the circuitry to ignite a torch plus a heat
exchanger and a pump to cool the torch. The power supply has a discrete machine interface to provide communication
with a CNC controller.

Ignition console
The ignition console uses a spark-gap assembly. The ignition console converts 120 VAC control voltage from the
power supply into high-frequency and high-voltage pulses (9-10 kV) to break over the torch electrode-nozzle gap.
The high-voltage, high-frequency signal is coupled to the pilot arc lead.

Fuel-gas console (optional, see system diagram 2)

The fuel-gas console manages the selection and flow rate of incoming fuel-gases. The fuel-gas console includes a
regulator, solenoid valves, check valves and a pressure transducer. The fuel-gas console also houses a relay PC board
and a control PC board.

Off-valve
The off-valve consists of 3 solenoid valves, a manifold block and a wiring harness with connector. The assembly
interfaces with the power supply.

Torch
The torch can cut 12 mm mild steel at up to 2032 mm/min (1/2 inch at up to 80 ipm). The recommended production
cutting capability of the torch is 16 mm (5/8 inch). Maximum pierce capability is 25 mm (1 inch) for mild steel and
19 mm (3/4 inch) for stainless steel and aluminum. The maximum severance capability is 38 mm (1.5 inch) for mild steel
and 25 mm (1 inch) for stainless steel and aluminum.

2-2 HySpeed HSD130 RHF Instruction Manual

 SPECIFICATIONS

C
CN

System diagram 1 – without a fuel-gas console

HySpeed HSD130 RHF Instruction Manual 2-3

SPECIFICATIONS

C
CN

System diagram 2 – with a fuel-gas console

2-4 HySpeed HSD130 RHF Instruction Manual

 SPECIFICATIONS

Specifications
System gas requirements

Gas quality and pressure requirements

Quality Pressure +/- 10% Flow rate
O2 Oxygen 99.5% pure 793 kPa / 7.93 bar 4250 l/h 150 scfh
Clean, dry, oil-free 115 psi
N2 Nitrogen* 99.99% pure 793 kPa / 7.93 bar 8500 l/h 300 scfh
Clean, dry, oil-free 115 psi
Air Clean, dry, oil-free 655 kPa / 6.55 bar 8500 l/h 300 scfh
95 psi
H35 Argon-hydrogen* 99.995% pure 793 kPa / 7.93 bar 4250 l/h 150 scfh
(H35 = 65% Argon, 35% Hydrogen) 115 psi
F5 Nitrogen-hydrogen* 99.98% pure 793 kPa / 7.93 bar 4250 l/h 150 scfh
(F5 = 95% Nitrogen, 5% Hydrogen) 115 psi

* These gases are only needed for systems with a fuel-gas console.

Mild steel Stainless steel Aluminum

Gas types Plasma Shield Plasma Shield Plasma Shield

Cutting 45 A Air Air Air / N2 / F5 Air / N2 Air Air
Cutting 50 A O2 Air N/A N/A N/A N/A
Cutting 130 A O2 / Air Air Air / N2 / H35 Air / N2 Air / H35 Air / N2

HySpeed HSD130 RHF Instruction Manual 2-5

SPECIFICATIONS

Noise levels
Measurements were made in a Hypertherm engineering laboratory, with other equipment operating nearby, in
accordance with Hypertherm instruction ESI-034. These measurements only provide a general indication of the noise
produced by the plasma system. Sound measurements should be taken after installation to determine the specific
noise levels at the site. Measurements were taken at distances of 1 m, 2 m, 3 m, and 5 m (straight-line distance)
from the center of the arc. An operator standing at the CNC controller would be approximately 1 m from the arc. All
measurements were made with a Bruel & Kjaer sound meter mounted on a tripod at a height of 336.55 mm (13.25 inch)
above the center of the arc.

Distance from the center Process 1 Process 2

of the arc Ambient room noise H35/N2 130 Amps Air/Air 130 Amps
1 m (3.3 ft) 80-84 dB 104-106 dB 106-108 dB

2 m (6.6 ft) 80-84 dB 97-99 dB 99-100 dB

3 m (9.9 ft) 80-84 dB 94-96 dB 96-97 dB

5 m (16.5 ft) 80-84 dB 93-97 dB 94-96 dB

2-6 HySpeed HSD130 RHF Instruction Manual

 Specifications

Power supply

General
Maximum OCV (U0) 311 VDC
Maximum output current (I2) 130 Amps
Output voltage (U2) 50 – 150 VDC
Duty cycle rating (X) 100% @ 19.5 kw, 40° C (104° F)
Ambient temperature/Duty cycle Power supplies will operate between -10° C and +40° C (+14° and 104° F)
Power factor(cosϕ) 0.91 @ 130 ADC output
Cooling Forced air (Class F)
Insulation Class H
Part AC Voltage Frequency Regulatory Power kW (+/- 10%)
Phase Amperage (I1)
number (U1) (Hz) approval (U1 x I1 x 1.73)
078515 200/208 3 50/60 62/60 CSA 21.5
078516 220 3 50/60 56 CSA 21.5
078517 240 3 60 52 CSA 21.5
078518 380 3 *50/60 33 CCC 21.5
078519 400 3 50/60 32 CE/GOST-R 21.5
078520 440 3 50/60 28 CSA 21.5
078521 480 3 60 26 CSA 21.5
078522 600 3 60 21 CSA 21.5

* 380 V CCC regulatory approval is for 50 Hz operation only.

1117.6 mm
44.0”

286.3 kg
631 lb

1073.2 mm
42.25”

571.5 mm
22.5”

HySpeed HSD130 RHF Instruction Manual 2-7

SPECIFICATIONS

Fuel-gas console (optional) – 078201

• The fuel-gas console is mounted on the top of the power supply. Allow 1m (3 ft) on all sides of the console for
servicing and ventilation.

• The maximum lead length, from the fuel-gas console to the off-valve, is 45.7 m (150 ft).

457.2 mm
508 mm 18"
20"

13.15 kg
29.0 lb

172.7 mm
6.8"

279.4 mm
11"

304.8 mm
12"

2-8 HySpeed HSD130 RHF Instruction Manual

 SPECIFICATIONS

Ignition console – 078172

• The ignition console should be mounted on the cutting table’s bridge. See Installation section for details.

• Maximum lead length from the ignition console to the torch lifter station is 15 m (50 ft). Allow room to remove
the top for servicing.

• The ignition console may be mounted horizontally or vertically.

283 mm
219 mm 11.125"
8.625"

194 mm 9.1 kg
7.625" 20 lb

216 mm
8.5"

152 mm
6"

HySpeed HSD130 RHF Instruction Manual 2-9

SPECIFICATIONS

Standard off-valve – 229105

• Maximum cable length from the off-valve to the torch lifter is 1.8 m (6 ft).

• Mount the off-valve assembly on the torch carriage on large tables. On small tables it can be mounted on a
bracket just above the bridge.

• The vent hole on the side of the manifold must be kept clear at all times.

70 mm
A
2.75"

19 mm
Vent hole 0.75"

130.8 mm
5.15" 1.30 kg
2.87 lb
5.16 mm
0.203"

54.4 mm
2.14" 109.7 mm
4.32"

139.7 mm
5.5"

A-A
2-10 HySpeed HSD130 RHF Instruction Manual
 SPECIFICATIONS

Fuel-gas off-valve – 229130

• Maximum cable length from the off-valve to the torch lifter is 1.8 m (6 ft).

• Mount the off-valve assembly on the torch carriage on large tables. On small tables it can be mounted on a
bracket just above the bridge.

• The vent hole on the side of the manifold must be kept clear at all times.

70 mm
A
2.75"

19 mm
Vent hole 0.75"

130.8 mm
5.15" 1.44 kg
3.18 lb
5.16 mm
0.203"

54.4 mm
2.14" 109.7 mm
4.32"

139.7 mm
5.5"

A-A
HySpeed HSD130 RHF Instruction Manual 2-11
SPECIFICATIONS

Torch – 228144 (includes mounting sleeve and consumables)

• The outside diameter of the torch mounting sleeve is 45 mm (1.75 inch).

1.8 m
6'

229 mm 116 mm
9.0" 4.55"

62 mm
2.43"

45 mm
1.75"

35°
345 mm
13.57"

0.93 kg
2.05 lb

2-12 HySpeed HSD130 RHF Instruction Manual

 Section 3

INSTALLATION

In this section:

Upon receipt................................................................................................................................................................................................3-3
Claims ...........................................................................................................................................................................................................3-3
Installation requirements...........................................................................................................................................................................3-3
Placement of system components .........................................................................................................................................................3-3
Torque specifications ......................................................................................................................................................................3-3
Installation requirements – standard system.....................................................................................................................................3-4
System components........................................................................................................................................................................3-5
Cables and hoses ............................................................................................................................................................................3-5
Customer-supplied power cable ..................................................................................................................................................3-5
Supply gas hoses ............................................................................................................................................................................3-5
Installation requirements — system with optional fuel gas console.................................................................................................3-6
System components........................................................................................................................................................................3-7
Cables and hoses ............................................................................................................................................................................3-7
Customer-supplied power cable ..................................................................................................................................................3-7
Supply gas hoses.............................................................................................................................................................................3-7
Recommended grounding and shielding practices............................................................................................................................3-8
Introduction..................................................................................................................................................................................................3-8
Types of grounding ..........................................................................................................................................................................3-8
Steps to take.....................................................................................................................................................................................3-9
Grounding diagram .......................................................................................................................................................................3-12
Placement of the power supply ............................................................................................................................................................3-13
Install the ignition console .....................................................................................................................................................................3-14
Install the off-valve ...................................................................................................................................................................................3-16
Torch mounting and alignment ..............................................................................................................................................................3-17
Mounting the torch ........................................................................................................................................................................3-17
Torch alignment ..............................................................................................................................................................................3-17
Torch lifter requirement.................................................................................................................................................................3-17
Install the fuel-gas console (optional component) ...........................................................................................................................3-18
Cable and hose assembly from power supply to off-valve.............................................................................................................3-19
Power supply to off-valve connections.....................................................................................................................................3-20
Fuel-gas console to off-valve connections.........................................................................................................................................3-21
Fuel-gas console to power supply connections ...............................................................................................................................3-22
Power supply to ignition console leads ..............................................................................................................................................3-24

HySpeed HSD130 RHF Instruction Manual 3-1

INSTALLATION

Ignition console power cable......................................................................................................................................................3-26

Ignition console coolant hoses...................................................................................................................................................3-27
Torch lead assembly................................................................................................................................................................................3-28
Connect the torch to the torch lead assembly .......................................................................................................................3-29
Work lead...................................................................................................................................................................................................3-32
Arc voltage connection...........................................................................................................................................................................3-33
Power supply to CNC interface cable ................................................................................................................................................3-34
Notes to CNC interface cable run list ......................................................................................................................................3-35
Examples of output circuits.........................................................................................................................................................3-36
Examples of input circuits............................................................................................................................................................3-37
Power requirements ................................................................................................................................................................................3-38
General ............................................................................................................................................................................................3-38
Line disconnect switch ................................................................................................................................................................3-38
Power cable....................................................................................................................................................................................3-38
Connect the power..................................................................................................................................................................................3-39
Torch coolant requirements ...................................................................................................................................................................3-40
Water purity requirements...........................................................................................................................................................3-40
Fill the power supply with coolant........................................................................................................................................................3-41
Gas requirements ....................................................................................................................................................................................3-42
Setting the supply regulators......................................................................................................................................................3-42
Gas regulators ...............................................................................................................................................................................3-43
Supply gas plumbing ..............................................................................................................................................................................3-44
Connect the supply gases.....................................................................................................................................................................3-45
Standard system............................................................................................................................................................................3-45
Fuel-gas system .............................................................................................................................................................................3-45
Supply gas hoses ....................................................................................................................................................................................3-46

3-2 HySpeed HSD130 RHF Instruction Manual

 INSTALLATION

Upon receipt
• Verify that all system components on your order have been received. Contact your supplier if any items
are missing.

• Inspect the system components for any physical damage that may have occurred during shipping. If there is
evidence of damage, refer to Claims. All communications regarding claims must include the model number and
serial number located on the back of the power supply.

Claims
Claims for damage during shipment – If your unit was damaged during shipment, you must file a claim with the
carrier. Hypertherm will furnish you with a copy of the bill of lading upon request. If you need additional assistance, call
Customer Service listed in the front of this manual, or your authorized Hypertherm distributor.

Claims for defective or missing merchandise – If any of the merchandise is defective or missing, contact your
supplier. If you need additional assistance, call Customer Service listed in the front of this manual, or your authorized
Hypertherm distributor.

Installation requirements
All installation and service of the electrical and plumbing systems must conform to national or local
electrical and plumbing codes. This work should be performed only by qualified, licensed personnel.

Direct any technical questions to the nearest Hypertherm Technical Service Department listed in the front of this manual,
or your authorized Hypertherm distributor.

Placement of system components

• Place all system components in position prior to making electrical, gas and interface connections. Use the
diagrams in this section for component placement guidelines.

• Ground all system components to earth. See Recommended grounding and shielding practices in this section
for details.

• To prevent leaks in the system, tighten all gas and water connections as shown below:

Torque specifications

Gas or water
hose size kgf-cm lbf-in lbf-ft

Up to 10 mm (3/8") 8.6-9.8 75-85 6.25-7

12 mm (1/2") 41.5-55 360-480 30-40

HySpeed HSD130 RHF Instruction Manual 3-3

INSTALLATION

Installation requirements – standard system

11
10

5
4
B
1
2

3
6
C

C
CN

System diagram 2 – without a fuel gas console

3-4 HySpeed HSD130 RHF Instruction Manual

 INSTALLATION

System components

A Power supply

B Ignition console

C Off-valve assembly

D Torch

Cables and hoses

1 Cable and hose assembly from power supply to off-valve

2 Pilot arc lead

3 Negative lead

4 Ignition console control cable

5 Ignition console coolant hoses

6 Torch lead assembly

7 Work lead

8 Power supply to CNC interface cable

Customer-supplied power cable

9 Main power cable

Supply gas hoses

10 Air

11 Oxygen

HySpeed HSD130 RHF Instruction Manual 3-5

INSTALLATION

Installation requirements – system with optional fuel gas console

13
12
1f 12
11
10
1e

1d

1c
5 4
1b B
1
1a
a 3
6 7
2
C

D
8

C
CN

System diagram 2 – with a fuel gas console

3-6 HySpeed HSD130 RHF Instruction Manual

 INSTALLATION

System components

A Power supply

B Ignition console

C Off-valve assembly

D Torch

E Fuel-gas console

Cables and hoses

1 Cable and hose assembly from the power supply to the off-valve
1a
a Cable and hose assembly from the fuel gas console to the off-valve
1b Gas power cable
1c Gas control cable
1d Cut gas 1 hose
1e Cut gas 2 hose
1f Air hose from power supply air filter to the fuel-gas console
2 Pilot arc lead
3 Negative lead
4 Ignition console power cable
5 Ignition console coolant hoses
6 Torch lead assembly
7 Work lead
8 Power supply to CNC interface cable

Customer-supplied power cable

9 Main power cable

Supply gas hoses

10 Air
11 Oxygen
12 F5 or H35

13 Nitrogen

HySpeed HSD130 RHF Instruction Manual 3-7

INSTALLATION

Recommended grounding and shielding practices

DANGER
ELECTRIC SHOCK CAN KILL

Disconnect electrical power before performing any maintenance. All work

requiring the removal of the power supply cover must be performed by a
qualified technician.
See Section 1 of the plasma system instruction manual for more safety
precautions.

Introduction
This document describes the grounding and shielding necessary to protect a plasma cutting system installation against
radio frequency interference (RFI) and electromagnetic interference (EMI) noise. It addresses the 3 grounding systems
described below. There is diagram on page 5 for reference.

Note: These procedures and practices are not known to succeed in every case to eliminate RFI/EMI
noise issues. The practices listed here have been used on many installations with excellent
results, and we recommend that these practices be a routine part of the installation process. The
actual methods used to implement these practices may vary from system to system, but should
remain as consistent as possible across the product line.

Types of grounding
A. The safety (PE) or service ground. This is the grounding system that applies to the incoming line voltage. It prevents
a shock hazard to any personnel from any of the equipment, or the work table. It includes the service ground coming
into the plasma power supply and other systems such as the CNC controller and the motor drivers, as well as the
supplemental ground rod connected to the work table. In the plasma circuits, the ground is carried from the plasma
power supply chassis to the chassis of each separate console through the interconnecting cables.

B. The DC power or cutting current ground. This is the grounding system that completes the path of the cutting current
from the torch back to the power supply. It requires that the positive lead from the power supply be firmly connected
to the work table ground bus with a properly sized cable. It also requires that the slats, on which the workpiece rests,
make good contact with the table and the workpiece.

C. RFI and EMI grounding and shielding. This is the grounding system that limits the amount of electrical “noise”
emitted by the plasma and motor drive systems. It also limits the amount of noise that is received by the CNC and
other control and measurement circuits. This grounding/shielding process is the main target of this document.

3-8 HySpeed HSD130 RHF Instruction Manual

 INSTALLATION

Steps to take
1. Unless noted, use only 6 AWG (16 mm2) welding cable (Hypertherm part no. 047040) for the EMI ground cables
shown on the diagram (blue).

2. The cutting table is used for the common, or star, EMI ground point and should have threaded studs welded to the
table with a copper bus bar mounted on them. A separate bus bar should be mounted on the gantry as close to
each drive motor as possible. If there are drive motors at each end of the gantry, run a separate EMI ground cable
from the far drive motor to the gantry bus bar. The gantry bus bar should have a separate, heavy EMI ground cable
(4 AWG part no. 047031) to the table bus bar. The EMI ground cables for the torch lifter and the RHF console
must each run separately to the table ground bus.

3. A ground rod that meets all applicable local and national electrical codes must be installed within 6 m (20 feet) of
the table. This is a PE ground and should be connected to the ground bus on the cutting table with 6 AWG
green/yellow grounding cable (Hypertherm part number 047121) or equivalent. All PE grounds are shown on the
diagram in green.

4. For the most effective shielding, use the Hypertherm CNC interface cables for I/O signals, serial communication
signals, power supply-to-power supply multi-drop connections, and interconnections between all parts of the
Hypertherm system.

5. All hardware used in the ground system must be brass or copper. The only exception is that the studs welded to the
table for mounting the ground bus can be steel. Under no circumstances should aluminum or steel hardware be
used.

6. AC power, PE, and service grounds must be connected to all equipment according to local and national codes.

7. * The positive, negative, and pilot arc leads should be bundled together for as long a distance as possible. The torch
lead, work lead, and the pilot arc (nozzle) leads may only be run parallel to other wires or cables if they are
separated by at least 150 mm (6 in.). If possible, run power and signal cables in separate cable tracks.

8. * The ignition console should be mounted as close as possible to the torch, and must have a separate ground cable
to the bus bar on the cutting table.

9. Each Hypertherm component, as well as any other CNC or motor-drive cabinet or enclosure, must have a separate
ground cable to the common (star) point on the table. This includes the ignition console, even if it is bolted to the
power supply or to the cutting machine.

10. The metal braided shield on the torch leads must be connected firmly to the ignition console and to the torch. It
must be electrically insulated from any metal and from any contact with the floor or building.

11. The torch holder and the torch breakaway mechanism – the part mounted to the lifter, not the part mounted on
the torch – must be connected to the stationary part of the lifter with copper braid at least 12.7 mm (1/2 in.) wide.
A separate cable must run from the lifter to the bus bar on the gantry. The valve assembly should also have a
separate ground connection to the gantry bus bar.

* Applies to systems that use a remote high frequency (RHF) console

HySpeed HSD130 RHF Instruction Manual 3-9

INSTALLATION

12. If the gantry runs on rails that are not welded to the table, then the rails need to be connected with a ground cable
from each end of both rails to the table. These need not go to the common (star) point, but could take the shortest
path to the table.

13. If the OEM is installing a voltage divider to process arc voltage for use in the control system, the voltage divider
board should be mounted as close as possible to the point where the arc voltage is sampled. One acceptable
location is inside the plasma power supply. If the Hypertherm voltage divider board is used, the output signal is
isolated from all other circuits. The processed signal should be run in twisted, shielded cable (Belden type 1800F
or equivalent). The cable used must have a braided shield, not a foil shield. The shield should be connected to the
chassis of the power supply and left unconnected at the other end.

14. All other signals (analog, digital, serial, encoder) should run in twisted pairs inside a shielded cable. Connectors on
these cables should have a metal housing and the shield, not the drain, should be connected to the metal housing
of the connectors at each end of the cable. Never run the shield or the drain through the connector on any of the
pins.

Power
supply Remote
lead (+) high frequency
Ground rod
(RHF) console
Gantry
CNC enclosure

Torch holder

Power supply
chassis

Example of a good cutting table ground bus. The picture above shows the connection from the
gantry ground bus, the connection from the ground rod, the power supply positive lead, the RHF
console*, the CNC enclosure, the torch holder, and the power supply chassis.

* Applies to systems that use a remote high frequency (RHF) console

3-10 HySpeed HSD130 RHF Instruction Manual

 INSTALLATION

Cable to ground
bus on the Component
cutting table ground cables

Example of a good gantry ground bus. It is bolted to the gantry, close to the motor. All of the individual
ground cables from the components mounted on the gantry go to the bus except those from the RHF
console* and the torch holder. A single heavy cable then goes from the gantry ground bus to the
ground bus bolted to the table.

* Applies to systems that use a remote high frequency (RHF) console

HySpeed HSD130 RHF Instruction Manual 3-11

 **
Command RHF Metering Gas/Selection CNC

3-12
THC console console console console

Bus bar
INSTALLATION

Gantry

Command
THC

**

Bus bar

Ground rod
Cutting table
Positive DC

Plasma
power supply

Grounding diagram (some systems will not include all the components shown)
** The lifter assembly and the RHF console each
require a separate path to the cutting table
AC earth/service ground Chassis and RFI ground ground bus bar.

HySpeed HSD130 RHF Instruction Manual

 INSTALLATION

A Placement of the power supply

DANGER
ELECTRICAL SHOCK CAN KILL

Remove all electrical connections to power supply before moving or positioning.

Transporting the unit can cause personal injury and equipment damage.

The power supply can be moved by forklift but the forks must be long enough to extend the entire length of the base.
Take care when lifting so that the underside of the power supply is not damaged.

• Place the power supply in an area that is free of excessive moisture, has proper ventilation, and is relatively
clean. Allow 1 m (3 ft) on all sides of the power supply for ventilation and servicing.

• Cooling air is drawn in through the front panel and is exhausted through the rear of the unit by a cooling fan.
Do not place any filter device over the air intake locations, which reduces cooling efficiency and VOIDS
THE WARRANTY.

• Do not place the power supply on an incline greater than 10° to prevent it from toppling.

HySpeed HSD130 RHF Instruction Manual 3-13

INSTALLATION

B Install the ignition console

• Mount the ignition console on the gantry (bridge).

• Allow room to remove the top for servicing.

Note: verify the hose orientation before running the coolant hoses. The fittings are different on the ignition
console end and the power supply end of each hose. The label marked IGN CSL on the end of each
hose indicates that it is the end that is connected to the ignition console.

32 mm 184 mm
1.25" 7.25"
216 mm
8.50"

32 mm
1.25"

248 mm
9.75"

279 mm
11.00" 7 mm
.028"
(4 places)

3-14 HySpeed HSD130 RHF Instruction Manual

 INSTALLATION

Ignition console grounding

Horizontal RHF mounting

Vertical RHF mounting

HySpeed HSD130 RHF Instruction Manual 3-15

INSTALLATION

C Install the off-valve (standard and fuel-gas)

• Mount the off-valve assembly near the torch lifter. The maximum length of the gas hoses between the off-valve
assembly and the torch is 1.8 m (6 ft).

Vent hole:
Keep clear at all times

Off-valve grounding

130.8 mm
5.15"

54.4 mm
2.14"

5.16 mm
0.203"

3-16 HySpeed HSD130 RHF Instruction Manual

 INSTALLATION

D Torch mounting and alignment

Mounting the torch

Installation
1. Install the torch (with torch leads
attached) in the torch mounting bracket.
Upper torch sleeve 2. Position the torch below the mounting
bracket, so that the bracket is around the
lower portion of the torch sleeve but not
Torch mounting touching the torch body.
bracket
(customer-supplied) 3. Tighten the securing screws.
Lower torch sleeve
Note: The bracket should be as low on the
torch sleeve as possible to minimize vibration
at the tip of the torch.

Torch alignment
To align the torch at right angles to the workpiece, use a square. See figure above.

See also Install consumables in Section 4 to install consumables in the torch.

Torch lifter requirement

The system requires a high-quality, motorized torch lifter with sufficient travel to cover all cutting thickness requirements.
The lifter must provide 203 mm (8 in.) of vertical travel. The unit should have the capability of maintaining a constant
speed of up to 5080 mm/min (200 ipm) with positive braking. A unit which drifts through the stop point is not
acceptable.

HySpeed HSD130 RHF Instruction Manual 3-17

INSTALLATION

E Install the fuel gas console (optional component)

• The fuel gas console is mounted on the top of the power supply. Allow 1 m (3 ft) on all sides of the console for
servicing and ventilation.

• The maximum lead length, from the fuel gas console to the off-valve, is 15 m (50 ft).

3-18 HySpeed HSD130 RHF Instruction Manual

 INSTALLATION

1 Cable and hose assembly from power supply to off-valve

Part no. Length

228053 7.5 m (25 ft)

228054 15 m (50 ft)

To power supply To off-valve solenoid cable

Power supply to off-valve cable

Cable signal list – power supply to off-valve cable
Power supply end Off-valve end
Pin # Description Pin #
1 120 Vac Hot – Shield 1
Male/Pins Female/Sockets
2 120 Vac Return – Shield 2
3 120 Vac Hot – Plasma preflow 3
4 120 Vac Return – Plasma preflow 4
5 120 Vac Hot – Plasma cutflow 5
6 120 Vac Return – Plasma cutflow 6
7 120 Vac Hot – Plasma vent 7
8 120 Vac Return – Vent 8
9 Ground 9

Off-valve solenoid cable Cable signal list – off-valve solenoid cable to off-valve cable
Function End B Color End A
Shield A Blue 1
C Blue 2
Plasma P Red/Black 3
Preflow P Red 4

1 2 3
Plasma P Red/Black 5
4 5 6 7 Cutflow C Red 6
8 9 10 11
12 13 14
Vent V Red/Black 7
V Red 8
Not used 9
A C B

Not used 10
End B End A ( male/pins) Ground Ground Green/Yellow 11
Ground 12
Ground 13
Ground 14

HySpeed HSD130 RHF Instruction Manual 3-19

INSTALLATION

Power supply to off-valve connections

1X3

Optional
Fuel-gas off-valve
connections

3-20 HySpeed HSD130 RHF Instruction Manual

1
 INSTALLATION

1a
a Fuel gas console to off-valve connections

Part no. Length

228148 7.5 m (25 ft)

228149 15 m (50 ft)

The cable and hose

are bundled together

HySpeed HSD130 RHF Instruction Manual 3-21

INSTALLATION

1b – 1f Fuel gas console to power supply connections

Before connections from the power supply to the fuel-gas console are made, the standard air hose must be removed
from the power supply.

1. Remove and discard the standard air hose.

2. The air hose for the power supply to the fuel-gas console connection is supplied with the fuel-gas console. Connect
the hose (024819) from the air filter on the power supply to the air inlet on the fuel-gas console.

The air supply

line must be
connected
here
Install the
fuel-gas
air hose

Remove the
standard
air hose

3-22 HySpeed HSD130 RHF Instruction Manual

 INSTALLATION

Part no. Description Length

078203 Fuel-gas console lead set
024819 Hose (black): CG1 1 m (3 ft)
024820 Hose (blue): CG2 1 m (3 ft)
123844 Cable: CAN Communication (3x2 to 1x2) 1.5 m (5 ft)
123684 Cable: Power (3x1 to 1x1) 1.5 m (5 ft)
024819 Hose: power supply air filter to fuel-gas console 1 m (3 ft)

HySpeed HSD130 RHF Instruction Manual 3-23

INSTALLATION

Power supply to ignition console leads

2 Pilot arc lead

Part no. Length

123932 7.5 m (25 ft)

123933 15 m (50 ft)
123934 23 m (75 ft)
123935 30.5 m (100 ft)
123936 38 m (125 ft)

3 Negative lead

Part no. Length

123926 7.5 m (25 ft)

123927 15 m (50 ft)
123928 23 m (75 ft)
123929 30.5 m (100 ft)
123930 38 m (125 ft)

Pilot arc
lead

3-24 HySpeed HSD130 RHF Instruction Manual

 INSTALLATION

Negative
lead

Pilot arc lead

Pilot arc lead

Negative lead

Negative lead

HySpeed HSD130 RHF Instruction Manual 3-25

INSTALLATION

4 Ignition console power cable

Part no. Length CABLE SIGNAL LIST – power supply to ignition console
123421 7.5 m (25 ft) Power supply end Ignition console end
123424 15 m (50 ft)
123425 23 m (75 ft) Pin # I/O Description Pin #
123426 30.5 m (100 ft) 1 120Vac Hot 1
123938 38 m (125 ft)
2 120Vac Return 2
3 Ground 3
4 Not connected 4

3-26 HySpeed HSD130 RHF Instruction Manual

 INSTALLATION

5 Ignition console coolant hoses

Note: verify the hose orientation before running the coolant hoses. The fittings are different on the ignition
console end and the power supply end of each hose. The label marked IGN CSL on the end of each
hose indicates that it is the end that is connected to the ignition console.

Red

Part no. Length

228157 7.5 m (25 ft)

228158 15 m (50 ft)
228159 23 m (75 ft)
228160 30.5 m (100 ft)
228161 38 m (125 ft)

Green

Red

HySpeed HSD130 RHF Instruction Manual 3-27

INSTALLATION

6 Torch lead assembly

Part no. Length

228050 7.5 m (25 ft)

228051 15 m (50 ft)

3-28 HySpeed HSD130 RHF Instruction Manual

 INSTALLATION

Connect the torch to the torch lead assembly

1. Route the leads through the cable track on the table. Leave 2 meters (6.5 ft.) of the leads loose at the torch end to
install the torch.

2. Hold the torch in place and remove the mounting sleeve from the torch assembly.

3. Push back the braided cover and slide the sleeve back over the leads. Align the torch connections with the hoses in
the lead assembly. The hoses must not twist, and they are taped together to help prevent twisting.

Sleeve

Braided cover

4. Connect the coolant hoses to the torch. Red connects to red. Use 2 wrenches to tighten gas and coolant fittings.

HySpeed HSD130 RHF Instruction Manual 3-29

INSTALLATION

5. Connect the shield gas hose.

6. Connect the plasma gas hose. This connection has left-hand threads.

7. Connect the pilot arc lead.

Note: Be careful not to damage or remove the small slotted metal band at the end of the pilot arc cable

7a. Pull the sleeve back until the connector is exposed.

7b. Screw the connector onto the pilot arc connection from the torch. Tighten by hand until it is firmly seated.

3-30 HySpeed HSD130 RHF Instruction Manual

 INSTALLATION

7c. Slide the sleeve forward until it clicks into place.

8. Slide the torch sleeve over the connections and screw it onto the torch body.

9. Slide the braided cover up to the torch sleeve. Push the brass collar into the torch sleeve. It is a snug fit. Make sure
the plasma and shield hoses are routed through the hole in the braided cover.

HySpeed HSD130 RHF Instruction Manual 3-31

INSTALLATION

7 Work lead
Part no. Length
Work table Power supply 123662 7.5 m (25 ft)
123663 15 m (50 ft)

To work table

Lower frame of work table (typical)

3-32 HySpeed HSD130 RHF Instruction Manual

 INSTALLATION

Arc voltage connection

If a torch height control is installed, and undivided arc voltage (0 to 311 VDC) is needed, it can be accessed by making
the connections shown in the figure on this page. The cables in the figure terminate at a voltage divider (supplied by the
torch height control manufacturer).

(+)

(—)

HySpeed HSD130 RHF Instruction Manual 3-33

INSTALLATION

8 Power supply to CNC interface cable

Part no. Length

123022 7.5 m (25 ft)

123023 15 m (50 ft)

Power supply CNC

Wire Input/ Input/

color Pin no. Output Signal name Function Output Notes
Black 1 Input None Not used Output
Red 20 Input None Not used Output

Black 2 Output None Not used Input

Green 21 Output None Not used Input

Black 3 None Not used

Blue 22 None Not used

Black 4 Output Motion E (-) Notifies the CNC that an arc transfer has occurred and to begin Input 2
Yellow 23 Output Motion C (+) machine motion once the CNC’s pierce delay has timed out. Input

Black 5 Output None Not used Input 2

Brown 24 Output None Not used Input

Black 6 Output Rampdown error E (-) Notifies the CNC that a rampdown error has occurred Input 2
Orange 25 Output Rampdown error C (+)

Red 7 Output None Not used Input 2

White 26 Output None Not used

Red 8 Output None Not used Input 2

Green 27 Output None Not used Input

Red 9 Output None Not used Input 2

Blue 28 Output None Not used Input

Red 10 Output None Not used Input 2

Yellow 29 Output None Not used Input

Red 11 None Not used

Brown 30 None Not used

Red 12 Input Corner - CNC Notifies the plasma system that a corner is approaching and to Output 1
Orange 31 Input Corner + reduce cut current (Cut current is CNC selectable or defaults to 75%. Output
of cut current)

Green 13 Input Pierce - CNC Notifies the plasma system to maintain the shield preflow until Output 1
White 32 Input Pierce + the CNC releases the signal.

Green 14 Input Hold - Not required without Command THC. Command THC requires signal Output 1
Blue 33 Input Hold + to preflow gases during IHS.

Green 15 Input Start - CNC initiates the plasma arc. Output 1

Yellow 34 Input Start + Output

Green 16 None Not used

Brown 35 None Not used

Green 17 None Not used

Orange 36 Power ground Ground

White 18 Power ground Ground

Black 37 CNC +24 VDC Available 24 VDC (200 milliamps maximum) See notes 3

19 CNC + 24 VDC Not connected

3-34 HySpeed HSD130 RHF Instruction Manual

 INSTALLATION

Notes to CNC interface cable run list

Note 1. Inputs are relay coils. They require 24 VDC at 8.3 mA, or dry-contact closure.

Note 2. Outputs are optically isolated, open-collector, transistors. The maximum rating is 24 VDC at 10 mA.

Note 3. CNC +24 VDC provides 24 VDC at 200 mA maximum. A jumper is required on J300 to use 24 V power.

Caution: The CNC cable must be constructed using cable with 360 degree shielding and
metal housing connectors at each end. The shielding must be terminated to
the metal housings at each end to ensure proper grounding and to provide the
best shielding.

HySpeed HSD130 RHF Instruction Manual 3-35

INSTALLATION

Examples of output circuits

1. Logic interface, active-high

5VDC-24VDC
HSD
C
+ CNC/PLC
To 1x4
-
10K
E
(optional)

High-impedance (≤10mA)

2. Logic interface, active-low

5VDC-24VDC
10K
(optional)

HSD CNC/PLC
C
+

-
E High-impedance (≤10mA)

3. Relay interface
CNC +24V
+24VDC CNC +24V
Install a °t
Jumper
J300 HSD
108056 C
+ CNC/PLC

-
E High-current
contact closure
inputs (AC or DC)
External relay
24VDC low-power coil
≤10mA or ≥2400ohm
Power
ground

4. Do not use this configuration. Warranty will be void.

HSD Any voltage
C V
+ WA OI D
RR S
AN
- TY
E

3-36 HySpeed HSD130 RHF Instruction Manual

 INSTALLATION

Examples of input circuits

Note: The external relay's life may be improved by adding a

metallized-polyester capacitor (0.022µF 100V or higher) in
parallel with the relay contacts.
1. Relay interface

+24 VDC
°t
Output from
HSD
CNC/PLC

External relay
(AC or DC)

Power
ground

2. Optocoupler interface
+24 VDC

CNC/PLC °t
HSD

Transistor-output
optocoupler
Power
ground

3. Amplified-output interface

CNC/PLC +24 VDC

24VDC °t
HSD

Power
Active-high drive ground Power
ground

HySpeed HSD130 RHF Instruction Manual 3-37

INSTALLATION

Power requirements
General
All switches, slow-blow fuses and power cables are customer-supplied and must be
chosen as outlined by applicable national and local electrical-codes. Installation must be
performed by a licensed electrician. Use a separate primary-line disconnect switch for
the power supply.

FUSE
Recommended cable size
for 15 m (50 feet)
Input Rated input current Recommended maximum length
voltage Phase @ 19.5 kW output slow-blow fuse size Rated for 60° C
200/208 VAC 3 62/58 amps 85 amps 30 mm2 (3 AWG)
220 VAC 3 56 amps 80 amps 30 mm2 (3 AWG)
240 VAC 3 52 amps 65 amps 26 mm2 (4 AWG)
400 VAC 3 32 amps 40 amps 10 mm2 (8 AWG)
440 VAC 3 28 amps 35 amps 8 mm2 (8 AWG)
480 VAC 3 26 amps 35 amps 8 mm2 (8 AWG)
600 VAC 3 21 amps 30 amps 6 mm2 (10 AWG)

Note: Cable AWG recommendations taken from table 310-16 of the National Electric Code handbook (USA).

Line disconnect switch

The line disconnect switch serves as the supply-voltage disconnecting (isolating) device. Install
this switch near the power supply for easy access by the operator.

Installation must be performed by a licensed electrician and according to applicable national

and local codes.

The switch should:

• isolate the electrical equipment and disconnect all live conductors from the supply SWITCH BOX

voltage when in the “OFF” position

• have one “OFF” and one “ON” position clearly marked with “O” (OFF) and “l” (ON)
• have an external operating handle capable of being locked in the “OFF” position
• contain a power-operated mechanism that serves as an emergency stop
• have slow-blow fuses installed for the proper breaking capacity (see table above).

9 Power cable
Cable sizes vary based on the distance of the receptacle from the main box. Use a 4-conductor Type SO input power
cable with a conductor temperature rating of 60° C (140° F). Installation must be performed by a licensed electrician.

3-38 HySpeed HSD130 RHF Instruction Manual

 INSTALLATION

Connect the power

DANGER
ELECTRICAL SHOCK CAN KILL

The line disconnect switch must be in the OFF position before making the power cable connections.
In the U.S., use a “lock-out/tag-out” procedure until installation is complete. In other countries,
follow appropriate national and local safety procedures.

1. Insert the power cable through the strain relief at the rear of the power supply.
2. Connect the ground lead (PE) to the ground terminal as shown below.
3. Connect the power leads to the terminals as shown below.
4. Check that the line disconnect switch is in the OFF position and remains in the OFF position for the
remainder of the installation of the system.
5. Connect the power cord leads to the line disconnect switch, following national and local electrical codes.

North American wire colors European wire colors

U = Black U = Black
V = White V = Blue
W = Red W = Brown
(PE) Earth ground = Green/Yellow (PE) Earth ground = Green/Yellow

Line
disconnect
switch Power
cable

L1
L2
L3
GND

L1 L3
L2 GND
L1 = White
L2 = Red
L3 = Black
GND = Green
Non-CE power supply CE power supply

HySpeed HSD130 RHF Instruction Manual 3-39

INSTALLATION

Torch coolant requirements

The power supply is shipped without any coolant in the tank. Hypertherm recommends a mixture of 30% propylene
glycol, 69.9% deionized water, and 0.1% benzotriazole. This mixture resists freezing to -12° C (+10° F) and contains a
corrosion inhibitor to protect copper surfaces in the coolant loop. This mixture is available in 1-gallon (3.8 liter)
containers by ordering 028872. 100% propylene glycol is available by ordering 028873.

Caution: For operating temperatures colder than the temperature stated above, the
percentage of propylene glycol must be increased. Failure to do so could result in
a cracked torch head, hoses or other damage to the torch coolant system due to
freezing.

See Material Safety Data Sheets Appendix to determine if a stronger propylene glycol:purified water solution is needed
for your particular application.

Observe the warning and cautions below. Refer to the Material Safety Data Sheets Appendix for data on safety,
handling and storage of propylene glycol and benzotriazole.

DANGER
COOLANT CAN BE IRRITATING TO SKIN AND EYES AND
HARMFUL OR FATAL IF SWALLOWED

Propylene glycol and benzotriazole are irritating to skin and eyes, and harmful or fatal if swallowed.
Upon contact, flush skin or eyes with water. If swallowed, induce vomiting and call a physician
immediately.

Caution: Always use propylene glycol in the coolant mixture. Do not use automotive
anti-freeze in place of propylene glycol. Antifreeze contains corrosion
inhibitors that will damage the torch coolant system.

Always use purified water in the coolant mixture in order to prevent damage to
the pump and corrosion in the torch coolant system.

Water purity requirements

It is critical to maintain a low level of calcium carbonate in the coolant to avoid reduced performance of the torch or
cooling system.

3-40 HySpeed HSD130 RHF Instruction Manual

 INSTALLATION

Fill the power supply with coolant

The system will take 11.4 – 15.1 liters (3 to 4 gallons) of coolant depending on the length of the torch leads and
whether the system has a local or remote ignition console.

1. Add coolant until the tank is full.

2. Press and hold the Amps knob on the power supply control panel and turn ON the power to the power supply. This
allows the user to override the 5-second pump time-out and fill the torch leads with coolant for the first time.
Release the amps knob after 60 seconds. If the coolant flow switch is satisfied, the pump will continue to run and
you are done. If the pump turns off, turn OFF the power to the power supply and repeat the process.

Power switch Amps knob

3. The level of coolant in the tank will have dropped. Add coolant until the tank is full and replace the filler cap.

HySpeed HSD130 RHF Instruction Manual 3-41

INSTALLATION

Gas requirements
The customer must furnish all gases and gas-supply regulators for the system. Use high-quality, 2-stage pressure
regulators located within 3 m (10 ft) of the power supply or optional fuel-gas console. See Gas regulators in this section
for recommendations. See Section 2 for gas and flow specifications.

Caution: Gas supply pressures not within the specifications in Section 2 can cause poor
cut quality, poor consumable life, and operational problems.

If the purity level of the gas is too low, or if there are leaks in the supply hoses or
connections,

• Cut speeds can decrease

• Cut quality can deteriorate
• Cutting thickness capability can decrease
• Parts life can shorten

Setting the supply regulators

1. Make sure the power is OFF. Set the oxygen regulator pressure to 8.3 bar (120 psi). Set the air regulator pressure to
7.2 bar (95 psi). If an optional fuel-gas console is being used, set H35, F5, and N2 pressures to 8.3 bar (120 psi).

2. Turn ON the power.

3. After the purge cycle stops, move the selection switch to the SET position.

4. Adjust all regulators while gas is flowing. Return to the supply regulators and adjust them to match the values in
step 1.

5. Move the selection switch back to the RUN position (center).

3-42 HySpeed HSD130 RHF Instruction Manual

 INSTALLATION

Gas regulators
Low-quality gas regulators do not provide consistent supply pressures and can result in poor cut quality and system
operation problems. Use high-quality, 1-stage, gas regulators to maintain consistent gas supply pressure, if using liquid
cryogenic or bulk storage. Use high-quality, 2-stage, gas regulators to maintain consistent gas supply pressure from
high-pressure gas cylinders.

The high-quality gas regulators listed below are available from Hypertherm and meet U.S. Compressed Gas Association
(CGA) specifications. In other countries, select gas regulators that conform to national and local codes.

2-stage regulator Single-stage regulator

Part
Number Description Qty.
128544 Kit: Oxygen, 2-stage * 1
128545 Kit: Inert Gas, 2-stage 1
128546 Kit: Hydrogen (H5, H35 and methane) 2-stage 1
128547 Kit: Air, 2-stage 1
128548 Kit: 1-stage (for use with cryogenic liquid nitrogen or oxygen) 1
022037 Oxygen, 2-stage 1
022038 Inert gas, 2-stage 1
022039 Hydrogen/methane, 2-stage 3
022040 Air, 2-stage 1
022041 Line regulator, 1-stage 1

* Kits include appropriate fittings

HySpeed HSD130 RHF Instruction Manual 3-43

INSTALLATION

Supply gas plumbing

Rigid copper plumbing or suitable flexible hose may be used for all gas supplies. Do not use steel or aluminum pipe.
After installation, pressurize the entire system and check for leaks.
Recommended hose diameters are 9.5 mm (3/8 in) for lengths < 23 m (75 ft) and 12.5 mm (1/2 in) for
lengths > 23 m (75 ft).

For flexible-hose systems, use a hose designed for inert gas to carry air, nitrogen or argon-hydrogen.

Caution: When configuring the gas console to the supply gases, make sure that all
hoses, hose connections, and fittings are acceptable for use with oxygen,
argon-hydrogen, and methane. Installation must be made in accordance with
local and national codes.

Note: When cutting with oxygen as the plasma gas, air must also be connected to the gas console to achieve
the proper mixtures in the preflow and cutflow modes.

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.
Flashback arrestors are required (unless not available for specific gases or required pressures) to
prevent fire from propagating to the gas supply.

3-44 HySpeed HSD130 RHF Instruction Manual

 INSTALLATION

Connect the supply gases

Standard system
Connect the supply gases to the power supply.

Fuel-gas system
Connect the supply gases to the gas console. Torch leads must be purged between gas changes.

Fitting Size
H35 / F5 9/16 – 18 LH,
(fuel gas)”B”
N2 5/8 – 18, RH, internal
(inert gas) “B”
O2 9/16 – 18, RH
(oxygen) “B”
Air 9/16 – 18, JIC, #6

HySpeed HSD130 RHF Instruction Manual 3-45

INSTALLATION

Supply gas hoses

10 Air hose

Part no. Length

024659 7.5 m (25 ft)

024660 15 m (50 ft)

11 Oxygen hose

Part no. Length

024205 7.5 m (25 ft)

024155 15 m (50 ft)

12 F5 or H35 hose

Part no. Length

024384 7.5 m (25 ft)

024656 15 m (50 ft)

13 Nitrogen hose

Part no. Length

024134 7.5 m (25 ft)

024112 15 m (50 ft)

3-46 HySpeed HSD130 RHF Instruction Manual

 Section 4

OPERATION

In this section:

Controls and indicators.............................................................................................................................................................................4-2

Main power switch ..........................................................................................................................................................................4-2
Daily start-up................................................................................................................................................................................................4-3
Check torch.......................................................................................................................................................................................4-3
System operation........................................................................................................................................................................................4-4
Amps display.....................................................................................................................................................................................4-4
Fuel-gas console operation......................................................................................................................................................................4-5
Consumable selection...............................................................................................................................................................................4-6
Mild steel............................................................................................................................................................................................4-6
Stainless steel...................................................................................................................................................................................4-6
Aluminum............................................................................................................................................................................................4-7
Install consumables....................................................................................................................................................................................4-8
Cut charts.....................................................................................................................................................................................................4-9
Estimated kerf width compensation ............................................................................................................................................4-9
Changing consumable parts .................................................................................................................................................................4-23
Remove consumables ..................................................................................................................................................................4-23
Inspect consumables....................................................................................................................................................................4-24
Inspect torch...................................................................................................................................................................................4-25
Inspect electrode pit depth .........................................................................................................................................................4-26
Replace torch water tube.......................................................................................................................................................................4-27
Common cutting faults ...........................................................................................................................................................................4-28
How to optimize cut quality ...................................................................................................................................................................4-29
Tips for table and torch ................................................................................................................................................................4-29
Plasma set-up tips.........................................................................................................................................................................4-29
Maximize the life of consumable parts......................................................................................................................................4-29
Additional factors of cut quality..................................................................................................................................................4-30
Additional improvements .............................................................................................................................................................4-31

HySpeed HSD130 RHF Instruction Manual 4-1

OPERATION

Controls and indicators

Main power switch

The switch illuminates when it is in the ON position.

On position (I)
AC power is sent to the control transformer, to turn ON the power supply.

Off position (O)

AC power is cut off to the control transformer, to turn OFF the power supply.

4-2 HySpeed HSD130 RHF Instruction Manual

 OPERATION

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 this manual.

Check the 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 Changing consumable parts later in this section for details and for consumable inspection tables.

• Refer to Consumable selection to choose the correct consumables for your cutting needs.

3. Replace consumables. Refer to Changing consumable parts later in this section for details.

4. Ensure that the torch is perpendicular to the workpiece.

Shield Retaining cap Nozzle Swirl ring Electrode Current ring Torch

HySpeed HSD130 RHF Instruction Manual 4-3

OPERATION

System operation
Process selection Amps Amps
knob display knob

Selection
switch

Plasma set Shield set

knob knob

1. Turn ON the power with the selection switch in the RUN position.

2. Set the current using the AMPS knob.

3. Choose a process using the process selection knob.

4. Move the selection switch to the SET position.

5. Set the PLASMA and SHIELD gas pressures using the data in the cut chart for the desired process. Pull the knob
towards you to unlock it and set the pressure. Push the knob towards the power supply until it clicks to lock it.
Note: when the selection switch is in the set position, the amps display shows the incoming shield supply
pressure.

6. Move the selection switch to the RUN position.

Amps display

• When the selection switch is in the run position, the display shows the current set point.

• During a cut the display shows the actual cutting current.

• Push the amps knob during a cut to display the output voltage of the power supply.

4-4 HySpeed HSD130 RHF Instruction Manual

 OPERATION

Fuel-gas console operation

Process selection
knob

Plasma set
knob

Note: The plasma set knob on the fuel-gas console is used when an H35 or F5 process is selected. The
plasma set knob on the power supply is used (as described on the previous page) when an O2, Air, or N2
process has been selected.

1. Turn ON the power with the selection switch in the RUN position.

2. Move the selection switch on the power supply to SET and choose the current using the AMPS knob.

3. Choose a process using the process selection knob on the fuel gas console.

4. Set the PLASMA gas pressure on the fuel gas console (H35/F5).

5. Set the SHIELD gas pressure on the power supply using the data in the cut chart for the desired process.

6. Move the selection switch on the power supply to the RUN position.

HySpeed HSD130 RHF Instruction Manual 4-5

OPERATION

Consumable selection
Mild steel
Shield Retaining cap Nozzle Swirl ring Electrode

45 A (Air)

220532 220578 220525 220529 220528

50 A (O2)

220532 220578 220530 220529 220528

130 A (Air)

220536 220578 220492 220488 220487

130 A (O2)

220491 220578 220489 220488 220487

Stainless steel
Shield Retaining cap Nozzle Swirl ring Electrode

45 A (Air)

220532 220578 220525 220529 220528

45 A (N2 and F5/N2)

220532 220534 220525 220529 220528

130 A (Air)

220536 220578 220492 220488 220487

130 A (H35)

220536 220534 220535 220529 020415

130 A (N2)

220536 220578 220535 220488 020415

4-6 HySpeed HSD130 RHF Instruction Manual

 OPERATION

Aluminum
Shield Retaining cap Nozzle Swirl ring Electrode

45 A (Air)

220532 220578 220525 220529 220528

130 A (Air)

220536 220578 220492 220488 220487

130 A (H35)

220536 220534 220535 220529 020415

HySpeed HSD130 RHF Instruction Manual 4-7

OPERATION

Install consumables

Apply a thin film of silicone grease on all o-rings. Clean the nozzle
mating surface with a
cotton swab and water
or 3% hydrogen
peroxide.

Do not overtighten parts! Only tighten until mating parts are seated.
Use compressed air to clean out the inside of the torch every time consumables
are changed.

Install the electrode Install the swirl ring Install the nozzle and
swirl ring

Install the retaining cap Install the shield

Tool part number

027102

4-8 HySpeed HSD130 RHF Instruction Manual

 OPERATION

Cut charts
The following Cut charts show the consumable parts, cutting speed, and the gas and torch 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.

Estimated kerf width compensation

Material thickness (mm)

Mild steel 1.524 3.429 6.350 9.525 12.70 19.05 25.40

130 O2/Air 1.549 1.778 1.981 2.235 2.336 3.073
130 Air/Air 1.346 1.574 1.879 2.082 2.717 3.251
50 O2/Air 1.041 1.168 1.473
45 Air/Air 0.812 1.270 1.422
Stainless steel
130 Air/Air 1.651 1.930 2.133 2.768
130 N2/N2 1.651 1.651 2.540 3.530
130 H35/N2 2.870 2.768 2.590 2.946
45 Air/Air 0.812 1.117 1.270
45 N2/N2 0.533 0.660 0.660
45 F5/N2 0.609 0.635 0.812
Aluminum
130 Air/Air 2.082 1.930 2.159 2.692 2.819
130 H35/N2 2.235 2.184 2.006 1.168
45 Air/Air 1.168 1.193 1.219

Material thickness (inches)

Mild steel 0.06 0.135 0.25 0.375 0.5 0.75 1

130 O2/Air 0.061 0.07 0.078 0.088 0.092 0.121
130 Air/Air 0.053 0.062 0.074 0.082 0.107 0.128
50 O2/Air 0.041 0.046 0.058
45 Air/Air 0.032 0.050 0.056
Stainless steel
130 Air/Air 0.065 0.076 0.084 0.109
130 N2/N2 0.065 0.065 0.100 0.139
130 H35/N2 0.113 0.109 0.102 0.116
45 Air/Air 0.032 0.044 0.050
45 N2/N2 0.021 0.026 0.026
45 F5/N2 0.024 0.025 0.032
Aluminum
130 Air/Air 0.082 0.076 0.085 0.106 0.111
130 H35/N2 0.088 0.086 0.079 0.046
45 Air/Air 0.046 0.047 0.048

HySpeed HSD130 RHF Instruction Manual 4-9

OPERATION

Mild steel Flow Rates – lpm/scfh

Air
Air Plasma / Air Shield Preflow 113 / 240
45 A Cutting Cutflow 122 / 258

220532 220578 220525 220529 220528

220490 (no IHS tab)

Metric
Select Set Material Arc Torch-to-Work Pierce Delay
Gases Cutflow Thickness Voltage Distance Cutting Speed Initial Pierce Height Time

Plasma Shield Plasma Shield mm Volts mm mm/m mm factor % seconds

0.5 104 1.5 8930 3.0 200 0.0
0.8 106 1.5 8400 3.0 200 0.0
1.0 107 1.5 7750 3.0 200 0.1
1.2 108 1.8 7250 3.6 200 0.1
1.5 109 1.8 6500 3.6 200 0.2
Air Air 57 50
2.0 110 1.8 5800 3.6 200 0.2
2.5 110 2.0 4700 4.0 200 0.2
3.0 110 2.0 3300 4.0 200 0.3
4.0 113 2.3 1950 4.6 200 0.4
6.0 115 2.5 1575 5.0 200 0.5

English
Select Set Material Arc Torch-to-Work Pierce Delay
Gases Cutflow Thickness Voltage Distance Cutting Speed Initial Pierce Height Time

Plasma Shield Plasma Shield in Volts in ipm in factor % seconds

.018 104 .060 360 0.120 200 0.0

.024 105 .060 345 0.120 200 0.0

.030 106 .060 335 0.120 200 0.0

.036 107 .060 315 0.120 200 0.1

.048 108 .070 285 0.140 200 0.1

Air Air 57 50 .060 109 .070 255 0.140 200 0.2

.075 110 .070 235 0.140 200 0.2

.105 110 .080 170 0.160 200 0.2

.135 110 .080 90 0.160 200 0.3

3/16 113 .090 70 0.180 200 0.4
1/4 116 .100 60 0.200 200 0.5

4-10 HySpeed HSD130 RHF Instruction Manual

 OPERATION

Mild steel Flow Rates – lpm/scfh

O2 Air
O2 Plasma / Air Shield Preflow 0/0 69 / 146
50 A Cutting Cutflow 29 / 62 73 / 155

220532 220578 220530 220529 220528

220490 (no IHS tab)

Metric
Select Set Material Arc Torch-to-Work Pierce Delay
Gases Cutflow Thickness Voltage Distance Cutting Speed Initial Pierce Height Time

Plasma Shield Plasma Shield 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
1.5 98 1.5 6150 3.0 200 0.1
O2 Air 72 36
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 5.0 200 0.5

English
Select Set Material Arc Torch-to-Work Pierce Delay
Gases Cutflow Thickness Voltage Distance Cutting Speed Initial Pierce Height Time

Plasma Shield Plasma Shield in Volts in ipm in factor % seconds

.018 98 .060 300 0.120 200 0.0

.024 98 .060 290 0.120 200 0.0

.030 98 .060 280 0.120 200 0.0

.036 98 .060 270 0.120 200 0.1

.048 98 .060 260 0.120 200 0.1

O2 Air 72 36 .060 98 .060 240 0.120 200 0.1

.075 98 .060 220 0.120 200 0.1

.105 100 .070 160 0.140 200 0.2

.135 103 .070 130 0.140 200 0.3

3/16 106 .090 85 0.180 200 0.4
1/4 108 .100 65 0.200 200 0.5

HySpeed HSD130 RHF Instruction Manual 4-11

OPERATION

Mild steel Flow Rates – lpm/scfh

Air
Air Plasma / Air Shield Preflow 67 / 142
130 A Cutting Cutflow 132 / 280

220536 220578 220492 220488 220487

220490 (no IHS tab)

Metric
Select Set Material Arc Torch-to-Work Pierce Delay
Gases Cutflow Thickness Voltage Distance Cutting Speed Initial Pierce Height Time

Plasma Shield Plasma Shield mm Volts mm mm/m mm factor % seconds

3 136 3.1 6000 6.2 200 0.1
4 13 3.1 4930 6.2 200 0.2
6 138 3.6 3850 7.2 200 0.3
10 142 4.1 2450 8.2 200 0.5
Air Air 72 35 12 144 4.1 2050 8.2 200 0.5
15 150 4.6 1450 9.2 200 0.8
20 153 4.6 810 10.5 230 1.2
25 163 4.6 410
Edge Start
32 170 5.1 250

English
Select Set Material Arc Torch-to-Work Pierce Delay
Gases Cutflow Thickness Voltage Distance Cutting Speed Initial Pierce Height Time

Plasma Shield Plasma Shield in Volts in ipm in factor % seconds

0.1350 136 .120 220 .240 200 0.1

0.1875 136 .120 160 .240 200 0.2

0.2500 138 .140 150 .280 200 0.3

0.3750 142 .160 100 .320 200 0.5
Air Air 72 35 0.5000 144 .160 75 .320 200 0.5

0.6250 150 .180 50 .360 200 0.8

0.7500 153 .180 35 .420 230 1.2

1 163 .180 15
Edge Start
1-1/4 170 .200 10

4-12 HySpeed HSD130 RHF Instruction Manual

 OPERATION

Mild steel Flow Rates – lpm/scfh

O2 Air
O2 Plasma / Air Shield Preflow 0/0 90 / 190
130 A Cutting Cutflow 48 / 102 92 / 195

220491 220578 220489 220488 220487

220490 (no IHS tab)

Metric
Select Set Material Arc Torch-to-Work Pierce Delay
Gases Cutflow Thickness Voltage Distance Cutting Speed Initial Pierce Height Time

Plasma Shield Plasma Shield mm Volts mm mm/m mm factor % seconds

3 128 2.5 6500 5 200 0.1
4 129 2.8 5420 5.6 200 0.2
6 130 2.8 4000 5.6 200 0.3
48
10 134 3.0 2650 6 200 0.3
12 136 3.0 2200 6 200 0.5
O2 Air 65
15 141 3.8 1650 7.6 200 0.7
20 142 3.8 1130 7.6 200 1
25 152 4.0 675 8 200 1.5
43
32 155 4.5 480
Edge Start
38 160 4.5 305

English
Select Set Material Arc Torch-to-Work Pierce Delay
Gases Cutflow Thickness Voltage Distance Cutting Speed Initial Pierce Height Time

Plasma Shield Plasma Shield in Volts in ipm in factor % seconds

0.1350 128 .100 240 0.2 200 0.1

0.1875 129 .110 190 0.22 200 0.2

0.2500 130 .110 150 0.22 200 0.3

48
0.3750 134 .120 110 0.24 200 0.3

0.5000 136 .120 80 0.24 200 0.5

O2 Air 65
0.6250 141 .150 60 0.3 200 0.7

0.7500 142 .150 50 0.3 200 1

1 152 .160 25 0.32 200 1.5

43
1-1/4 155 .180 20
Edge Start
1-1/2 160 .180 12

HySpeed HSD130 RHF Instruction Manual 4-13

OPERATION

Stainless steel Flow Rates – lpm/scfh

Air
Air Plasma / Air Shield Preflow 149 / 315
45 A Cutting Cutflow 161 / 342

220532 220578 220525 220529 220528

220490 (no IHS tab)

Metric
Select Set Material Arc Torch-to-Work Pierce Delay
Gases Cutflow Thickness Voltage Distance Cutting Speed Initial Pierce Height Time

Plasma Shield Plasma Shield mm Volts mm mm/m mm factor % seconds

0.5 102 1.5 6800 3.0 200 0.0
0.8 104 1.5 6100 3.0 200 0.0
1.0 105 1.5 5600 3.0 200 0.1
1.2 108 1.8 5100 3.6 200 0.1
1.5 109 1.8 4500 3.6 200 0.2
Air Air 62 73
2.0 110 1.8 3650 3.6 200 0.2
2.5 113 2.0 3000 4.0 200 0.2
3.0 117 2.0 2250 4.0 200 0.3
4.0 120 2.3 1500 4.6 200 0.4
6.0 122 2.5 1050 5.0 200 0.5

English
Select Set Material Arc Torch-to-Work Pierce Delay
Gases Cutflow Thickness Voltage Distance Cutting Speed Initial Pierce Height Time

Plasma Shield Plasma Shield in Volts in ipm in factor % seconds

.018 102 .060 270 0.120 200 0.0

.024 103 .060 260 0.120 200 0.0

.030 104 .060 245 0.120 200 0.0

.036 105 .060 230 0.120 200 0.1

.048 108 .070 200 0.140 200 0.1

Air Air 62 73 .060 109 .070 175 0.140 200 0.2

.075 110 .070 150 0.140 200 0.2

.105 113 .080 110 0.160 200 0.2

.135 117 .080 70 0.160 200 0.3

3/16 120 .090 50 0.180 200 0.4
1/4 122 .100 40 0.200 200 0.5

4-14 HySpeed HSD130 RHF Instruction Manual

 OPERATION

Stainless steel Flow Rates – lpm/scfh

N2
N2 Plasma / N2 Shield Preflow 74 / 157
45 A Cutting Cutflow 91 / 192

220532 220534 220525 220529 220528

220533 (no IHS tab)

Metric
Select Set Material Arc Torch-to-Work Pierce Delay
Gases Cutflow Thickness Voltage Distance Cutting Speed Initial Pierce Height Time

Plasma Shield Plasma Shield mm Volts mm mm/m mm factor % seconds

0.5 106 1.5 7000 3.0 200 0.0
0.8 107 1.5 6500 3.0 200 0.0
1.0 107 1.5 5850 3.0 200 0.1
1.2 109 1.8 5350 3.6 200 0.1
1.5 112 1.8 4600 3.6 200 0.2
N2 N2 73 25
2.0 114 1.8 3950 3.6 200 0.2
2.5 118 2.0 3300 4.0 200 0.2
3.0 119 2.0 2450 4.0 200 0.3
4.0 121 2.3 1700 4.6 200 0.4
6.0 126 2.5 1125 5.0 200 0.5

English
Select Set Material Arc Torch-to-Work Pierce Delay
Gases Cutflow Thickness Voltage Distance Cutting Speed Initial Pierce Height Time

Plasma Shield Plasma Shield in Volts in ipm in factor % seconds

.018 106 .060 280 0.120 200 0.0

.024 106 .060 270 0.120 200 0.0

.030 107 .060 260 0.120 200 0.0

.036 107 .060 240 0.120 200 0.1

.048 109 .070 210 0.140 200 0.1

N2 N2 73 25 .060 112 .070 180 0.140 200 0.2

.075 114 .070 160 0.140 200 0.2

.105 118 .080 120 0.160 200 0.2

.135 119 .080 75 0.160 200 0.3

3/16 121 .090 60 0.180 200 0.4
1/4 126 .100 40 0.200 200 0.5

HySpeed HSD130 RHF Instruction Manual 4-15

OPERATION

Stainless steel Flow Rates – lpm/scfh

F5 N2
F5 Plasma / N2 Shield Preflow 0/0 162 / 344
45 A Cutting Cutflow 32 / 67 147 / 311

220532 220534 220525 220529 220528

220533 (no IHS tab)

Metric
Select Set Material Arc Torch-to-Work Pierce Delay
Gases Cutflow Thickness Voltage Distance Cutting Speed Initial Pierce Height Time

Plasma Shield Plasma Shield mm Volts mm mm/m mm factor % seconds

0.5 122 2.3 7000 4.6 200 0.0
0.8 124 2.3 6500 4.6 200 0.0
1.0 125 2.3 5875 4.6 200 0.1
1.2 128 2.5 5360 5.0 200 0.1
1.5 129 2.5 4650 5.0 200 0.2
F5 N2 82 82
2.0 132 2.8 3200 5.6 200 0.2
2.5 137 3.0 2975 6.0 200 0.2
3.0 138 3.0 2740 6.0 200 0.3
4.0 140 3.3 2350 6.6 200 0.4
6.0 148 3.6 1325 7.2 200 0.6

English
Select Set Material Arc Torch-to-Work Pierce Delay
Gases Cutflow Thickness Voltage Distance Cutting Speed Initial Pierce Height Time

Plasma Shield Plasma Shield in Volts in ipm in factor % seconds

.018 122 .090 280 0.180 200 0.0

.024 123 .090 270 0.180 200 0.0

.030 124 .090 260 0.180 200 0.0

.036 125 .090 240 0.180 200 0.1

.048 128 .100 210 0.200 200 0.1

F5 N2 82 82 .060 129 .100 180 0.200 200 0.2

.075 132 .110 130 0.220 200 0.2

.105 137 .120 115 0.240 200 0.2

.135 138 .120 100 0.240 200 0.3

3/16 140 .130 80 0.260 200 0.4
1/4 148 .140 45 0.280 200 0.6

4-16 HySpeed HSD130 RHF Instruction Manual

 OPERATION

Stainless steel Flow Rates – lpm/scfh

Air
Air Plasma / Air Shield Preflow 67 / 142
130 A Cutting Cutflow 132 / 280

220536 220578 220492 220488 220487

220490 (no IHS tab)

Metric
Select Set Material Arc Torch-to-Work Pierce Delay
Gases Cutflow Thickness Voltage Distance Cutting Speed Initial Pierce Height Time

Plasma Shield Plasma Shield mm Volts mm mm/m mm factor % seconds

6 143 3.6 2600 7.2 200 0.3
10 148 4.1 1700 8.2 200 0.5
Air Air 72 35 12 148 4.1 1380 8.2 200 0.8
15 158 4.6 900
Edge Start
20 160 4.6 430

English
Select Set Material Arc Torch-to-Work Pierce Delay
Gases Cutflow Thickness Voltage Distance Cutting Speed Initial Pierce Height Time

Plasma Shield Plasma Shield in Volts in ipm in factor % seconds

1/4 143 .140 100 .280 200 0.3

3/8 148 .160 70 .320 200 0.5

Air Air 72 35 1/2 148 .160 50 .320 200 0.8
5/8 158 .180 30
Edge Start
3/4 160 .180 20

HySpeed HSD130 RHF Instruction Manual 4-17

OPERATION

Stainless steel Flow Rates – lpm/scfh

N2
N2 Plasma / N2 Shield Preflow 165 / 350
130 A Cutting Cutflow 173 / 366

220536 220578 220535 220488 020415

220490 (no IHS tab)

Metric
Select Set Material Arc Torch-to-Work Pierce Delay
Gases Cutflow Thickness Voltage Distance Cutting Speed Initial Pierce Height Time

Plasma Shield Plasma Shield mm Volts mm mm/m mm factor % seconds

6 130 3.0 2340 6.0 200 0.3
10 132 3.6 1640 7.2 200 0.5
N2 N2 46 71 12 141 3.6 1080 7.2 200 0.8
15 144 3.8 700
Edge Start
20 153 4.3 300

English
Select Set Material Arc Torch-to-Work Pierce Delay
Gases Cutflow Thickness Voltage Distance Cutting Speed Initial Pierce Height Time

Plasma Shield Plasma Shield in Volts in ipm in factor % seconds

1/4 130 .120 90 .240 200 0.3

3/8 132 .140 70 .280 200 0.5

N2 N2 46 71 1/2 141 .140 35 .280 200 0.8
5/8 144 .150 25
Edge Start
3/4 153 .170 15

4-18 HySpeed HSD130 RHF Instruction Manual

 OPERATION

Stainless steel Flow Rates – lpm/scfh

H35 N2
H35 Plasma / N2 Shield Preflow 0/0 164 / 348
130 A Cutting Cutflow 61 / 130 141 / 298

220536 220534 220535 220529 020415

220533 (no IHS tab)

Metric
Select Set Material Arc Torch-to-Work Pierce Delay
Gases Cutflow Thickness Voltage Distance Cutting Speed Initial Pierce Height Time

Plasma Shield Plasma Shield mm Volts mm mm/m mm factor % seconds

10 150 4.6 980 7.8 170 0.3
12 154 4.6 820 7.8 170 0.5
H35 N2 70 75 15 157 4.6 580 7.8 170 0.8
20 162 4.6 360 7.8 170 1.3
25 167 4.6 260 Edge Start

English
Select Set Material Arc Torch-to-Work Pierce Delay
Gases Cutflow Thickness Voltage Distance Cutting Speed Initial Pierce Height Time

Plasma Shield Plasma Shield in Volts in ipm in factor % seconds

3/8 150 .180 40 .310 170 0.3

1/2 154 .180 30 .310 170 0.5

H35 N2 70 75 5/8 157 .180 20 .310 170 0.8
3/4 162 .180 15 .310 170 1.3
1 167 .180 10 Edge Start

HySpeed HSD130 RHF Instruction Manual 4-19

OPERATION

Aluminum Flow Rates – lpm/scfh

Air
Air Plasma / Air Shield Preflow 149 / 315
45 A Cutting Cutflow 161 / 342

220532 220578 220525 220529 220528

220490 (no IHS tab)

Metric
Select Set Material Arc Torch-to-Work Pierce Delay
Gases Cutflow Thickness Voltage Distance Cutting Speed Initial Pierce Height Time

Plasma Shield Plasma Shield mm Volts mm mm/m mm factor % seconds

0.5 113 1.5 7600 3.0 200 0.0
0.8 116 1.5 6900 3.0 200 0.1
1.0 117 1.8 6350 3.6 200 0.1
1.2 118 1.8 5800 3.6 200 0.2
1.5 119 1.8 5000 3.6 200 0.2
Air Air 62 73
2.0 120 2.0 3950 4.0 200 0.2
2.5 120 2.0 2950 4.0 200 0.3
3.0 121 2.0 2400 4.0 200 0.3
4.0 122 2.3 1950 4.6 200 0.4
6.0 130 2.5 1150 5.0 200 0.5

English
Select Set Material Arc Torch-to-Work Pierce Delay
Gases Cutflow Thickness Voltage Distance Cutting Speed Initial Pierce Height Time

Plasma Shield Plasma Shield in Volts in ipm in factor % seconds

0.016 113 .060 310 0.120 200 0.0
0.020 114 .060 300 0.120 200 0.0
0.025 115 .060 290 0.120 200 0.0
0.032 116 .060 270 0.120 200 0.1
0.040 117 .070 250 0.140 200 0.1
0.051 118 .070 220 0.140 200 0.2
Air Air 62 73
0.064 119 .070 185 0.140 200 0.2
0.081 120 .080 150 0.160 200 0.2
0.102 120 .080 110 0.160 200 0.3
1/8 121 .080 90 0.160 200 0.3
3/16 122 .090 65 0.180 200 0.4
1/4 130 .100 40 0.200 200 0.5

4-20 HySpeed HSD130 RHF Instruction Manual

 OPERATION

Aluminum Flow Rates – lpm/scfh

Air
Air Plasma / Air Shield Preflow 67 / 142
130 A Cutting Cutflow 132 / 280

220536 220578 220492 220488 220487

220490 (no IHS tab)

Metric
Select Set Material Arc Torch-to-Work Pierce Delay
Gases Cutflow Thickness Voltage Distance Cutting Speed Initial Pierce Height Time

Plasma Shield Plasma Shield mm Volts mm mm/m mm factor % seconds

6 147 2.8 2370 5.6 200 0.2
10 148 3.0 1465 6.1 200 0.3
12 152 3.0 1225 6.1 200 0.5
Air Air 72 35
15 162 3.3 1050 6.6 200 0.8
20 166 3.6 725 7.8 220 1.3
25 173 4.1 525 Edge Start

English
Select Set Material Arc Torch-to-Work Pierce Delay
Gases Cutflow Thickness Voltage Distance Cutting Speed Initial Pierce Height Time

Plasma Shield Plasma Shield in Volts in ipm in factor % seconds

1/4 147 .110 90 .220 200 0.2
3/8 148 .120 60 .240 200 0.3
1/2 152 .120 45 .240 200 0.5
Air Air 72 35
5/8 162 .130 40 .260 200 0.8
3/4 166 .140 30 .310 220 1.3
1 173 .160 20 Edge Start

HySpeed HSD130 RHF Instruction Manual 4-21

OPERATION

Aluminum Flow Rates – lpm/scfh

H35 N2
H35 Plasma / N2 Shield Preflow 0/0 164 / 348
130 A Cutting Cutflow 61 / 130 141 / 298

220536 220534 220535 220529 020415

220533 (no IHS tab)

Metric
Select Set Material Arc Torch-to-Work Pierce Delay
Gases Cutflow Thickness Voltage Distance Cutting Speed Initial Pierce Height Time

Plasma Shield Plasma Shield mm Volts mm mm/m mm factor % seconds

10 150 4.6 1615 7.8 170 0.3
12 151 4.6 1455 7.8 170 0.5
H35 N2 70 75 15 152 4.6 1305 7.8 170 0.8
20 155 4.6 940 7.8 170 1.3
25 158 4.6 540 Edge Start

English
Select Set Material Arc Torch-to-Work Pierce Delay
Gases Cutflow Thickness Voltage Distance Cutting Speed Initial Pierce Height Time

Plasma Shield Plasma Shield in Volts in ipm in factor % seconds

3/8 150 .180 65 .310 170 0.3
1/2 151 .180 55 .310 170 0.5
H35 N2 70 75 5/8 152 .180 50 .310 170 0.8
3/4 155 .180 40 .310 170 1.3
1 158 .180 20 Edge Start

4-22 HySpeed HSD130 RHF Instruction Manual

 OPERATION

Changing consumable parts

WARNING

Always disconnect power to the power supply before inspecting or changing torch consumable parts.
Coolant will flow from the torch if there is power to the system.
Use gloves when removing consumables. The torch might be hot.

Remove 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.

Turn OFF all power to the system.

Remove the retaining Remove the nozzle Remove the Remove the
cap and shield and swirl ring swirl ring electrode

Tool part number

027102

HySpeed HSD130 RHF Instruction Manual 4-23

OPERATION

Inspect consumables

Part Check for Action

Cap
Erosion, missing material Replace cap

Cracks Replace cap

Burn marks Replace cap

Nozzle

Erosion or missing material Replace nozzle*

Blocked gas holes Replace nozzle*

Center hole 1. Must be round Replace nozzle if hole is no longer round*

2. Signs of arcing Replace nozzle*

O-rings 1. Damage Replace nozzle*

2. Lubricant Apply a thin film of silicone lubricant if dry

Swirl ring

Damage Replace swirl ring

Dirt or debris Clean and check for damage, and replace swirl ring
if damaged

Gas holes Blocked holes Replace swirl ring

O-rings 1. Damage Replace swirl ring

2. Lubricant Apply a thin film of silicone lubricant if dry

Electrode

See Inspect electrode pit depth later in

Center surface Wear this section

O-rings 1. Damage Replace electrode*

2. Lubricant Apply a thin film of silicone lubricant if dry

*Note: Always replace the nozzle and electrode as a set.

4-24 HySpeed HSD130 RHF Instruction Manual

 OPERATION

Inspect torch

Water
tube

Nozzle External
seating o-rings
surface

Inspect Check for Action

All surfaces Dirt or debris Clean surfaces

Erosion, missing material Replace torch

Cracks Replace torch

Internal burn or arcing marks Replace torch

Nozzle seating surface 1. Dirt or debris Clean (use compressed air to remove debris)

2. Pitted or missing material Replace torch

Threads Wear or damage Replace torch

External o-rings 1. Damage Replace o-ring

2. Lubricant Apply a thin film of silicone lubricant if dry

Water tube* 1. Pitted or missing material Replace water tube*

*Note: See Replace torch water tube later in this section.

HySpeed HSD130 RHF Instruction Manual 4-25

OPERATION

Inspect electrode pit depth

0
90 10
0
1 4

2 3
80
20

70 30

60 40
50

Electrode pit depth gauge (004630)

Part Check for Action

Electrode

Center surface Wear Replace electrode if pit is deeper than 1 mm (0.040 in.)*

*Note: Always replace the nozzle and electrode as a set.

4-26 HySpeed HSD130 RHF Instruction Manual

 OPERATION

Replace torch water tube

WARNING

Always disconnect power to the power supply before inspecting or changing torch consumable parts.
Coolant will flow from the torch if there is power to the system.
Use gloves when removing consumables. The torch might be hot.

Note: The water tube may seem loose when correctly inserted, but any side-to-side looseness will disappear
after the electrode is installed.

Turn OFF all power to the system.

Remove consumables from torch. See Remove consumables in this section.

Remove water tube Install new water tube Replace consumables.

See Install consumables
in this section.

HySpeed HSD130 RHF Instruction Manual 4-27

OPERATION

Common cutting faults

• Torch pilot arc will initiate, but will not transfer. Causes can be:

1. Work cable connection on the cutting table is not making good contact.

2. Malfunction in the system. See Section 5..

3. Torch-to-work distance is too high.

• The workpiece is not totally penetrated, and there is excessive sparking on top of the workpiece.
Causes can be:

1. Current is set too low (check Cut chart information).

2. Cut speed is too high (check Cut chart information).

3. Torch parts are worn (see Changing consumable parts).

4. Metal being cut is too thick.

• Dross forms on the bottom of the cut. Causes can be:

1. Cutting speed is not correct (check Cut chart information).

2. Arc current is set too low (check Cut chart information).

3. Torch parts are worn (see Changing consumable parts).

• Cut angle is not square. Causes can be:

1. Wrong direction of machine travel.

High-quality side is on the right with respect to the forward motion of the torch.

2. Torch-to-work distance is not correct (check Cut chart information).

3. Cutting speed is not correct (check Cut chart information).

4. Arc current is not correct (check Cut chart information).

5. Damaged consumable parts (see Changing consumable parts ).

• Short consumable life. Causes can be:

1. Arc current, arc voltage, travel speed, motion delay, gas flow rates, or initial torch height not set as specified
in the Cut charts.

2. Attempting to cut highly magnetic metal plate, such as armor plate with a high nickel content, will shorten
consumable life. Long consumable life is difficult to achieve when cutting plate that is magnetized or
becomes magnetized easily.

3. Beginning or ending the cut off the plate surface. To achieve consumable long life, all cuts must begin
and end on the plate surface.

4-28 HySpeed HSD130 RHF Instruction Manual

 Operation

How to optimize cut quality

The following tips and procedures will help produce square, straight, smooth and dross-free cuts.

Tips for table and torch

• Use a square to align the torch at right angles to the workpiece.

• The torch may travel more smoothly if you clean, check and “tune” the rails and drive system on the cutting table.
Unsteady machine motion can cause a regular, wavy pattern on the cut surface.

• The torch must not touch the workpiece during cutting. Contact can damage the shield and nozzle, and affect
the cut surface.

Plasma set-up tips

Follow carefully each step in the Daily start-up procedure described earlier in this section.

Purge the gas lines before cutting.

Maximize the life of consumable parts

Hypertherm’s LongLife® process automatically “ramps up” the gas and current flows at the start and ramps them down
at the end of each cut, to minimize erosion of the electrode’s center surface. The LongLife process also requires that
cuts start and stop on the workpiece.

• The torch should never fire into the air.

– Starting the cut at the edge of the workpiece is acceptable, as long as the arc is not fired in the air.
– To start with a pierce, use a pierce height that is 1.5 to 2 times the torch-to-work distance. See Cut charts.

• Each cut should end with the arc still attached to the workpiece, to avoid arc blow-outs (ramp-down errors).
– When cutting drop parts (small parts that drop down after being cut from the workpiece), check that the arc
stays attached to the edge of the workpiece, for proper ramp-down.

• If arc blow-outs occur, try one or more of the following:

– Reduce the cutting speed during the final part of the cut.
– Stop the arc before the part is completely cut, to allow completion of the cut during the ramp-down.
– Program the path of the torch into the scrap area for ramp-down.
Note: Use a “chain cut” if possible, so the path of the torch can lead directly from one cut part into
the next, without stopping and starting the arc. However, do not allow the path to lead off the
workpiece and back on, and remember that a chain cut of long duration will cause electrode
wear.
Note: It may be difficult to achieve the full benefits of the LongLife process in some conditions.

HySpeed HSD130 RHF Instruction Manual 4-29

Operation

Additional factors of cut quality

Cut angle
A cut part whose 4 sides average less than 4° of cut angle is considered acceptable.
Note: The squarest cut angle will be on the right side with respect to the forward motion of the torch.
Note: To determine whether a cut-angle problem is being caused by the plasma system or the drive
system, make a test cut and measure the angle of each side. Next, rotate the torch 90° in its
holder and repeat the process. If the angles are the same in both tests, the problem is in the
drive system.

If a cut-angle problem persists after “mechanical causes” have been eliminated (see Tips for table and torch, previous
page), check the torch-to-work distance, especially if cut angles are all positive or all negative.

• A positive cut angle results when more material is removed from the top of the cut than from the bottom.

• A negative cut angle results when more material is removed from the bottom of the cut.

Problem Cause Solution

Negative cut angle The torch is too low. Increase arc voltage to raise the torch.

Square cut

Positive cut angle

\
The torch is too high. Decrease arc voltage to lower the torch.

Dross
Low-speed dross forms when the torch’s cutting speed is too slow and the arc shoots ahead. It forms as a heavy,
bubbly deposit at the bottom of the cut and can be removed easily. Increase the speed to reduce the dross.

High-speed dross forms when the cutting speed is too fast and the arc lags behind. It forms as a thin, linear bead of
solid metal attached very close to the cut. It is welded to the bottom of the cut and is difficult to remove. To reduce
high-speed dross:

• Decrease the cutting speed.

• Decrease arc voltage, to decrease the torch-to-work distance.
• Increase O2 in the shield gas to increase the range of dross-free cutting speeds. (Only HyDefinition and
HT4400 systems can accommodate mixed-gas shield gases.)
Notes: Dross is more likely to form on warm or hot metal than on cool metal. For example, the first cut
in a series of cuts will likely produce the least dross. As the workpiece heats up, more dross
may form on subsequent cuts.
Dross is more likely to form on mild steel than on stainless steel or aluminum.
Worn or damaged consumables may produce intermittent dross.

4-30 HySpeed HSD130 RHF Instruction Manual

 Operation

Straightness of the cut surface

A typical plasma cut surface is slightly concave.

The cut surface may become more concave, or convex. Correct torch height is required to keep the cut
surface acceptably close to straight.

A strongly concave cut surface occurs when the torch-to-work distance is too low. Increase the arc voltage
to increase the torch-to-work distance and straighten the cut surface.

A convex cut surface occurs when the torch-to-work distance is too great or the cutting current is too high.
First, reduce the arc voltage, then reduce the cutting current. If there is overlap between different cutting
currents for that thickness, try the consumables designed for the lower current.

Additional improvements
Some of these improvements involve trade-offs, as described.

Smoothness of cut surface (surface finish)

• (HyDefinition and HT4400 only) On mild steel, a higher concentration of N2 in the O2-N2 shield mixture may
produce a smoother cut surface.
Trade-off: This may produce more dross.

• (HyDefinition and HT4400 only) On mild steel, a higher concentration of O2 in the O2-N2 shield mixture may
increase the cutting speed and produce less dross.
Trade-off: This may produce a rougher cut surface.

Piercing
The pierce delay must be sufficiently long that the arc can pierce the material before the torch moves, but not so long
that the arc “wanders” while trying to find the edge of a large hole.

When piercing maximum thicknesses, the ring of dross that forms during the pierce may become high enough to contact
the torch when the torch begins to move after the pierce is complete.

• A “flying pierce,” which makes the pierce while the torch is moving, may eliminate the torch vibration that follows
contact between the torch and the ring of dross.

• In some Hypertherm systems, the shield gas pressure automatically increases during pierce delay.

• If the above steps do not solve the problem, increasing the setting of the shield gas pressure may help blow the
molten metal away during piercing.
Trade-off: This may reduce starting reliability.

How to increase cutting speed

• Decrease the torch-to-work distance.
Trade-off: This will increase the negative cut angle

Note: The torch must not touch the workpiece while piercing or cutting.

HySpeed HSD130 RHF Instruction Manual 4-31

Operation

4-32 HySpeed HSD130 RHF Instruction Manual

 Section 5

MAINTENANCE

In this section:
Introduction..................................................................................................................................................................................................5-2
Routine maintenance .................................................................................................................................................................................5-2
System description ....................................................................................................................................................................................5-3
Control and signal cables ..............................................................................................................................................................5-3
Sequence of operation..............................................................................................................................................................................5-4
PCB block diagram....................................................................................................................................................................................5-5
Error codes ..................................................................................................................................................................................................5-6
Error code troubleshooting – 1 of 8 ............................................................................................................................................5-7
Error code troubleshooting – 2 of 8............................................................................................................................................5-8
Error code troubleshooting – 3 of 8............................................................................................................................................5-9
Error code troubleshooting – 4 of 8 .........................................................................................................................................5-10
Error code troubleshooting – 5 of 8 .........................................................................................................................................5-11
Error code troubleshooting – 6 of 8 .........................................................................................................................................5-12
Error code troubleshooting – 7 of 8 .........................................................................................................................................5-13
Error code troubleshooting – 8 of 8 .........................................................................................................................................5-14
Power supply states................................................................................................................................................................................5-15
Plasma system operation with pump timeout....................................................................................................................................5-16
CNC operation with pump timeout......................................................................................................................................................5-17
Initial checks..............................................................................................................................................................................................5-18
Automated diagnostic tests...................................................................................................................................................................5-19
Power measurement ...............................................................................................................................................................................5-20
Power supply coolant system servicing..............................................................................................................................................5-21
Draining the coolant system. ......................................................................................................................................................5-21
Coolant system filter replacement .......................................................................................................................................................5-22
Air filter replacement ...............................................................................................................................................................................5-23
Coolant flow test procedure..................................................................................................................................................................5-24
Testing the flow switch.................................................................................................................................................................5-25
Gas leak test procedure.........................................................................................................................................................................5-26
PCB4: Power supply control board ....................................................................................................................................................5-27
PCB3: Power supply power distribution board................................................................................................................................5-28
PCB2: Start circuit..................................................................................................................................................................................5-29
Operation ........................................................................................................................................................................................5-29
Start-circuit functional schematic ..............................................................................................................................................5-29
Start-circuit troubleshooting .......................................................................................................................................................5-29
Pilot arc current levels ..................................................................................................................................................................5-31
PCB2: Fuel-gas console control board..............................................................................................................................................5-32
PCB1: Fuel-gas console power distribution board .........................................................................................................................5-33
PCB3: Fuel-gas console AC valve-driver board...............................................................................................................................5-34
Chopper tests...........................................................................................................................................................................................5-35
Phase-loss detection test ......................................................................................................................................................................5-38
Torch lead test ..........................................................................................................................................................................................5-40
Preventive maintenance..........................................................................................................................................................................5-41

HySpeed HSD130 RHF Instruction Manual 5-1

MAINTENANCE

Introduction
Hypertherm assumes that the service personnel that troubleshoots and tests the plasma systems are
high-level electronic service technicians who have worked with high-voltage electro-mechanical systems.
Knowledge of final isolation troubleshooting techniques is also assumed.

In addition to being technically qualified, maintenance personnel must perform all testing with safety in
mind. Refer to the Safety section for operating precautions and warning formats.

WARNING
Shock Hazard

Use extreme caution when working near the chopper components. The large blue capacitors store high
voltage. Even if the power is off, dangerous voltages exist at the capacitor terminals, on the choppers,
and the heatsinks. Discharging any capacitor with a screwdriver or other implement may result in an
explosion, property damage, or personal injury. Wait at least 5 minutes after turning off the power
supply before touching the chopper or the capacitors.

Routine maintenance
For a complete list of routine maintenance recommendations, see the Preventative Maintenance Schedule, located at
the end of this section. Contact the Technical Services department listed at the front of this manual with any questions
regarding the maintenance schedule or procedures.

5-2 HySpeed HSD130 RHF Instruction Manual

 MAINTENANCE

System description
Control and signal cables

CAN Bus signal cable: Digital signal cable:

Provides process and status Provides signals between the
signals between the power supply power supply and the off-valve
and the fuel-gas Console. for a fuel-gas system.

Power cable:
Provides 120 VAC to
the fuel-gas console.

Power cable:
Provides 120 VAC to
the ignition console.

Digital signal cable:

Provides signals between the
Power cable:
power supply and the off-valve.
Provides 120 VAC to
the off-valve.

HySpeed HSD130 RHF Instruction Manual 5-3

MAINTENANCE

Sequence of operation
1. Power-up – The system verifies that all of these signals are off at power-up
Coolant flow off
Chopper current off
Transfer off
Phase Loss off
Chopper 1 over-temp off
Magnetics over-temp off
Coolant over-temp off
Plasma start off

2. Purge – Air or O2 gas flows through torch for 24 seconds

Coolant flow on
Contactor closes and the chopper performs a chopper test and a current sensor test
Plasma start off
Contactor opens when the purge cycle ends
Gas pressure OK

3. Idle
Gas pressure OK
Coolant flow on
Chopper current off
Line voltage OK

4. Preflow – Gas flows for 1.25 seconds

5. Pilot arc – Current flows between electrode and nozzle

Chopper, main contactor, and pilot arc relay are on
High frequency present
Chopper current sensor = pilot arc current

6. Transfer – Pilot arc current sensed on the worklead

7. Ramp-up – Chopper current increases to set-point and the gas switches to cutflow
Coolant flow on
Gas pressure OK
Phase loss on
Line voltage OK

8. Steady state – normal operating parameters

Coolant flow on
Gas pressure OK
Phase loss on
Chopper over-temp off
Magnetics over-temp off
Coolant over-temp off

9. Ramp-down – Current and gas flow decrease after plasma start has been removed
Cutflow gas off

10. Auto Off – 10-second postflow

Main contactor off
Chopper off

5-4 HySpeed HSD130 RHF Instruction Manual

 Power supply PHC interface board (optional)
Command THC
control module
PCB (optional) Plasma interface cable
Arc voltage
Control board (PCB4) Machine interface cable
PCB block diagram

Chopper current
Duty cycle Chopper (CH1)
CNC interface cable Output
control

HySpeed HSD130 RHF Instruction Manual

Torch
CAN bus signals Transfer
Chopper temperature
sensor
Power distribution board Work
(PCB3) Phase loss
CNC controller

DC power for PCBs and I/O board

sensors (PCB2)
Pilot arc enable
AC power for solenoids, AC power
motors, fans, relays, and
contactors PA controller (PCB2)

Fuel-gas console RHF console

Control board (PCB2)
Valve control AC power High-frequency
signals DC power
board (PCB9)
Power distribution
board (PCB1)
Valve driver board
(PCB3) AC power to high-voltage
AC power transformer

5-5
MAINTENANCE
MAINTENANCE

Error codes
Set the selection switch on the power supply to ERROR. The power supply states are shown in the 3-digit LED display
on the power supply. The state ID numbers are 2 digits with a dash in front of them and error codes have 3 digits. When
the selection switch is set to ERROR, the state ID number will be displayed for 2 seconds. An error code number will
then be displayed for 2 seconds. The display will continue to cycle through both numbers until the selection switch is
moved.

3-digit display

5-6 HySpeed HSD130 RHF Instruction Manual

 MAINTENANCE

Error code troubleshooting (1 of 8)

Error code
Name Description Corrective action
number

000 No error System is ready to run. None needed.

012
fuel-gas Test in One of the gas tests is
The test will run for about 3 minutes.
console progress running.
only
014
Plasma-gas A gas leak of more than
fuel-gas
channel 0.7 bar (10 psi) in the Check the plasma gas lines for leaks.
console
failure plasma gas channel.
only
015
Preflow-gas A gas leak of more than
fuel-gas
channel 0.7 bar (10 psi) in the Check the preflow gas lines for leaks.
console
failure preflow gas channel.
only
016
Shield-gas A gas leak of more than
fuel-gas
channel 0.7 bar (10 psi) in the Check the shield gas lines for leaks.
console
failure shield gas channel.
only
017
Fuel-gas A gas leak of more than
fuel-gas
channel 0.7 bar (10 psi) in the Check the fuel plasma line for leaks.
console
failure plasma gas channel.
only

1. Verify that the consumable parts are in good condition.

2. Verify proper pre-flow and cut-flow settings.
3. Fuel-gas only: Perform leak test.
No current detected from
4. Verify spark across spark gap.
020 No pilot arc chopper at ignition and
5. Inspect CON1 for excessive wear.
before 1-sec timeout.
6. Perform torch lead test (see Maintenance section).
7. Perform start circuit test (see Maintenance section).
8. Perform chopper test (see Maintenance section).

1. Verify proper pierce height.

No current detected on
2. Verify proper gas settings.
No arc work lead 500 milli-
021 3. Inspect work lead for damage or loose connections.
transfer seconds after pilot arc
4. Verify the condition of the current transfer sensor on the
current was established.
I/O PCB.

1. Verify that the consumable parts are in good condition.

2. Verify proper gas settings.
Lost current from chopper 3. Verify pierce delay time.
024 Lost current
after transfer. 4. Verify that the arc did not lose contact with plate while
cutting (hole cutting, scrap cutting, etc).
5. Perform chopper test (see Maintenance section).

HySpeed HSD130 RHF Instruction Manual 5-7

MAINTENANCE

Error code troubleshooting (2 of 8)

Error code
Name Description Corrective action
number

1. Verify that the consumable parts are in good condition.

2. Verify proper gas settings.
3. Verify pierce delay time.
After transfer lost the
4. Verify that the arc did not lose contact with plate while
026 Lost transfer transfer signal. The signal
cutting (hole cutting, scrap cutting, etc).
is < 3.5 amps.
5. Inspect work lead for damage or loose connections.
6. Try connecting work lead directly to the plate.
7. Perform chopper test (see Maintenance section).
1. Verify phase-to-phase voltage to power supply.
2. Disconnect power to power supply, remove cover on
contactor, and inspect contacts for excessive wear.
Phase imbalance to
3. Inspect the power cord, contactor, and input to chopper for
027 Lost phase chopper after contactor
loose connections.
engaged or while cutting.
4. Inspect the phase-loss fuses on the power distribution
board (PCB3). Replace board if fuses are blown.
5. Perform phase-loss test (see Maintenance section).
1. If a mechanical relay is being used to provide the HSD with
a start signal, this relay is either bouncing when activated or
the contacts are faulty. Replace the relay.
Start signal was received
2. Inspect interface cable for damage; faulty crimps, or poor
031 Start loss and then lost before an arc
electrical connections.
was established.
3. If interface cable is good and a relay is not driving the start
input, the CNC is dropping the start signal before a steady
state arc has been established.
1. Check the interface cable for damage. The hold wires may
be short-circuiting inside.
Hold signal was active for 2. The CNC is maintaining this input, it could be waiting for an
032 Hold timeout
longer than 60 seconds. IHS complete input from another torch.
3. If CNC interface cable is good and it is a one-torch system,
change PCB4.

1. Put the selection switch in the SET position. The 3-digit LED
Preflow gas pressure
Low preflow shows the preflow supply pressure. The pressure reading
035 under lower limit of
pressure should be between 6.2 bar and 8.3 bar (90 psi and 120 psi).
0.4 bar (5 psi).
2. Verify that the Burkart valve is functioning properly.

Low or no nitrogen
pressure during purge. 1.Verify that the nitrogen supply is turned on, and inspect gas
Nitrogen gas Purge occurs when supply pressure and volume of gas remaining in supply tanks.
042
purge error switching from a fuel gas 2. Verify that the gas regulator is set to 7.2 bar (105 psi). See
process to an oxygen or air Setting the supply regulators (Installation section).
process.

5-8 HySpeed HSD130 RHF Instruction Manual

 MAINTENANCE

Error code troubleshooting (3 of 8)

Error code
Name Description Corrective action
number

1. Verify gas supply pressure settings.

2. Verify gas regulator settings on gas console with cut chart.
Gas pressure is above the 3. See Setting the supply regulators (Installation section).
High preflow
043 upper limit of 6.8 bar 4. Solenoid at off-valve is not opening. Verify power to valves,
pressure
(99 psi) disconnect plasma and shield hoses exiting off-valve. If
pressures decrease, a valve is not functioning or no power
to the valve.

1. Inspect gas supply pressure and volume of gas remaining in

supply tanks.
Gas pressure is below the 2. Verify gas regulator settings on the front panel of the power
Low plasma
044 lower limit of 3.5 bar supply with cut chart.
gas pressure
(50 psi) 3. See Setting the supply regulators (Installation section).
4. Fuel-gas only – Perform leak test procedure
(Maintenance section).

1. Verify gas supply pressure settings.

2. Verify plasma gas regulator settings on the front panel of the
power supply with cut chart.
Gas pressure above the
High plasma 3. See Setting the supply regulators (Installation section).
045 upper limit of 6.8 bar
gas pressure 4. Solenoid at off-valve is not opening. Verify power to valves,
(99 psi)
disconnect plasma and shield hoses exiting off-valve. If
pressures decrease, a valve is not functioning or no power
to the valve.

1. Verify input-line voltage. Voltage needs to be within 10 % of

Line voltage is close to or
nominal (120 VAC).
below the lower limit of
2. Verify fuses on PCB3.
Low line 102 VAC (120 VAC
046 3. Verify 120 VAC voltage on plug J3.4, pins 3 and 4 on
voltage –15%). The normal lower
PCB3.
limit for operation is 108
4. If AC voltage on J3.4, pins 3 and 4, is greater than
VAC (120 VAC –10%).
108 VAC, replace PCB3.

1. Verify input-line voltage. Voltage needs to be within 10 % of

Line voltage is close to or
nominal (120 VAC).
above the upper limit of
2. Verify fuses on PCB3.
High line 138 VAC (120 VAC
047 3. Verify 120 VAC voltage on plug J3.4, pins 3 and 4 on
voltage +15%). The normal upper
PCB3.
limit for operation is 132
4. If AC voltage on J3.4, pins 3 and 4, is less than
VAC (120 VAC +10%).
132 VAC, replace PCB3.

HySpeed HSD130 RHF Instruction Manual 5-9

MAINTENANCE

Error code troubleshooting (4 of 8)

Error code
Name Description Corrective action
number

1. Stop or clear the cutting program. The plasma start signal

to the plasma was not dropped after the last cut.
2. Verify that the CNC interface cable is not damaged.
Start signal is Plasma start signal input is 3. Remove CNC interface cable from PCB4 and look for an
050 on at active during power-up of open circuit between pins 15 and 34.
power-up the power supply. 4. If the circuit is closed either the CNC is issuing a plasma
start or the CNC interface cable is damaged.
5. If circuit is open, and D44 is illuminated with the CNC
Interface cable removed from PCB4, replace PCB4.

1. Verify gas supply pressure and that a sufficient volume of

gas remains in your supply.
Shield pressure is below 2. Verify gas regulator settings on the front panel with cut
Low shield
053 lower limit of 0.14 bar chart.
pressure
(2 psi). 3. See Setting the supply regulators (Installation section).
4. Fuel-gas only – Perform leak test procedure
(Maintenance section).

1. Verify gas supply regulator settings. See Setting the

supply regulators (Installation section).
Shield gas pressure is 2. Verify pressure settings on the front panel with cut chart.
High shield
054 above upper limit of 3. Solenoid at off-valve is not opening. Verify power to valves,
pressure
6.8 bar (99 psi). disconnect plasma and shield hoses exiting off-valve. If
pressures decrease, a valve is not functioning or no power
to the valve.

1. If you have a base system (no fuel-gas console), replace

No plasma Plasma gas has not been the control board (PCB4)
061
gas type selected. 2. If the system has a fuel gas console, replace the fuel-gas
console control board (PCB2)

1. If you have a base system (no fuel-gas console), replace

No shield gas Shield gas has not been the control board (PCB4)
062
type selected. 2. If the system has a fuel gas console, replace the fuel-gas
console control board (PCB2)

1. Verify Air or nitrogen gas supply pressure and that a

sufficient volume of gas remains in your supply.
2. Verify that the Burkart valve is functioning properly.
Low preflow Inlet pressure is < 4.1 bar
063 3. Put the selection switch in the SET position. The 3-digit
inlet pressure (60 psi).
LED shows the supply pressure. The pressure reading
should be between 6.2 bar and 8.3 bar
(90 psi and 120 psi).

5-10 HySpeed HSD130 RHF Instruction Manual

1
 MAINTENANCE

Error code troubleshooting (5 of 8)

Error code
Name Description Corrective action
number

1. Verify that both chopper fans are operating properly.

Spinning fan blades should be difficult to see.
2. Blow dust out of the system, especially from fans and the
chopper’s heat sink.
The chopper has 3. Verify that the voltage on the back side of J3.19, pins 1
Chopper over overheated. The and 2 on PCB3, is less than or equal to 2.9 VDC.
065
temp temperature is > 85° C 4. If the voltage is low, verify correct wiring between chopper
(185° F). temp sensor and J3.19 pins 1 and 2.
5. If wiring is good and over temp error does not clear after
30 minutes, replace chopper.
6. If voltage is higher than 2.9 VDC and over temp LED does
not clear after 30 minutes, replace PCB3.

1. Verify that the large fan is operating properly. Spinning fan

blades should be difficult to see.
2. Blow dust out of system, especially from fans and large
power transformer.
The power transformer or 3. Verify that the voltage on the back side of J3.20 pins 3 and
Magnetics inductors have overheated. 4, is equal to or less than 3.2 VDC.
067
over temp The temperature is 4. If voltage is low, inspect wiring between the transformer's
> 150° C (302° F). temp sensor and J3.20 pins 3 and 4. Look for short
circuits to wires or ground.
5. If wiring is good, the transformer has overheated.
6. If voltage is higher than 3.2 V and over temp error does not
clear after 30 minutes, replace PCB3.

1. Verify that all fans in the coolant heat exchanger are

running.
2. Blow dust out of the system, especially from the heat
exchanger.
3. Verify that the voltage on the back side of J3.20 pins 1 and
Torch coolant has 2, is equal to or lower than 2.8 VDC.
Coolant over overheated. The 4. If voltage is low, inspect wiring between coolant sensor
071
temp temperature is > 70° C and J3.20, pins 1 and 2, for short circuits to wires or
(158° F). ground.
5. If wiring is good, the coolant has overheated; let system
stand for 30 minutes to cool.
6. If voltage is higher than 2.8 VDC and the over temp error
does not clear after 30 minutes, replace the temperature
switch.

1. Measure voltage across the current sensor (CS2).

a) Red to black = +15 VDC, green to black = -15 VDC,
A Current < 10 Amps has
white to black = 0 VDC at idle and varies with current
been detected on chopper
Low current output (4 VDC = 100 amps).
075 channel 2 by current
on CS2 b) If possible, take a voltage reading on current sensor
sensor 2 during the
while trying to cut. Ratio is 4 VDC = 100 amps.
chopper test at power-up.
c) If the current sensor voltage is approximately 6.4 VDC
or greater at idle, replace the current sensor.

HySpeed HSD130 RHF Instruction Manual 5-11

MAINTENANCE

Error code troubleshooting (6 of 8)

Error code
Name Description Corrective action
number

1. If this is a new system, follow start procedure.

2. Verify that the coolant filter is in good condition.
Coolant flow signal was
3. Perform coolant flow test procedure (Maintenance
No coolant lost or was never satisfied.
093 section).
flow Coolant flow is < 2 lpm
4. Verify that the CNC drives the plasma start signal for at
(0.6 gpm)
least 10 seconds to allow the timed-out pump to turn on
again.

1. Verify phase-to-phase voltage to the power supply.

2. Verify that the fuses on PCB3 (F5, F6, and F7) are good.
Voltage detected on the
3. Verify the voltage from F5 to F6, F5 to F7, and F6 to F7. All
Phase-loss at phase-loss circuit during
098 3 readings should be about 311 VAC. If the voltage
power-up the chopper test at power-
readings are correct, U5 should be active and J8, pins 1
up.
and 2 should be closed. If these conditions are not met,
replace PCB3.

1. Verify that the temperature sensor for the chopper has not
Chopper over been jumped out or the wires to the temp switch shorted
Chopper is indicating an
099 temp at out in the harness.
over temp at power-up.
power-up 2. If no jumper is present, the chopper is overheated and
needs time to cool to 83° C (181.4° F).

1. Verify that the transformer temperature sensor for the

Magnetics The main transformer or chopper has not been jumped out or the wires to the
101 over temp at inductors are indicating an temperature sensor are not shorted out in the harness.
power-up over temp at power-up. 2. If not, the main transformer is overheated and needs time
to cool to 150° C (302° F).

Chopper current signal 1. Verify proper electrical connections to chopper current

Output
from CS1 is active sensor (CS1) and to J4.2 on PCB4.
102 current at
(greater than 5 amps) at 2. Verify that the contactor is not stuck in the closed (on)
power-up
power-up. position.

1. Verify that there is not a short circuit between the negative

lead and the work lead.
A Current > 35 Amps has 2. Measure voltage across the current sensor (CS1)
been detected on chopper a) Red to black = +15 VDC, green to black = –15 VDC,
High current channel “A” by white to black = 0 VDC at idle and varies with current
103
on CS1 current sensor 1 during output (4 VDC = 100 amps).
the chopper test at b) If possible, take a voltage reading on current sensor
power-up. while trying to cut. Ratio is 4 VDC = 100 amps.
c) If the current sensor voltage is approximately 6.4 VDC
or greater at idle, replace the current sensor.

5-12 HySpeed HSD130 RHF Instruction Manual

 MAINTENANCE

Error code troubleshooting (7 of 8)

Error code
Name Description Corrective action
number

1. Measure voltage across the current sensor (CS1).

A Current < 10 Amps has a) Red to black = +15 VDC, green to black = -15 VDC,
been detected on chopper white to black = 0 VDC at idle and varies with current
Low current channel 1 by output (4 VDC = 100 amps).
105
on CS1 current sensor 1 during b) If possible, take a voltage reading on current sensor
the chopper test at while trying to cut. Ratio is 4 VDC = 100 amps.
power-up. c) If the current sensor voltage is approximately 6.4 VDC
or greater at idle, replace the current sensor.

1. Verify that there is not a short circuit between the negative

lead and the work lead.
2. Measure voltage across the current sensor (CS2).
A Current > 35 Amps has
a) Red to black = +15 VDC, green to black = -15 VDC,
been detected on channel
High current white to black = 0 VDC at idle and varies with current
107 2 by current sensor 2
on CS2 output (4 VDC = 100 amps).
during the chopper test at
b) If possible, take a voltage reading on current sensor
power-up.
while trying to cut. Ratio is 4 VDC = 100 amps.
c) If the current sensor voltage is approximately 6.4 VDC
or greater at idle, replace the current sensor.

The system has detected

Transfer at 1. Disconnect J6.6 on the I/O PCB (PCB6). If the problem is
108 current on the work lead >
power-up resolved, replace PCB6.
3.5 amps during power-up.

Coolant flow is > 2 lpm

Coolant flow 1. The coolant flow sensor was bypassed or the flow switch
109 (0.6 gpm) when the pump
at power-up is faulty. Replace the flow switch.
is off.

1. Verify that the coolant temperature sensor has not been

Coolant over jumped out or the wires to the sensor are not shorted out
Coolant is indicating an
111 temp at in the harness.
over temp at power-up.
power-up 2. If not, the coolant temperature is over the set point and
needs time to cool to 70° C (158° F).

1. Verify that the power supply to gas console control cable is

not damaged and is properly connected to PCB4 and to
the back of the gas console.
An error occurred with the
Watchdog 2. Verify that the power supply to gas console power cable is
116 CAN communication
interlock not damaged and is properly connected inside the power
system.
supply and to the back of the gas console.
3. Use the CAN bus tester to verify CAN bus
communications.

HySpeed HSD130 RHF Instruction Manual 5-13

MAINTENANCE

Error code troubleshooting (8 of 8)

Error code
Name Description Corrective action
number

1. Verify that the wiring between CS1 and PCB4 is correct

and not damaged.
2. Measure voltage across the current sensor.
a) Red to black = +15 VDC, green to black = -15 VDC,
Chopper channel 1 current
Chopper white to black = 0 VDC at idle and varies with current
134 feedback has exceeded
overcurrent output (4 VDC = 100 amps).
90 amps.
b) If possible, take a voltage reading on the current
sensor while trying to cut. Ratio is 4 VDC = 100 amps.
c) If the current sensor voltage is approximately 6.4 VDC
or greater at idle, replace the current sensor.

Purge This is a warning for a possible gas restriction in the leads.

The purge cycle did not
139 time-out Verify that there are no restrictions in the plasma and shield
complete within 3 minutes.
error hoses.

The software has detected

Software
151 an incorrect state or 1. Replace the power supply control board (PCB4).
failure
condition.

Communication problem
Internal flash to the flash chip on
152 1. Replace the power supply control board (PCB4).
error the power supply control
board.

EEPROM memory on
PS EEPROM
153 power supply control 1. Replace the power supply control board (PCB4).
error
board is not working.

1. Verify that the wiring between CS2 and PCB4 is correct

and not damaged.
2. Measure voltage across the current sensor.
a) Red to black = +15 VDC, green to black = -15 VDC,
Chopper channel 2 current
Chopper white to black = 0 VDC at idle and varies with current
154 feedback has exceeded
overcurrent output (4 VDC = 100 amps).
90 amps.
b) If possible, take a voltage reading on the current
sensor while trying to cut. Ratio is 4 VDC = 100 amps.
c) If the current sensor voltage is approximately 6.4 VDC
or greater at idle, replace the current sensor.

Chopper current signal 1. Verify proper electrical connections to chopper current

Output
from CS2 is active sensor (CS1) and to J4.2 on PCB4.
157 current at
(greater than 5 amps) at 2. Verify proper electrical connections to chopper current
power-up
power-up. sensor (CS2) and to J4.2 on PCB4.

5-14 HySpeed HSD130 RHF Instruction Manual

 MAINTENANCE

Power supply states

Set the selection switch on the power supply to ERROR. The power supply states are shown in the 3-digit LED display
on the power supply. The state ID numbers are 2 digits with a dash in front of them and error codes are 3 digits. When
the selection switch is set to ERROR, the state ID number will be displayed for 2 seconds. An error code number will
then be displayed for 2 seconds. The display will continue to cycle through both numbers until the selection switch is
moved.

3-digit display
State ID Name

-00 Idle

-02 Purge

-03 Idle 2

-04 Preflow

-05 Pilot arc

-06 Transfer

-07 Ramp-up

-08 Steady state

-09 Ramp-down

-10 Final ramp-down

-11 Auto off

-12 Test cutflow

-14 Shutdown

-15 Reset

-16 Maintenance

-22 Manual pump control

-26 System test state

HySpeed HSD130 RHF Instruction Manual 5-15

MAINTENANCE

Plasma system operation with pump timeout

HSD
power supply
power-up

Internal hold signal off.

Fire the torch
and begin cutting.

Gas preflow
complete

Internal hold signal on.

Coolant flow
If the pump has timed out,
error code 093
turn on the pump.

< 45 seconds > 45 seconds

5-16 HySpeed HSD130 RHF Instruction Manual

 MAINTENANCE

CNC operation with pump timeout

Are all torches

in position to cut?

HySpeed HSD130 RHF Instruction Manual 5-17

MAINTENANCE

Initial checks
Before troubleshooting, do a visual check that proper voltages are present at the power source, transformers and power
distribution board.

DANGER

SHOCK HAZARD: Always use extreme caution when servicing a power supply when it is plugged in and
the covers are removed. Dangerous voltages exist within the power supply which could cause injury or
death.

1. Disconnect line power by turning OFF the main disconnect switch.

2. Remove the power supply’s top panel and 2 side panels.

3. Inspect interior of power supply for discoloration on PC boards, or other apparent damage. If a component or module
is obviously defective, remove and replace it before doing any testing. Refer to the Parts List section to identify parts
and part numbers.

4. If no damage is apparent, connect power to the power supply, and turn the main disconnect switch ON.

5. Measure the voltage between the W, V and U terminals of TB1 located on the right side of the power supply. See
Power measurement later in this section. Also refer to the wiring diagram in Section 7, if required. The voltage
between any 2 of the 3 terminals should be equal to the supply voltage. If there is a problem at this point, disconnect
main power and check connections, power cable, and fuses at line disconnect switch. Repair or replace any
defective component.

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Automated diagnostic tests

Move the process selection knob on the power supply to the TEST position while the machine is idle and the system will
run the following tests automatically:

1. The system tests the chopper. The Amps display will show the open circuit voltage (OCV). A normal reading is
approximately 300 VDC.

2. The plasma select valve (SV1) turns on for 3 seconds.

3. The shield off-valve (SV2) turns on for 3 seconds.

4. The preflow off-valve (SV3) turns on for 3 seconds.

5. The plasma off-valve (SV4) turns on for 3 seconds.

6. The vent off-valve (SV5) turns on for 3 seconds.

7. (Fuel Gas Console Only) The off-valve closes and the inlet valves open until the system is pressurized, and then
they close. The system should maintain pressure. If a leak is detected, the HSD130 will display an error code. Put the
toggle switch in the Error position to monitor for errors.

8. (Fuel Gas Console Only) The inlet valve closes and the off-valve opens until the pressure in the system is released
and then it closes. The system looks for an increase in pressure. The test ensures that the valves are closing properly
and are not allowing gas to leak through. Put the toggle switch in the Error position to monitor for errors.

The following error codes may be seen during automated tests 7 and 8:

Error 012 – Test in progress – Wait for test completion.

Error 014 – Test failed – Plasma gas channel

Error 015 – Test failed – Preflow gas channel

Error 016 – Test failed – Shield channel

Note: When the process selection knob is in the TEST position the display will alternate between “-26” (test
position) and “012” (test in progress). If the error code changes from “012” to “000”, the system
passed all tests.

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Power measurement

DANGER

There is line voltage at the contactor when the line disconnect switch is ON, even if the the circuit
breaker on the power supply is OFF. Use extreme caution when measuring primary power in these
areas. Voltages present at the terminal block and contactors can cause injury or death.

W
U
Ground
V

U
V
W
Ground

Note: Check lines in the following order:

U to V
U to W
V to W
Check each line to ground. If one line
is 10% or higher than the other two, put that
leg on U.

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Power supply coolant system servicing

Draining the coolant system

1. Turn OFF the power, and remove the right-side panel from the power supply.

2. Locate the coolant drain valve and use a 20 liter (5 gallon) container to catch the coolant. Coolant will flow as soon
as the drain is opened. Close the drain valve when the coolant stops flowing. Always dispose of coolant according to
local and national codes.

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Caution: Coolant will flow from the filter when its housing is removed.
Drain coolant before replacing the filter.

Coolant system filter replacement

1. Make sure that the coolant has been drained and then turn OFF all power to the system.

2. Remove housing.

3. Remove and discard the filter element.

4. Install the new filter element 027664.

5. Re-install housing.

6. Refill the power supply with coolant.

2 3 4 5

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Air filter element replacement

1. Disconnect the electrical power and the gas supply.
Remove the filter bowl and the old filter element.

a. Pull down and hold the black release tab. (If you do not see the tab,
check the back of the filter bowl.)

b. Rotate the filter bowl in either direction until it releases. A

c. Pull the filter bowl down to remove it. The bowl has an o-ring
around the top. Do not discard the o-ring. If the o-ring needs to be B
replaced, use part number 011105.

Use a screwdriver to remove the filter element from the filter

housing. Then install the new filter element.

Note: Do not allow the filter element to turn when loosening the
screw.

Re-install the filter bowl.

a. Hold down the black tab and slide the filter bowl over
the new filter element.

b. Align the marks on filter bowl and the filter body. B

c. Rotate the filter bowl until it locks in place.

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Coolant flow test procedure

The control board (PCB4) receives a contact closure signal from the flow switch when the flow rate is 2.3 lpm (0.6 gpm)
or greater. Normal flow is 4.5 lpm (1.2 gpm), but this will vary depending on lead lengths and whether the power is
50 Hz or 60 Hz. PCB4 will allow the system to operate if the coolant flow is 2.3 lpm (0.6 gpm) or greater. If the system
shows a coolant flow error (093) the system will need to be turned OFF and then ON again and the following test
needs to be performed to determine if the problem is coolant flow or the flow switch.

1. Turn OFF the power, and remove the right-side panel from the power supply.

2. Remove the return hose at the top of the coolant tank. Apply gentle pressure to the hose while pulling back on the
collar of the elbow fitting. This will release the coolant hose. No tools required. Put the end of the return hose into a
20 liter (5 gallon) container.

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3. Turn ON the power and have another person push and hold the current knob, to override the flow time-out error.
Allow the coolant to flow for 45 seconds, and turn OFF the power.

4. Measure the amount of coolant in the container. It should be about 4 liters (1 gallon). If there is less than 3 liters
(3/4 gallon) there may be a restriction in the coolant system or a problem with the pump.

5. If the flow is 2.3 lpm (0.6 gpm) or higher, check the flow switch for contact closure at J11 (blue and white wires). The
wires should be shorted. The LED lamp on the flow switch should be illuminated when the pump is running and the
flow is > 2.3 lpm (0.6 gpm).

LED lamp

Testing the flow switch

6. Reconnect the return hose to the coolant tank and turn ON the power. Have another person push and hold the
current knob to override the flow time-out error.

7. If the LED lamp on the flow switch is illuminated, D67 on the control board (PCB4) should also be illuminated.

D67

041938

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Gas leak test procedure (standard system)

The fuel-gas system has 2 automated leak test modes. See Automated diagnostic tests in this section.

Leak test for a standard system (no fuel-gas console)

1. Turn ON the power to the system.

2. After the initial gas purge, move the process selection switch to SET.

3. Adjust the air supply regulator to 5.5 bar (80 psi).

4. Adjust the O2 supply regulator to 5.5 bar (80 psi).

5. Move the process selection switch to RUN.

6. Disconnect the off-valve cable (1x3)

from the rear panel of the power supply.
1X3

7. Move the process selection switch to SET.

8. Turn off the oxygen and the air at the supply.

9. Monitor the plasma pressure and the shield pressure displays for 10 minutes. The pressure should not decrease
more than 0.7 bar (10 psi) in 10 minutes.

10. When the test is complete, reconnect the 1x3 cable, move the process selection switch to RUN, and reset the
incoming gas supply pressures.

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PCB4: Power supply control board

041938

Control PCB4 firmware list

Item Part number

U53 081118 EVEN

U54 081118 ODD

PCB4 LED list

LED Description Color LED Description Color

D44 Plasma start input Green D59 Hold output Green

D45 Corner current input Green D60 Pilot arc enable output Green
D47 + 5 VDC Green D61 High-frequency enable Green
D48 Coolant temperature Green D62 Pump enable Green
D49 Hold ignition input Green D63 Contactor enable Green
D50 + 3.3 VDC Green D64 SVA drive Green
D51 Pierce complete input Green D65 CAN transmit Green
D52 Chopper temperature Green D66 CAN receive Green
D53 Magnetics temperature Green D67 Flow switch Green
D54 Chopper temperature 2 Green D68 Work lead (transfer) Green
D55 Magnetics temperature 2 Green D69 Phase loss Green
D57 Motion output Green D70 Overpressure (not used) Green
D58 Ramp-down error output Green

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PCB3: Power supply power distribution board

041935
A

Note: FH1, FH2, and FH3 are 6 Amp slow-blow fuses

FH5, FH6, and FH7 are 3 Amp fast-blow fuses

PCB3 LED list

LED Output Color LED Output Color

D1 120 VAC Green D15 Main contactor Red

D6 Vent solenoid (SV5) Red D21 24 VAC Green
D7 Plasma cutflow solenoid (SV4) Red D48 240 VAC Green
D8 Plasma preflow solenoid (SV3) Red D52 + 24 VDC Red
D9 Shield off-valve solenoid (SV2) Red D54 Pump on Green
D10 Plasma select solenoid (SV1) Red D55 + 5 VDC Red
D11 Shield select solenoid (SV0) Red D56 – 15 VDC Red
D12 Power switch closed Green D57 + 15 VDC Red
D14 High-voltage transformer Red

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PCB2: Start-circuit
Operation
The start circuit is a high-speed switch that quickly transfers the pilot arc current from the pilot arc lead to the work lead.
The start circuit performs 2 functions:

1. It allows the initial pilot arc current to flow through the pilot arc lead quickly, with little impedance.

2. After initial pilot arc current is established, the start circuit introduces resistance to the pilot arc lead to aid in
transferring the arc to the workpiece. See schematic below.

Start circuit functional schematic

Power supply
control board

Start-circuit troubleshooting

DANGER

SHOCK HAZARD: Always use extreme caution when servicing a power supply when it is plugged in and
the covers are removed. Dangerous voltages exist within the power supply which could cause injury or
death.

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MAINTENANCE

D4 should always be illuminated.

D5 illuminates as soon as the torch fires and will extinguish as soon as the arc
transfers to the workpiece. If arc transfer is immediate, the LED may not
illuminate.
If there is no arc at the torch or if the arc will not transfer:
1. Turn OFF all power to the system.
2. Remove wires from J4 ( TO WORK) and J3 (TO NOZZLE) studs on the
board.
3. Verify a resistance of 2 Ω between J4 and J7. If the resistance value is not
correct, replace PCB2.
Note: Resistance value may slowly increase to the correct value due to the
capacitance in the circuit.
4. Verify a resistance of 4 Ω across R7 and R6.
• The work lead should not have any cuts or breaks. verify a resistance of 1Ω or less. The work lead connection
to the cutting table should be clean and have good contact to the table.
• Verify that D4 is illuminated. If it is not illuminated the board may need to be replaced or the board may not be
receiving power.
• Fire the torch in the air and verify that D5 is illuminated. If it is not illuminated, but a pilot arc is established,
PCB2 may need to be replaced.
5. Place a 10 AWG (6 mm2) jumper across J3 and J4. Perform a test cut. The nozzle will wear out after just a few
starts. If the arc transfers, replace PCB2.

2Ω

R7

J3
4Ω TO NOZZLE
J4
TO WORK

R6

PCB2

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Pilot arc current levels

The pilot arc current level will change depending on the chosen process and arc current level. See table below.

Pilot arc current

Plasma gas 45 Amps 50 Amps 130 Amps
O2 30 20 30
N2 30 20 35

H35 30 20 35

F5 30 20 35

Air 30 20 35

Transfer current
Transfer is determined by CS1 on PCB6. Transfer occurs when current on the work lead is > 3.5 Amps.

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PCB2: Fuel-gas console control board

Gas console control board LED list

LED Signal name Color

D1 + 5 VDC Green
D2 + 3.3 VDC Green
D7 CAN transmit Green
D8 CAN receive Green

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PCB1: Fuel-gas console power distribution board

041805

5 Amp
slow-blow
fuse

Gas console power distribution board LED list

LED Signal name Color

D1 120 VAC Green

D7 + 5 VDC Red
D9 + 24 VDC Red

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PCB3: Fuel-gas console AC valve-driver board

5 Amp
slow-blow
fuse

041962

Gas console AC valve driver board LED list

LED Signal name Color

D1 SV0 Red
D2 SV1 Red
D3 SV2 Red
D4 SV3 Red
D5 SV4 Red
D6 SV5 Red
D7 SV6 Red
D8 SV7 Red
D9 SV8 Red
D10 SV9 Red

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Chopper tests

WARNING

SHOCK HAZARD: Use extreme care when working near the chopper modules. Each large electrolytic
capacitor (blue-cased cylinder) stores large amounts of energy in the form of electric voltage. Even if
the power is off, dangerous voltages exist at the capacitor terminals, on the chopper, and the diode
heatsinks. Never discharge any capacitor with a screwdriver or other implement … explosion, property
damage and/or personal injury will result.

Test 1 – automatic chopper and current sensor tests during power-up

Turn ON the system. When the preflow starts, the contactor will close and the system will automatically test the chopper
and current sensors. The system closes the contactor and turns chopper channel 1 on at 90% duty cycle. The chopper
will charge the surge capacitor on the I/O board (PCB 6). The current that charges the capacitor should be between
10 amps and 35 amps. Error code 105 will show in the AMPS display if the current is < 10 amps or there is no
feedback on current sensor 1 (CS1). Error code 103 will show in the AMPS display if the current is > 35 amps.

If Channel 1 passes the test, the system will repeat the test for channel 2 and current sensor 2. Error code 075 will
show in the AMPS display if the current is < 10 amps. Error code 107 will show in the AMPS display if the current is
> 35 amps.

Place the toggle switch in the ERROR position if the system completes the power-up sequence. If the system shows a
status of -03 the test has passed. The chopper and current sensors are OK.

Troubleshooting low-current error codes 75 and 105

1. Verify that the current sensor (CS1 or CS2) and the cables are not damaged.

2. Exchange CS1 and CS2 to see if the error code switches channels. Replace the faulty sensor if the channel
switches.

3. Measure the resistance between J6.2 and J6.3 on PCB6 with a meter. The value should be increasing as the
capacitor charges. Replace PCB6 if a constant value is seen.

4. Check for loose wires or opens from chopper to PCB6.

5. Check for 220 VAC to 1A, 1B, and 1C on the chopper when the contactor closes.

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Troubleshooting high-current error codes 103 and 107

1. Verify that the current sensor (CS1 or CS2) and the cables are not damaged.

2. Exchange CS1 and CS2 to see if error the code switches channels. Replace the faulty sensor if the channel
switches.

3. Look at the surge capacitor to ensure that it is not short circuited. Replace PCB6 if it is open.

4. Check for short circuits from work to negative. Resistance should be about 100K ohm from negative to work.
Resistance will vary if you have a voltage divider for a height control system.

Test 2 – using the TEST position on the process selection knob.

1. Turn the process selection knob to TEST.

Power supply Fuel-gas console

selection knob selection knob

2. The contactor will close and the open circuit voltage (OCV) for the chopper will show in the AMPS display.

3. The OCV is 311 VDC. The AMPS display will show approximately 280 VDC for OCV based on where the
measurement is taken.

Note: At any time while the system is cutting you can push in on AMPS knob to display the actual voltage
while cutting. The refresh rate is slow but you can compare the value to the height control set point.

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Test 3 – using a meter to measure open circuit voltage (OCV)

DANGER

SHOCK HAZARD: The system will close the contactor and feed voltage to the I/O board (PCB6) with
no input from the technician. Lethal voltages greater than 300 VDC will be present at times during
power-up.

1. It is best to use clip-on test leads to keep your hands and the meter outside the power supply. Connect the meter to
J6.3 (WORK) and J6.2 (NEGATIVE) on the I/O board (PCB 6).

2. Turn ON the system.

3. The automatic chopper test will begin when the purge cycle starts. You will hear the main contactor close and 0 to
5 seconds later the meter should show 311 VDC. This is the OCV for channel 1. The voltage will start to decrease to
0 VDC and will then spike back up to 311 VDC again. The second reading represents the OCV for channel 2.

J6.3 J6.2
(WORK) (NEGATIVE)

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Phase-loss detection test

1. Turn OFF all power to the system and remove the cover from CON1. On non-CE units the contactor is located on
the back of the power supply. On CE units the contactor is located inside the power supply on the left side.

CON1

Non-CE power supply CE power supply

2. Inspect the condition of the 3 contacts for excessive wear. If one or more of the contacts are worn excessively,
replace CON1 and restart the system. If the error remains, perform the following steps.

OK Excessive wear

3. Test the fuses F5, F6, and F7 on the power distribution board (PCB3). If any of the fuses are blown, replace PCB3.
041935

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4. Remove J3.8 from PCB3 and place a jumper wire between pins 1 and 2 on the cable connector.

a. Make a test cut. If the phase-loss error continues, verify wiring between the connectors J3.8 on PCB3 and
J4.301 on the power supply control board (PCB4) by verifying the continuity between

– J3.8 pin1 to J4.301 pin13

– J3.8 pin2 to J4.301 pin14.

b. If the wiring is OK, replace PCB4. If any wiring is damaged, repair or replace damaged wires.

c. If the phase-loss error goes away while the jumper is on J3.8, make another cut and measure the phase-to-
phase voltage across the fuses F5, F6, and F7. The voltage should be 220 VAC +/–15%. If one of the
3 voltage readings is less than 187 VAC, check the contacts to the contactor, and check for loose connections
between the power cord, contactor, power transformer, and the chopper.
041935

041938

Power supply control board (PCB4)

Power distribution board (PCB3)

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MAINTENANCE

DANGER

SHOCK HAZARD: Always use extremecaution when servicing a power supply when it is plugged in and
the covers are removed. Dangerous voltages exist within the power supply which could cause injury
or death.

Torch lead test

1. Turn OFF all power to the system.
2. Locate the pilot arc controller.

3. Install a temporary jumper wire between J4 (work) and J3 (nozzle) on the start circuit PCB1.

J3
TO NOZZLE J3
TO NOZZLE
J4

J4 TO WORK

TO WORK

4. Measure the ohm value between the nozzle and the plate. The reading should be < 3 ohms. A measurement
> 3 ohms indicates a faulty connection between the torch and ignition console, or between the ignition console and
the power supply.

5. Verify that the pilot arc wire on the torch lead is not damaged. If it is damaged, replace the lead. If it is not damaged,
replace the torch head.

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Preventive maintenance

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

DANGER
ELECTRIC SHOCK CAN KILL

Turn off all electrical power before removing the power supply cover and set the
line disconnect switch to OFF. In the U.S., use a ìlock-o ut and tag-out” procedure
until the service or maintenance is complete. In other countries, follow appropriate
local or national safety procedures.

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.

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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.

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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.

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MAINTENANCE

Preventive Maintenance Master Schedule

Daily:
• Verify proper inlet gas pressure.
• Verify proper gas flow settings. – Mandatory at every consumable change.
• Inspect torch and replace consumables as needed.

Weekly:
Week Jan Feb March April May June July Aug Sept Oct Nov Dec
1
2
3
4
5

• Clean power supply with dry, oil free compressed air or vacuum.
• Verify cooling fans are working properly.
• Clean torch threads and current ring.
• Verify proper coolant level.

Bi-Annually:
Year 1st Service 2nd Service

• Replace service parts per the Service Part Replacement Schedule.

Annually:
Year

• Replace service parts per the Service Part Replacement Schedule.

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Preventive Maintenance Protocol Checklist

Customer: Hypertherm system:
Location: System serial #:
Contact: System arc hours:
Date: (if equipped with an hour meter)

Comments P – Performed NP – Not present on system

Power supply Gas flows (cont.)

앮P 앮NP 1. Inspect for particulates and blow out 앮P 앮NP 14. Perform gas leak test
앮P 앮NP 2. Inspect wiring harnesses A. Oxygen pressure drop at ____________
앮P 앮NP 3. Inspect main contactor psi in 10 minutes ( ____________ bar)
B. Air pressure drop at ____________
Coolant system psi in 10 minutes ( ____________ bar)
앮P 앮NP 4. Inspect filter element 앮P 앮NP 15. Inspect for hose restrictions

앮P 앮NP 5. Perform coolant flow test 앮P 앮NP A. Off-valve to torch body

A. Coolant flow checked at _________ 앮P 앮NP B. Gas console to Off-valve

gallons per minute ( _________ l/min) 앮P 앮NP C. Hoses in power track

Torch main body Cable connections

앮P 앮NP 6. Inspect water tube 앮P 앮NP 16. Inspect cables
앮P 앮NP 7. Clean threads on torch front end 앮P 앮NP A. Height control
앮P 앮NP 8. Inspect Vespel torch insulator 앮P 앮NP B. Control cable from off-valve to
앮P 앮NP 9. Inspect torch and consumable o-rings power supply
앮P 앮NP 10. Verify proper fit of retaining or shield cap 앮P 앮NP C. From ignition console and gas
console to power supply
앮P 앮NP 11. Inspect hose fittings
앮P 앮NP 12. Inspect torch-to-torch-lead connections Ignition console
앮P 앮NP 17. Inspect for moisture, dust and
Gas flows particulates
앮P 앮NP 13. Inspect plumbing from gas supply 앮P 앮NP 18. Inspect spark gap subassembly
앮P 앮NP A. Oxygen 앮P 앮NP 19. Inspect torch leads
앮P 앮NP B. Nitrogen
앮P 앮NP C. Air System grounding
앮P 앮NP D. Nitrogen-Hydrogen 앮P 앮NP 20. Inspect for proper system
component grounding
앮P 앮NP E. Argon-Hydrogen
앮P 앮NP 21. Inspect connection from cutting
앮P 앮NP F. Inspect compressed air filter system table to workpiece (+) lead

General comments and recommendations:

Preventive maintenance performed by: Date:

HySpeed HSD130 RHF Instruction Manual 5-45

MAINTENANCE
HSD130 Service Parts Replacement Schedule
Timeline Component Part Number Quantity
Coolant Filter Element 027664 1
6 months or 300 arc hrs.
Coolant Solution 70/30 028872 4
Annual Kit Coolant Filter Element 027664 1
228167 Coolant Solution 70/30 028872 4
1 Year or 600 arc hrs. Main Contactor 003139 1
Torch Main Body 220474 1
Air filter 011093 1
Coolant Filter Element 027664 1
1.5 Years or 900 arc hrs.
Coolant Solution 70/30 028872 4
Coolant Filter Element 027664 1
Coolant Solution 70/30 028872 4
Main Contactor 003139 1
2 Years or 1200 arc hrs. Torch Main Body 220474 1
Air filter 011093 1
Coolant Pump 229126 1
Torch leads System Dependent 1
Coolant Filter Element 027664 1
2.5 Years or 1500 arc hrs.
Coolant Solution 70/30 028872 4
3 Years or 1800 arc hrs. Coolant Filter Element 027664 1
Coolant Solution 70/30 028872 4
Main Contactor 003139 1
Torch Main Body 220474 1
Air filter 011093 1
Off-valve Assembly System Dependent 1
Cooling Fan 127039 System Dependent
Cooling Fan 027079 1
Coolant Filter Element 027664 1
3.5 Years or 2100 arc hrs.
Coolant Solution 70/30 028872 4
Coolant Filter Element 027664 1
Coolant Solution 70/30 028872 4
Main Contactor 003139 1
4 Years or 2400 arc hrs. Torch Main Body 220474 1
Air filter 011093 1
Coolant Pump 229126 1
Torch Leads System Dependent 1
Coolant Pump Motor 128385 1
Coolant Filter Element 027664 1
4.5 Years or 2700 arc hrs.
Coolant Solution 70/30 028872 4
Coolant Filter Element 027664 1
Coolant Solution 70/30 028872 4
Main Contactor 003139 1
Torch Main Body 220474 1
5 Years or 3000 arc hrs. Air filter 011093 1
High Voltage Transformer 129854 1
Power Distribution Board 041935 1
Pilot Arc Lead System Dependent 1
Gas Leads System Dependent 1
Coolant Filter Element 027664 1
5.5 Years or 3300 arc hrs.
Coolant Solution 70/30 028872 4
Coolant Filter Element 027664 1
Coolant Solution 70/30 028872 4
Main Contactor 003139 1
Torch Main Body 220474 1
6.0 Years or 3600 arc hrs. Air filter 011093 1
Coolant Pump 229126 1
Torch Leads System Dependent 1
Off-valve Assembly System Dependent 1
Cooling Fan 6" 127039 System Dependent
Cooling Fan 10" 027079 1
6.5 Years or 3900 arc hrs. Repeat schedule starting at 6 months or 300 arc hrs.

5-46 HySpeed HSD130 RHF Instruction Manual

 Section 6

PARTS LIST

In this section:

Power supply ...............................................................................................................................................................................................6-2

RHF Ignition console ................................................................................................................................................................................6-8
Fuel-gas console ........................................................................................................................................................................................6-9
Off-valve (standard).................................................................................................................................................................................6-10
Off-valve (fuel-gas)...................................................................................................................................................................................6-10
HySpeed torch .........................................................................................................................................................................................6-11
Torch assembly ..............................................................................................................................................................................6-11
Torch leads......................................................................................................................................................................................6-11
Mild steel consumable parts kit ............................................................................................................................................................6-12
Stainless steel / Aluminum consumable parts kit.............................................................................................................................6-13
Recommended spare parts ...................................................................................................................................................................6-14

HySpeed HSD130 RHF Instruction Manual 6-1

Parts List

Power supply

1
2

4 3

Part
Item number Description Qty.
1 078515 HySpeed (HSD) Plasma power supply: 200/208 volt
078516 HySpeed (HSD) Plasma power supply: 220 volt
078517 HySpeed (HSD) Plasma power supply: 240 volt
078518 HySpeed (HSD) Plasma power supply: 380 volt
078519 HySpeed (HSD) Plasma power supply: 400 volt
078520 HySpeed (HSD) Plasma power supply: 440 volt
078521 HySpeed (HSD) Plasma power supply: 480 volt
078522 HySpeed (HSD) Plasma power supply: 600 volt
2 075241 Sheet metal screw 1
3 027967 Handle 2
4 005262 Power switch: green illuminated 1
5 108590 knob 2
108591 Knob cover 2

6-2 HySpeed HSD130 RHF Instruction Manual

 PARTS LIST

Power supply

2
1
3

10

7
9 8

Part
Item number Description Qty.
1 001963 Cover: power supply 1
2 001965 Cover: LHF rear box 1
3 001964 Enclosure: LHF rear box 1
4 001960 Panel: power supply rear 1
5 001966 Enclosure: power supply PCB 1
6 001962 Panel: power supply left side 1
7 001810 Base: power supply 1
8 001957 Panel: power supply front 1
9 001958 Panel: fan cover 1
10 001961 Panel: power supply right side 1

HySpeed HSD130 RHF Instruction Manual 6-3

PARTS LIST

Power supply

3
2

Part
Item number Description Designator Qty.
1 027634 Filter assembly 1
027664 Filter element 1
2 127014 Cap: coolant reservoir 1
3 229107 Chopper assembly CH1 1
4 127039 6" fan :230 CFM, 115 VAC 50-60 HZ 2
5 027079 10" fan :450-550 CFM, 120 VAC 50-60 HZ 1
6 109638* EMI filter (not shown) 1

*400 volt power supplies

6-4 HySpeed HSD130 RHF Instruction Manual

 PARTS LIST

Power supply

1 2

Part
Item number Description Designator Qty.
1 041932 PCB: I/O PCB6 1
2 229106 Pilot arc start circuit assembly PCB2 1
3 109004 Current sensor: hall 100 amp, 4 volt CS1, CS2 2
4 014310 Inductor: 65A 1Mh L1/L2 2
5 014283 Main transformer: 200V, 50-60 Hz T1 1
014284 Main transformer: 220V, 50 Hz T1 1
014282 Main transformer: 240V, 60 Hz T1 1
014303 Main transformer: 380V, 50-60 Hz T1 1
014283 Main transformer: 400V, 50-60 Hz T1 1
014284 Main transformer: 440V, 50 Hz T1 1
014282 Main transformer: 480V, 60 Hz T1 1
014281 Main transformer: 600V, 60 Hz T1 1

HySpeed HSD130 RHF Instruction Manual 6-5

PARTS LIST

Power supply

3
4
A

6
7
8 5
10 9

Part
Item number Description Designator Qty.
1 041935 Power distribution PCB PCB3 1
2 229102 Gas manifold 1
3 109393 Temperature switch 1
4 006046 Solenoid valve CLT SOL 1
5 229119 Flow switch FLS 1
6 027978 Heat exchanger assembly 1
7 127039* 6" fan :230 CFM, 115 VAC 50-60 HZ 1
8 128385 Motor assembly: 1/3HP 240 V 50-60 HZ 1
9 229126 Pump 1
10 008709** Fuse: 20 amp, 500 volt F1, F2 2
008551*** Fuse: 7.5 amp, 600 volt F1, F2 2

*200, 220, 380, 400 and 440, volt power supplies

**200, 220 and 240 volt power supplies
***380, 400, 440, 480 and 600 volt power supplies

6-6 HySpeed HSD130 RHF Instruction Manual

 PARTS LIST

Power supply

4
5

Part
Item number Description Designator Qty.
1 041938 Control PCB PCB4 1
2 011101 Regulator 2
3 006075 Check valve 1
4 129786 Control transformer: 200 V power supply T2 1
229117 Control transformer: 220 V power supply T2 1
129966 Control transformer: 240 V power supply T2 1
229094 Control transformer: 380 V power supply T2 1
129787 Control transformer: 400 V power supply T2 1
229013 Control transformer: 440 V power supply T2 1
129967 Control transformer: 480 V power supply T2 1
129989 Control transformer: 600 V power supply T2 1
5 011093 Filter element 1
011105 O-ring: filter bowl 1

HySpeed HSD130 RHF Instruction Manual 6-7

PARTS LIST

RHF Ignition console

Part
Item Number Description Designator Qty.
1 078172 Ignition Console
2 129831 Coil assembly T2 1
3 041817 HFHV Ignition PCB 1
4 129854 Transformer T1 1

6-8 HySpeed HSD130 RHF Instruction Manual

 PARTS LIST

Fuel-gas console

1
3

4 5
8
7

Part
Item number Description Designator Qty.
1 078201 Fuel-gas console 1
001970 Cover: fuel-gas console 1
001971 Front panel: fuel-gas console 1
2 041805 Power distribution PCB PCB1 1
3 006135 Solenoid valve SV0 and SV7 2
4 006075 Check valve 1
5 006109 Solenoid valve SV1-SV5 5
006112 Replacement solenoid coil 5
6 041971 Control PCB PCB2 1
7 041962 Valve driver PCB PCB3 1
8 108590 knob 2
108591 Knob cover 2

HySpeed HSD130 RHF Instruction Manual 6-9

PARTS LIST

Off-valve (standard)
Part
Item number Description Designator Qty.
229105 Off valve assembly (includes cable) 1
1 006135 Solenoid valve SV2 1
2 006109 Solenoid valve SV3-SV5 3
006112 Replacement solenoid coil 3
3 123870 Off-valve cable 1

1 2 3

Off-valve (fuel-gas)
Part
Item number Description Designator Qty.
229130 Off valve assembly 1
1 006135 Solenoid valve SV2 1
2 006109 Solenoid valve SV3-SV6 4
006112 Replacement solenoid coil 4
3 123870 Off-valve cable 1
4 123912 Off-valve cable (fuel-gas) 1

1 2 3

6-10 HySpeed HSD130 RHF Instruction Manual

 PARTS LIST

HySpeed torch

Torch assembly
1

2 3 4

Part
Item number Description
1 228144 HSD machine torch assembly
2 220521 Water tube
3 220474 Torch main body
4 220473 Torch mounting sleeve

Torch leads

Part
number Description
228050 7.5 m (25 ft)
228051 15 m (50 ft)

HySpeed HSD130 RHF Instruction Manual 6-11

PARTS LIST

Mild steel consumable parts kit – 228146

Note: See Consumable selection or Cut charts for specific applications

Part
number Description Qty.
004630 Electrode gauge assembly 1
044026 O-ring: 1.239" X .070" 2
027055 Lubricant: silicone 1/4-oz tube 2
027102 Tool: electrode removal / replacement 1
220487 Electrode 3
220488 Swirl ring 1
220489 Nozzle 3
220490 Retaining cap 1
220491 Shield 1
220492 Nozzle 3
220525 Nozzle 2
220528 Electrode 2
220529 Swirl ring 1
220530 Nozzle 2
220532 Shield 1
220578 Retaining cap with IHS tab 1
220340 Water tube with o-ring 1

6-12 HySpeed HSD130 RHF Instruction Manual

 PARTS LIST

Stainless steel / Aluminum consumable parts kit – 228156

Note: See Consumable selection or Cut charts for specific applications

Part
number Description Qty.
044026 O-ring: 1.239" X .070" 2
027055 Lubricant: silicone 1/4-oz tube 2
027102 Tool: electrode removal / replacement 1
020415 Electrode 3
220488 Swirl ring 1
220490 Retaining cap: clockwise 1
220491 Shield 1
220492 Nozzle 2
220525 Nozzle 2
220528 Electrode 2
220529 Swirl ring 1
220532 Shield 1
220533 Retaining cap: counter-clockwise 1
220534 Retaining cap: counter-clockwise with IHS tab 1
220535 Nozzle 3
220536 Shield 1
220578 Retaining cap: clockwise with IHS tab 1
220340 Water tube with o-ring 1

HySpeed HSD130 RHF Instruction Manual 6-13

PARTS LIST

Recommended spare parts

Power supply
Part
number Description Designator Qty.
005262 Power switch: green illuminated 1
011093 Filter element 1
229107 Chopper assembly CH1 1
127039 6" fan :230 CFM, 115 VAC 50-60 HZ 1
027079 10" fan :450-550 CFM, 120 VAC 50-60 HZ 1
041932 PCB: I/O PCB6 1
229106 Pilot arc start circuit assembly PCB2 1
109004 Current sensor: hall 100 amp, 4 volt CS1, CS2 1
008709* Fuse: 20 amp, 500 volt F1, F2 2
008551** Fuse: 7.5 amp, 600 volt F1, F2 2
041935 Power distribution PCB PCB3 1
041938 Control PCB PCB4 1
229119 Flow switch FLS 1
006075 Check valve 1
006046 Solenoid valve CLT SOL 1
229126 Coolant pump 1
128385 Kit: motor, 1/3HP 240 V 50-60 HZ 1
*200, 220 and 240 volt power supplies
**380, 400, 440, 480 and 600 volt power supplies

Fuel-gas console (optional)

Part
number Description Designator Qty.
041805 Power distribution PCB PCB1 1
041962 Valve driver PCB PCB3 1
041971 Control PCB PCB2 1
006135 Solenoid valve SV0 and SV7 1
006109 Solenoid valve SV1-SV5 2

Off-valve (standard)
Part
number Description Designator Qty.
006135 Solenoid valve SV2 1
006109 Solenoid valve SV3-SV5 1

Off-valve (fuel-gas)
Part
number Description Designator Qty.
006135 Solenoid valve SV2 1
006109 Solenoid valve SV3-SV5 1

6-14 HySpeed HSD130 RHF Instruction Manual

 PARTS LIST

Ignition console
Part
number Description Designator Qty.
041817 HFHV Ignition PCB PCB9 1
129854 Transformer T1 1

HySpeed HSD130 RHF Instruction Manual 6-15

Parts List

6-16 HySpeed HSD130 RHF Instruction Manual

 Section 7

WIRING DIAGRAMS

Introduction
This section contains the wiring diagrams for the system. When tracing a signal path or referencing with the Parts List or
Troubleshooting sections, please be aware of the following format to assist you in understanding the wiring diagrams'
organization:

• Sheet numbers are located in the lower right-hand corner.

• Page-to-page referencing is done in the following manner:

SHEET
C 4-D3

Source Connection Source Reference Block Destination Sheet # Destination

Coordinates

SHEET
4-D3 C

Source Sheet # Source Coordinates Source Reference Block Destination

Coordinates

Destination and Source Coordinates refer to letters A-D on the Y-axis of each sheet and numbers 1-4 on the X-axis
of each sheet. Lining up the coordinates will bring you to the source or destination blocks (similar to a road map).

Wiring diagram symbols

Wiring diagram symbols and their identification precede the system wiring diagrams in this section.

HySpeed HSD130 RHF Instruction Manual 7-1

 7-2

WIRING DIAGRAMS
Battery Fuse Push Button,
Normally Closed

Cap, polarized Ground Clamp Push Button,

Normally Open

Cap, non-polarized Ground, Chassis Receptacle

Cap, feed-thru Ground, Earth Relay, Coil

Circuit breaker IGBT Relay, Normally Closed

Coax shield Inductor Relay, Normally Open

Current Sensor LED Relay, Solid State, AC

Current sensor Lamp Relay, Solid State, DC

DC supply MOV Relay, Solid State, Dry

HySpeed HSD130 RHF Instruction Manual

Pin Resistor
Diode

Door interlock Socket SCR

Plug Shield
Fan

Feedthru LC PNP Transistor Shunt

Potentiometer Spark Gap

Filter, AC
HySpeed HSD130 RHF Instruction Manual

Switch, Flow Time Delay Open,

NC/On Torch Symbols

Switch, Level, Time Delay Closed,

Normally Closed NO/Off
Electrode
Switch, Pressure,
Normally Closed Transformer

Switch, Pressure,
Normally Open Nozzle
Transformer, Air Core

Switch, 1 Pole, 1 Throw

Transformer Coil
Switch, 1 Pole, 2 Throw Shield

Switch, 1 Pole, 1 Throw,

Center Off Triac

Switch, Temperature, Torch

Normally Closed VAC Source

Switch, Temperature,
Normally Open Valve, Solenoid

Torch, HyDefinition™

Terminal Block

WIRING DIAGRAMS
Voltage Source

Time Delay Closed,

NC/Off Zener Diode

Time Delay Open,

NO/Off
7-3
Wiring Diagrams

7-4 HySpeed HSD130 RHF Instruction Manual

 4 3 2 1

N2 Air F5 H35 O2

Optional Fuel Gas/Valve Cable 228148

Optional
Fuel Gas
D
Console Fuel Gas
D
078201

123925

024820

024819
123844
C
FGS & Leads
078203
C
Negative Lead
Shielded Torch Leads Shielded Torch & Gas Leads 228067
123662
3 Phase HF/PS Cable Optional 228050
C
Power 123670
w/ Ground Nozzle Lead RHF
123666 078172
Cooling Supply Lead
HSD130 PAC Cooling Return Lead Torch
028440 Atm Vent Valve Assy 72"
C
Dry Cutting System Lifter
LHF 229105 (Optional Unit)
Plasma Cutflow
Optional Plasma
C Plasma Preflow Fuel Gas C
Valve Assy Shield
Shield
229130
200-208V/50-60 078194
240V/60 078195
380V/50-60 078196
400V/50-60 078197 Gas/Valve Cable
440V/50-60 078198
480V/60 078199
600V/60 078200 228053
220V/50-60 078204 Torch 220474
Positive Lead
123662 Workpiece

HSD130 PAC
C Dry Cutting System
B RHF B

THESE ITEMS ARE REQUIRED WHEN A RHF IS USED

C WHEN A LHF IS USED SHIELDED TORCH LEADS CONNECT DIRECTLY TO
200-208V/50-60 078515
240V/60 078517 POWER SUPPLY
380V/50-60 078518
400V/50-60 078519 Machine Interface I/O Cable
440V/50-60 078520
480V/60 078521 123022
600V/60 078522
220V/50-60 078516 CNC
Interface
(Customer Supplied)

A A

ELECTRICAL SCHEMATIC: HSD130A POWER SUPPLY

013363
SHEET 1 OF 15 C

4 3 2 1

7-5
 4 3 2 1

SHEET
C (PWM Drv A) C
6-C1
INPUT POWER
FROM FACILITY SHEET
PE D (PWM Drv C) C
D 6-B1 D
L1
L2
L3 SHEET
E 4-C1
SHEET

RED/BLK
A 5-A2
SHEET

SHLD

SHLD

RED
M

RED

RED
BLK

BLK
5-A2 SHEET

RED
G

BLK
3-C3
TB1
1 W J1.2 J1.4
J1 SHEET SHEET
V J

1
3
4
5
6

3
2

2
2 5-B2 H

1
7-A3

WHT
U J2 J4

BLU
RED/BLK 20
19
3

120V RTN
120V HOT
DUTY CYCLE

DUTY CYCLE
4 PE

WHT
GRN
RED

BLK
J4

RED

1
2
+5V

+5V
T1
A4 1A 1A J2
V W CH1 +
A3 0

3
4
2
A2 1B 1B 300Vdc T2
C L1 A4 A1 0 C A CH1-L1 C CH1- C
L2 B4 B4 1C 1C L1 SHEET
L3 C4 CH1-CS2 CH1-CS1 C L
B3 0
C 3-D1
C B CH1-L2 C CH1- L2
B2
CON1 B1 0 CHOPPER SA T3
229101
C4 CH1

2
4
3

1
1C
1B
1A
C30 J3
C2 J1
C10

2
3

1
BLK L2
BLK L3

2
1

BLK
WHT
GRN
RED
T1 J1.1 J5
SHOWN WIRED FOR 480V
SHEET
SEE PAGES 8 AND 9 FOR

SHIELD
RED
BLK
B 4-D4
OTHER CONFIGURATIONS SHEET

WHT
BLU
I 7-A3
SHEET
F1 F2 SHEET K 5-B2
F 5-C4

B B
BLK
BLK

CONTROL
TRANSFORMER

T2
YEL 24VAC
RED 120VAC
ORN 240VAC

SHEET
N 4-D4

A A

ELECTRICAL SCHEMATIC: HSD130A POWER SUPPLY

013363
SHEET 2 OF 15 C

4 3 2 1

7-6
 4 3 2 1

SHEET
X 5-D1

YEL/BLK
YEL
D D

SHEET
J2 L 2-C1

SHEET
(-)NEGATIVE AI 13-D2
R3 R2 R1 C1
10K 10K 10K
350UF
R4 10

J5 PCB6
SHEET
2-D1 G I/O
R5 C2
SURGE INJECTION
041932 100K .22UF
C C
J1
SHEET
J4 AJ 13-C2
PA

.022UF C3 R6 10K

CS1 J3
+

(+)POSITIVE
.22UF C4 R7 10K

3
2
J6.6

RED
BLU
BLK
B SHEET B
R 6-C1
BLK

BLK

J4 J3

PCB2
START CIRCUIT SA J5 J2.5
229106 C RED
120V RTN 1
J2.6 J6
RED 2
1 + 24V RED/BLK
BLK 3
2 ENABLE D5 120V HOT
SHEET SHEET
6-B1 Q P 4-C1
A A

ELECTRICAL SCHEMATIC: HSD130A POWER SUPPLY

013363
SHEET 3 OF 15 C

4 3 2 1

7-7
 4 3 2 1
SHEET
2-C2 B J3.17 J17 F5
BLK 1A
1
2 F6
BLK 1B U5 SHEET
3 PHASE LOSS INPUT J8 J3.8 V 6-C1
4 F7 + BLU CLT SOL
BLK 1C PCB3 1
5 PHASE LOSS OUTPUT – WHT
POWER DISTRIBUTION 2
6
041935 J8
SHEET BLK
D 2-A3 N 1 1 D
J3.4 J4 WHT 2 2
1 F2 J11 J3.11
YEL 24VAC 24VAC BLK
2 F4 240VAC HOT 1
3 2
RED 120VAC 120VAC
4 3
5 4
ORN 240VAC 240VAC WHT
6 5
240VAC RTN 6
SHEET
7-D4 S J3.14 J14 FAN 1 FAN 2
BLU CHP CHP
1 +24V D3 120VAC J1 J3.1
WHT RED/BLK 5
2 +24V COM D12 24VAC 1 6
RED/BLK
3 2 7
BLU D26 Pump motor signal RED/BLK
4 +5V K2 3 8 FAN
WHT D25 +24V RED J12
5 +5V COM 4
RED F3 120VAC HOT RED
6 +15V D23 240VAC 5 2 2
BLK RED FAN 2 CLT
7 +/-15V COM D31 +5V 6 1 1
YEL RED/BLK FAN 1 CLT
8 -15V 7
D32 -15V RED/BLK
K1 8
C D33 +15V RED/BLK C
9 CHOPPER
RED POWER
D35 Remote F1 10
RED SHEET
11
K3 RED E 2-D2
12
13 BLK
RED/BLK SHEET

AC1
AC2
14 P 3-A2

LINE VOLTAGE OUTPUT

BUS VOLTAGE OUTPUT

+

–
15 PUMP MTR
RED FAN 50HZ ONLY START CIRCUIT
16

PUMP MOTOR CNTRL

REMOTE ON/OFF
POWER
17

PUMP MOTOR
TEST CONNECTOR
120VAC RTN 18

240VAC HOT

24VAC HOT

24VAC RTN
240VAC

SIGNAL

SIGNAL

24VAC
+24V

COM
COM

COM

COM
B B

+
–
J16 J12 J13 J2 J7 J9

RED/BLK
1 2 1 2 1 2 1 2 3 4 1 2 1 2 3 4 5 6
J3.16 J3.12 J3.13 J3.2 J3.7

RED
WHT SW1

WHT

WHT

WHT

WHT
BLU

BLU

BLU
BLK
WHT

1A 1
BLU

FLOWSWITCH RED
DC POWER SHEET 2A 2
1 2 Y 7-A2
SHEET
6-C1 AB J7 SHEET

GRN/YEL

RED/BLK
U 7-A2
1 2

RED
SHEET
T 6-D1

C
1X1

1
4
3
2
CABLE: 123925
SHEET
AC

GRN
10-B4
A A

WHT
BLK
ELECTRICAL SCHEMATIC: HSD130A POWER SUPPLY
013363
SHEET 4 OF 15 C
4 3 2 1

7-8
 4 3 2 1

SHEET
6-D1 AK J3.5 J5
BLU
1 + CONTACTOR PCB3
WHT SHEET
SHEET 2 D15 CONTACTOR POWER DISTRIBUTION J18 J3.18 X 3-D1
6-D1 W BLU YEL
3 + HV XFMR 041935 BUS VOLTAGE INPUT 1
WHT
4 D14 HV XFMR 2
YEL/BLK
VBGND 3
SHEET
D 6-D4 AA J3.6 J6 D
CABLE: 123885 1 D11 SV0-SHIELD SELECT
2
3 D10 SV1-PLASMA SELECT
4
5 D9 SV2-SHIELD OFFVALVE SHEET
J21 J3.21 Z 7-A2
6 BLU
7 D8 SV3-PLASMA PREFLOW A +5V 1
VIO
8 COOLANT TEMP 2
VIO
9 D7 SV4-PLASMA CUTFLOW CHOPPER TEMP 3
VIO
10 MAGNETICS TEMP 4
VIO
11 D6 SV5-Atm CHOPPER TEMP 2 5
VIO
12 MAGNETICS TEMP 2 6
WHT
13 SV +5V COM 7
14
15
16 SVGND

COOLANT TEMP SENSOR + (A +5V)

TRANSFORMER TEMP SENSOR +

TRANSFORMER TEMP SENSOR -

INDUCTOR TEMP SENSOR 1B +

INDUCTOR TEMP SENSOR 2B +

INDUCTOR TEMP SENSOR 1A +

INDUCTOR TEMP SENSOR 2A +

SHEET

INDUCTOR TEMP SENSOR 1B -

INDUCTOR TEMP SENSOR 2B -

INDUCTOR TEMP SENSOR 2A -
INDUCTOR TEMP SENSOR 1A -
C 2-B2 F J3.19 J19 C
RED

COOLANT TEMP SENSOR -

1 CHOPPER TEMP SENSOR 1A+ (A +5V)
BLK
2 CHOPPER TEMP SENSOR 1A-
3 CHOPPER TEMP SENSOR 1B+
4 CHOPPER TEMP SENSOR 1B-
5 CHOPPER TEMP SENSOR 2A+

120VAC RTN

CONTACTOR
6 CHOPPER TEMP SENSOR 2A-
7 CHOPPER TEMP SENSOR 2B+

HF XFMR
8 CHOPPER TEMP SENSOR 2B-

SV3
SV4
SV5
SV2

SV1
9
10
11
12

J3 J20
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 11 12 13 14
J3.3 J3.20
RED/BLK
RED/BLK
RED/BLK
RED/BLK

RED/BLK

RED/BLK

RED/BLK
B B

WHT

WHT

WHT
RED
RED
RED

RED
RED

RED

RED
RED

BLU

BLU

BLU
BLK
1 1
2 2
J10

AH

K
J
1 2 SHEET

SHEET

SHEET

SHEET

SHEET
13-D3
GRN/YEL
GRN/YEL
GRN/YEL
GRN/YEL
GRN/YEL
GRN/YEL
RED/BLK

RED/BLK

RED/BLK

RED/BLK

2-D3

2-D3

2-D1

2-B1
SV1
RED

RED

RED

RED

1X3
10
11
12
13
14
1
2
3
4
5
6
7
8
9

Vent
CABLE: 123877 SV5
A A
Plasma
10
11
12
13
14
1
2
3
4
5
6
7
8
9

SV4

Preflow
SV3
OFF-VALVE 229105
ELECTRICAL SCHEMATIC: HSD130A POWER SUPPLY
Shield
SV2 013363
229105
SHEET 5 OF 15 C

4 3 2 1

7-9
 4 3 2 1

PCB4
SHEET POWER SUPPLY CONTROL
5-D4 AA J4.305 J305 041938
CABLE: 123885 1 SOLENOID VALVE 0
2
3 SOLENOID VALVE 1
4 J301 J4.301 SHEET
AK 5-D4
D 5 SOLENOID VALVE 2 BLU D
+24V 1
6 WHT SHEET
CONTACTOR 2 T
7 SOLENOID VALVE 3 BLU 4-A2
3
8 WHT SHEET
PUMP 4 W
9 SOLENOID VALVE 4 BLU 5-D4
5
10 WHT SHEET
HF 6 R
11 SOLENOID VALVE 5 3-B2
7
12 RED
+12V 8
13 BLU FLS
WORK LEAD 9
14 BLK
10 J11.3
15 +5V BLU
FLOWSWITCH 11 1 1
16 D48 COOLANT TEMP D59 HOLD OUTPUT WHT
12 2 2
BLU
D52 CHOPPER TEMP D60 PILOT ARC PHASE LOSS 13
WHT
D53 MAGNETICS TEMP D61 HF 14 SHEET 1 2
OVERPRESSURE 15 V 4-D1 J13
D54 CHOPPER TEMP 2 D62 PUMP 1 2
16

WHT
D55 MAGNETICS TEMP 2 D63 CONTACTOR

BLU
D67 FLOWSWITCH D64 SVA
C SHEET
C
D68 WORK LEAD D44 PLASMA START INPUT AB 4-A3
D69 PHASE LOSS D45 CNC CORNER CURRENT INPUT
D70 OVERPRESSURE D49 HOLD IGNITION INPUT J302 J4.302 SHEET
C 2-D2
D57 MOTION D51 CNC PIERCE COMPLETE INPUT RED
+5V 1
BLK
D58 RD ERROR PWM DRV A 2
3
PWM DRV B 4
SHEET
5 D
RED 2-D2
6
BLK
PWM DRV C 7
SHIELD
8
PWM DRV D 9
SHEET
10 Q
RED 3-A4
+24V 11
BLK
PA-E 12
RED 1
13

CORNER CURRENT +
CORNER CURRENT –
BLK 2 VA
SVA 14
B CNC INTERFACE CLEAR B
MOTION-C
CNC +24V

CNC +24V
PWR GND
MOTION-E

PIERCE +
RDERR-C

PIERCE –
RDERR-E

START +
START –
HOLD +
HOLD –
+24V

J300 J303
1 2 1 20 2 21 3 22 4 23 5 24 6 25 7 26 8 27 9 28 10 29 11 3012 31 13 32 14 33 15 34 16 35 17 36 18 37 19

123887
A A

1X4
1 20 2 21 3 22 4 23 5 24 6 25 7 26 8 27 9 28 10 29 11 3012 31 13 32 14 33 15 34 16 35 17 36 18 37 19
ELECTRICAL SCHEMATIC: HSD130A POWER SUPPLY
013363
SHEET 6 OF 15 C

4 3 2 1

7-10
 4 3 2 1

D D
J105
SHEET PCB4 FLASHCS\
1
4-D4 S POWER SUPPLY CONTROL SPISIMO
J4.100 J100 2
041938
BLU +24V 3
1 +3.3V
WHT PWR GND 4
2 SPICLK
3 5
BLU +5V 0 6
4 SPISOMI
WHT GND 7
5 SD CARD
RED +15V 8
6
BLK COM 9
7 FLASHCD\
YEL -15V 10
8 FLASHWP\
11
12
13
J104 14
TMS COM
1 15
TRST\ TP3 TP1 TP12 TP8 TP13 TP5
2
C TDI C
3
COM J106
4
+5V TP11 TP7 COM
5 1
1/2 1/2 1/2 1/2 1 1
6 2
TDO TX+
7 JTAG 3

CHOPPER SENSOR C
TX-

CHOPPER SENSOR D
CHOPPER SENSOR B
MFG TEST

CHOPPER SENSOR A
8 4

MAGNETICS TEMP 2
LINE VOLTAGE INPUT
BUS VOLTAGE INPUT
TCK RX+

MAGNETICS TEMP
CHOPPER TEMP 2
9 1/3 1/3 5

CHOPPER TEMP
COOLANT TEMP
10 RX-
6
11 TP6 7

CAN +24V
CAN GND

PRESS B
PRESS A
12
EMU0

A +5V
13 CANH
CANL

+15V

+15V

+15V
COM

COM

COM
EMU1 J204 J4.204

COM

COM
-15V
14
+15V
1
1/3 2
COM
3
121 PRESS C 4 P3-GREEN

CABLE: 123878
B B
J101 J103 J200 J201 J202 J203
1 2 1 6 2 7 3 8 4 9 5 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 1 2 3 4
J4.101 J4.200 J4.201 J4.202 J4.203

SHEET
AG
SHIELD

11-B4
WHT

WHT

WHT

WHT

WHT
GRN

GRN
RED

RED

RED

RED

BLU

BLU

BLU
BLK

BLK

BLK

BLK

VIO
VIO
VIO
VIO
VIO
SHIELD
1X2
SHIELD
1 CABLE: 123886 P1-YELLOW P2-BLUE
CABLE: 123844 6 CABLE: 123878 CABLE: 123878
BLK BLK
2
RED RED C C
7
H

U
Y

Z
BLK BLK
I

3
SHEET

SHEET

SHEET

SHEET

SHEET
8
2-C1

5-D1
2-B1

4-A2

4-A2
4
RED RED
A 9 A
5

ELECTRICAL SCHEMATIC: HSD130A POWER SUPPLY

013363
SHEET 7 OF 15 C

4 3 2 1

7-11
 4 3 2 1

INPUT POWER INPUT POWER

FROM FACILITY FROM FACILITY
PE PE
L3 WIRED FOR 480V 60HZ L3 WIRED FOR 240V 60HZ
L2 L2
L1 L1
TB1 TB1
D 1 U 1 U D
2 V 2 V
T1 T1
3 W 3 W
A4 1A A4 1A
4 PE V W 4 PE V W
A3 0 A3 0
A2 1B A2 1B
L1 A4 A1 0 L1 A4 A1 0
L2 B4 B4 1C L2 B4 B4 1C
L3 C4 B30 L3 C4 B30
B2 B2
CON1 014282 CON1 014282
B10 B10
C4 C4
F1 F2 C30 F1 F2 C30
C2 C2
C10 C10
T1 T1

WHT

WHT
GRY

BLK
T2 T2
C C

INPUT POWER
INPUT POWER FROM FACILITY
FROM FACILITY PE
PE L3 WIRED FOR 200-208V 50-60HZ
L3 WIRED FOR 400V 50-60HZ L2
L2 L1
L1
TB1
1 U
2 V
T1
3 W
T1 A4 1A
4 PE V W
A4 1A A30
V W
B A3 0 A2 1B
B
A2 1B L1 A4 A10
TB1 L1 L1 A4 A1 0 L2 B4 B4 1C
1 U
EMI FILTER L2 L2 B4 B4 1C L3 C4 B30
2 V
L3 L3 C4 B30 B2
W CON1
3 B10
PE CON1 B2 014283
4 B10 C4
C4 F1 F2 C30
F1 F2 C30 C2
109638 C10
C2
C10 T1

WHT
BLK
T1
WHT
BLU

T2
T2

A A

ELECTRICAL SCHEMATIC: HSD130A POWER SUPPLY

013363
SHEET 8 OF 15 C

4 3 2 1

7-12
 4 3 2 1

INPUT POWER INPUT POWER

FROM FACILITY FROM FACILITY
PE PE
WIRED FOR 220V 50-60HZ L3 WIRED FOR 380V 50HZ
L3
L2 L2
L1 L1

TB1 TB1
D U 1 U D
1
V 2 V
2 T1 T1
W 3 W
3 A4 1A A1 1A
PE 4 PE V W
4 V W A30 0
A2 1B
L1 A4 L1 A1
A1 0
L2 B4 1C L2 B1 B1 1B
B4
L3 C4 B30 L3 C1 0
B2 CON1
CON1 014284
B10
C4 C1 1C
C30 0
F1 F2 F1 F2
C2 014303
T1
C10
T1

WHT
WHT

BLK
BLK
T2 T2
C C

INPUT POWER INPUT POWER

FROM FACILITY FROM FACILITY
PE PE
L3 WIRED FOR 440V 50-60HZ L3 WIRED FOR 600V 60HZ
L2 L2
L1 L1
TB1 TB1
1 U 1 U
2 V 2 V
T1 T1
3 W 3 W
A4 1A A1 1A
4 PE V W 4 PE V W
A3 0 0
B A2 1B B
L1 A4 A10 L1 A1
L2 B4 B4 1C L2 B1 B1 1B
L3 C4 B30 L3 C1 0
CON1 B2 014284 CON1
B10
C4 C1 1C
C30 0
F1 F2 F1 F2
C2 014281
C10 T1
T1
WHT

WHT
GRY

GRY
T2 T2

A A

ELECTRICAL SCHEMATIC: HSD130A POWER SUPPLY

013363
SHEET 9 OF 15 C

4 3 2 1

7-13
 4 3 2 1

D D
J1.2 J2 F1
RED
1 120V RTN
RED/BLK PCB1
2 120V HOT GAS CONSOLE
SHEET 3 POWER DISTRIBUTION
10-B4 AD 041805

J1.3 J3
BLU GAS CONSOLE
1 +24V DC POWER
WHT +24V COM
2
3 J1 J1.1
BLU RED/BLK
4 +5V 120VAC HOT 1
WHT 5 2 AC VALVE
+5V COM
D4 120VAC DRIVER POWER
SHEET 6 3
11-D4 AF RED
7 D8 +5V 4
C 8 D12 +24V 5 C
SHEET
6 AE 12-D3
7
8
9
10
11
12
13
14
15
16
17
120VAC RTN 18

SHEET
10-D4 AD

B B
RED/BLK
RED

GAS CLS PWR 3X1

1
4
3
2

A A
WHT
GRN

C CABLE: 123925
BLK

ELECTRICAL SCHEMATIC: HSD130A POWER SUPPLY

SHEET
4-A1 AC
013363
SHEET 10 OF 15 C

4 3 2 1
7-14
 4 3 2 1

J7
D J2.1 J1 D
1
BLU
1 +24V 2
WHT PCB2
2 +24V COM GAS CSL CONT TX + 3
3 041971 MFG TEST TX - 4
BLU RS-422 RX +
4 +5V 5
WHT 5 +5V COM RX - 6
SHEET 6 7
10-C4 AF 7
8

8 1
3X2
CABLE: 123844 CABLE: 123692 J2.2 J2
1 1
BLK BLK
2 2 CANL S2
BLK BLK CAN GND
C 3 3 C
4 4
5 CAN A 5
6 6
RED RED CANH
7 7
8 8
RED RED J6
9 9 CAN PWR
TMS 1
SHIELD
TRST\ 2
SHIELD TDI 3
+5V COM 4
+5V 5
6
TDO

PRESS A
SHEET JTAG 7
7-A4 AG
8
+24V

COM
TCK 9
10
11
12
B EMU0 13 B
EMU1 14

J8
1 2 3 4
J2.8

P1-YELLOW
CABLE: 123878
C

A A

ELECTRICAL SCHEMATIC: HSD130A POWER SUPPLY

013363
SHEET 11 OF 15 C

4 3 2 1
7-15
 4 3 2 1

SHEET PCB3
10-C1 AE AC VALVE DRIVER
J3.1 J1 J3 J3.3
041962 RED/BLK
PCB2 1 120V HOT SV3 H35 Inlet 1 7 1 RED/BLK
RED/BLK SV0
D GAS CSL CONT 2 120V RTN SV2 F5 Inlet 2 5 RED Air Inlet D
041971 RED/BLK 2
3 SV1 N2 Purge 3 3 RED/BLK
RED/BLK 3 SV1
SV0 Air Inlet 4 1 RED N2 Purge
RED/BLK 4
SV4 O2 Inlet 5 9
RED RED/BLK
J5 J2.5 J3.4 J4 SV2 RTN 6 6 5 SV2
RED RED F5 Inlet
SV1 RTN 7 4 6
SOLENOID VALVE 0 1 1 D1 SV0 RED RED/BLK
SV0 RTN 8 2 7 SV3
COM 2 2 COM RED/BLK RED
SV5 O2 Inlet2 9 11 8 H35 Inlet
SOLENOID VALVE 1 3 3 D2 SV1 RED
SV3 RTN 10 8
4 4 RED/BLK
120V HOT 11 9 SV4
SOLENOID VALVE 2 5 5 D3 SV2 RED O2 Inlet
120V HOT 12 10
6 6 RED/BLK RED/BLK
SV6 F5-H35 Select 13 11 SV5
SOLENOID VALVE 3 7 7 D4 SV3 RED RED
SV4 RTN 14 10 12 O2 Inlet2
8 8
120V HOT 15
SOLENOID VALVE 4 9 9 D5 SV4
120V HOT 16
10 10 RED/BLK
SV7 N2-Air Select 17 15
SOLENOID VALVE 5 11 11 D6 SV5 RED RED/BLK
SV5 RTN 18 12 15 SV7
12 12 RED RED N2-Air Select
SV6 RTN 19 16
SOLENOID VALVE 6 13 13 D7 SV6 RED
C SV7 RTN 20 16 C
14 14
SV8 Spare 21
SOLENOID VALVE 7 15 26COND RIBBON 15 D8 SV7
SV9 Spare 22
16 16
SV9 RTN 23
SOLENOID VALVE 8 17 17 D9 SV8
SV8 RTN 24
18 18
SOLENOID VALVE 9 19 19 D10 SV9
20 20
21 21
22 22
23 23
24 24
+5V 25 25 +5V
26 26

B B
C C SV6
3X3 CABLE: 228148 F5-H35 Select
CABLE: 123903 BLK RED/BLK
1 1
RED RED
2 2
SHIELD
3 3
CLEAR
4 4

A A

ELECTRICAL SCHEMATIC: HSD130A POWER SUPPLY

013363
SHEET 12 OF 15 C

4 3 2 1

7-16
 4 3 2 1

D D

SHEET
5-A2 AH

RED/BLK
SHEET

RED
AI 3-D1

SHEET
CATHODE AJ 3-C1
109636 FLTR
BLOCK

C TORCH C2 C
0.22uF 1kVDC PILOT ARC
T1 J4 009224
J5
129150 C1
J7 0.22uF 1kVDC
009224 COIL SECONDARY IN
J6
C3
J1 1400pF 20kV
SG1 009975 COIL PRIMARY 2
109344 C4
5kV 1400pF 20kV
009975
C5 T2
SG2 1400pF 20kV
109344 009975 009793
5kV
COIL PRIMARY 1
COIL NOZZLE
J2 J3 SECONDARY CONNECTION
OUT
PCB9
HFHV IGN
B 041817 B

SHEET
5-A2 AH
C
1X5
1
2
3
4
CABLE: 123670
RHF

1
2
3
4

A A

ELECTRICAL SCHEMATIC: HSD130A POWER SUPPLY

013363
SHEET 13 OF 15 C

4 3 2 1

7-17
 4 3 2 1

D D

C
Auxilliary Off Valve SA (shown)
229130
Plasma Fuel Off Valve SA Standard Off Valve SA (not shown)
229105
Atm SV6 not used on 229105
Auxilliary
Customer Supplied Gas Power
Gas Regulators Console Supply F5-H35
SV6

O2 O2 Plasma Offvalve
Inlet Inlet2 SV4
SV5 Plasma Select
SV4 SV1
Oxidizer PR2 Plasma Cutflow
O2
Gas 1
Vent
H35 (Oxygen Supply) SV5
Inlet P1
C SV3 PR1
C
Gas 3
Fuel
H35 Torch
(Fuel Supply)
VA
F5 P1 Atm
Inlet Plasma Preflow Plasma
SV2
Fuel Preflow Offvalve
F5 SV3
P2 Shield
N2-Air
N2 Select SV7
Purge
SV1 CV1 F1
Inert PR1 Shield Offvalve
N2 Shield
SV2
Gas 2
Air
Inlet P3
SV0 (Air Supply)
Oxidizer F1
Air 6'
B B

10'-75'

4'

A A

ELECTRICAL SCHEMATIC: HSD130A POWER SUPPLY

013363
SHEET 14 OF 15 C

4 3 2 1

7-18
 4 3 2 1

D D

HEAT EXCHANGER

CHECK VALVE FLOW SWITCH

RESERVOIR

MANIFOLD

C C

FILTER PUMP
SHUT OFF VALVE
THERMISTOR C

B B

TORCH

A A

ELECTRICAL SCHEMATIC: HSD130A POWER SUPPLY

013363
SHEET 15 OF 15 C

4 3 2 1

7-19
 Appendix A

HYPERTHERM TORCH COOLANT SAFETY DATA

In this section:

Section 1 Chemical Product and Company Identification .........................................................................................................a-2

Section 2 Information on Ingredients ..............................................................................................................................................a-2
Section 3 Hazards Identification.......................................................................................................................................................a-2
Section 4 First Aid Measures ............................................................................................................................................................a-3
Section 5 Fire Fighting Measures ....................................................................................................................................................a-3
Section 6 Accidental Release Measures........................................................................................................................................a-3
Section 7 Handling and Storage ......................................................................................................................................................a-3
Section 8 Exposure Controls / Personal Protection ....................................................................................................................a-4
Section 9 Physical and Chemical Properties ................................................................................................................................a-4
Section 10 Stability and Reactivity.....................................................................................................................................................a-4
Section 11 Toxicological Information .................................................................................................................................................a-4
Section 12 Ecological Information......................................................................................................................................................a-5
Section 13 Disposal Considerations .................................................................................................................................................a-5
Section 14 Transport Information........................................................................................................................................................a-5
Section 15 Regulatory Information .....................................................................................................................................................a-5
Section 16 Other Information ..............................................................................................................................................................a-5

Hypertherm Plasma systems a-1

4/06/07
 MATERIAL SAFETY DATA SHEET
SECTION 1 – CHEMICAL PRODUCT AND COMPANY IDENTIFICATION
PRODUCT NAME Hypertherm Torch Coolant

Latest Revision 09-02-2004

Date EMERGENCY TELEPHONE NUMBERS
ISSUE DATE 03-10-2005

DISTRIBUTOR: Hypertherm, Inc. Transportation: (800) 424-9300 *

Etna Road Product Information: (603) 643-3441
Hanover, N.H. 03755

SECTION 2 – COMPOSITION / INFORMATION ON INGREDIENTS

Hazardous EXPOSURE LIMITS

Component CAS No. % by wt. OSHA PEL ACGIH TLV R Phrases
Benzotriazole 95-14-7 <1,0 N.E. N.E. R22,36/37/38

Propylene Glycol 57-55-6 <50,0 N.E. N.E. R36/37/38

SECTION 3 – HAZARDS IDENTIFICATION

Emergency Causes eye irritation.

Overview May be harmful if swallowed.
May cause skin irritation

Potential Health Effects

Ingestion ................................................ Oral LD 50 (rat) as reported for 100% Benzotriazole is 560 mg./Kg.

Inhalation .............................................. Mists are harmful.

eye contact ............................................ Causes eye irritation.

skin contact .......................................... Can cause skin irritaion.

a-2 Hypertherm Plasma systems

9/2/04
MSDS Product Hypertherm Torch Coolant CODE Page 2 of 4

SECTION 4 – FIRST AID MEASURES

Ingestion Never give anything by mouth to an unconscious person. Give several glasses of water. If
vomiting is not spontaneous, induce vomiting. Keep airway clear. Get medical attention.

Inhalation If affected, remove from exposure. Restore breathing. Keep warm and quiet. Get medical
attention.

Eye Contact Immediately flush eye with cool running water. Remove contact lenses if applicable. Continue
flushing with water for at least 15 minutes. Get immediate medical attention.

Skin Contact Wash with soap and water. If irritation develops or persists, get medical attention.

Note to Physician Treatment based on judgment of the physician in response to reactions of the patient.

SECTION 5 – FIRE FIGHTING MEASURES

Flash Point / Method None to boiling. Flammable Not Established

limits
Extinguishing media Product is an aqueous solution. Use Carbon Dioxide, Dry Chemical, Foam.

special fire fighting Full protective equipment including self-contained breathing apparatus should
be used. During emergency conditions overexposure to decomposition
procedures
products may cause a health hazard. Symptoms may not be immediately
apparent. Get medical attention.
Fire and explosion hazards Water base solution.

SECTION 6 – ACCIDENTAL RELEASE MEASURES

Response to Small spills: Mop up residues and place in a covered waste disposal container.
spills Large spills: Dike or dam spill. Pump to containers or soak up on inert absorbent. Place in
covered waste dissposal container.

SECTION 7 – HANDLING AND STORAGE

Handling Keep container in upright position. Avoid breathing or creating airborne mists. Avoid contact
precautions with skin eyes, and clothing. Avoid inhalation of vapor or mists. DO NOT TAKE
INTERNALLY. Clean up spills immediately.
Storage Store in a cool dry place. Keep from freezing. Keep containers tightly closed when not in use.
precautions

Hypertherm Plasma systems a-3

9/2/04
MSDS Product Hypertherm Torch Coolant CODE Page 3 of 4

SECTION 8 – EXPOSURE CONTROLS / PERSONAL PROTECTION

Hygienic practices Normal procedures for good hygiene.

Engineering controls Good general ventilation. Eye wash station in immediate area of use.
M.E.L./O.E.S Nil. U.K HSE EH:40 Not listed

Personal protective equipment

X Respirator If exposed to mists.
X goggles / face shield Recommended
APRON
X Gloves Recommended; PVC, Neoprene or Nitrile acceptable
Boots

SECTION 9 – PHYSICAL AND CHEMICAL PROPERTIES

Appearance Clear Pink/Red Liquid Boiling point 100EC

ODOR None freezing point Not established
pH of Concentrate 5,5-7,0 vapor pressure Not applicable
Specific gravity 1,0 vapor density Not applicable
solubility in water Complete evaporation rate Not determined

SECTION 10 – STABILITY AND REACTIVITY

Chemical Stability Stable X Unstable
Conditions to avoid None

Incompatibility None Known

Hazardous products of BY FIRE: Carbon Dioxide, Carbon Monoxide Nitrogen Oxides

decomposition
Polymerization Will not occur X May occur
Conditions to avoid Not applicable

SECTION 11 – TOXICOLOGICAL INFORMATION

Carcinogenicity
THIS PRODUCT CONTAINS A KNOWN OR SUSPECTED CARCINOGEN
X THIS PRODUCT DOES NOT CONTAIN ANY KNOWN OR ANTICIPATED CARCINOGENS ACCORDING
TO THE CRITERIA OF THE NTP ANNUAL REPORT ON CARCINOGENS AND OSHA 29 CFR 1910, Z

Other effects
Acute Not determined
Chronic Not determined

a-4 Hypertherm Plasma systems

9/2/04
MSDS Product Hypertherm Torch Coolant CODE Page 4 of 4

SECTION 12 – ECOLOGICAL INFORMATION

Biodegradability Considered biodegradable Not biodegradable

BOD / COD Value Not established

Ecotoxicity As reported for 100% Benzotriazole: Bluegill Sunfish (96 hr. Tlm):28mg/l; Minnow
(96hr. Tlm):28mg/l; Trout (96 hr. LC 50): 39mg/l; Algae(96hr. EC 50): 15.4mg/l;
Daphina magna (48 hr. LC 50): 141.6mg/l

SECTION 13 – DISPOSAL CONSIDERATIONS

Waste disposal method Waste material must be disposed of in accordance with national/local
legislative requirements.

RCRA Classification Non Hazardous

Recycle container Yes X CODE 2 – HDPE No

SECTION 14 – TRANSPORT INFORMATION

DOT Classification Hazardous Not Hazardous X

Description Not applicable

SECTION 15 – REGULATORY INFORMATION

REGULATORY STATUS: Benzotriazole
1. Labeling Information Irritant
2. R Phrases R 36/37/38, 22
3. S Phrases S 24/25, 26
4. EI NECS No. Not listed
5. EC annex 1 Classification Nil.
6. German WGK —

SECTION 16 – OTHER INFORMATION

NFPA Classification
1 BLUE Health hazard
0 RED Flammability
0 YELLOW reactivity
— WHITE Special hazard

Information contained in this MSDS refers only to the specific material designated and does not relate to any process or use
involving other materials. This information is based on data believed to be reliable, and the Product is intended to be used in a
manner that is customary and reasonably foreseeable. Since actual use and handling are beyond our control, no warranty, express or
implied, is made and no liability is assumed by Hypertherm, Inc., in connection with the use of this information.

Hypertherm Plasma systems a-5

9/2/04
 40

30

20

10
Temperature, °C

-10

-20

-30

-40

-50

-60

-70
0 10 20 30 40 50 60
% of Propylene Glycol

Freezing Point of Propylene Glycol Solution

a-6 Hypertherm Plasma systems

9/2/04