Hypertherm HD4070 Rev.8 - Manual (Page 196)

MAINTENANCE
HD4070 Instruction Manual 5-49
7
Preventive Maintenance
Introduction
Deteriorating consumable parts life is frequently one of the first symptoms to indicate that something is wrong with
a plasma system. Reduced parts life dramatically increases operating costs for two reasons: first, and perhaps
most obvious, shorter consumable life means that the end user will have to use more consumables to cut the same
amount of metal. The second, and even more important factor, is that shorter consumable life means that the end
user must shut down his cutting operation to change consumables more often. In an average cutting operation,
labor and overhead can account for over 80% of the cost of cutting, so improved productivity, in the form of less
downtime, can reduce cutting costs dramatically.
Proper maintenance often eliminates the problems that lead to shortened consumables life. Since the basic
premise behind the purchase of a Hypertherm plasma system is reduced cutting costs and increased productivity,
maintaining a system in proper operating condition is a key to ensuring customer satisfaction.
The Preventive Maintenance Protocol is intended to be simple to follow. After you have performed it a few times,
you should expect to take approximately 3 hours to complete it for each individual plasma system involved.
Hypertherm wants to meet or exceed our customers’ expectations. We hope that this booklet will help you meet or
exceed those customers’ expectations.
Preventive maintenance protocol
The following protocol covers the basic elements of a Hypertherm mechanized plasma system. These basic
elements apply broadly to all our mechanized systems, although certain specific components, such as the high-
frequency console or the coolant system, are not present in all mechanized systems. The protocol may therefore
vary slightly from a MAX100 to an HT2000, for example, and as we move through the protocol, we have tried to
note where certain steps would not be necessary for certain systems.
It is important to have available for reference a copy of the appropriate manual for the Hypertherm system to be
maintained.
If inspection suggests that a component is worn and might require replacement, and you would like confirmation of
your recommendation, please contact Hypertherm's Technical Service department.
The power supply
When performing preventive maintenance in any plasma system power supply, it is critical to turn off power to the
power supply at the source. Extreme electrical hazard is present in the power supply and at the torch. Please
consult the manual for a complete list of safety precautions.
1. With power to the power supply off, remove all side panels and inspect for accumulated dust. Using
compressed air, blow out the inside of the power supply to remove dust and particulates.
2. Inspect wiring harnesses and connections for any wear or damage. Check for loose connections and look for
any discoloration that might indicate overheating. If this condition is observed, 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 should be recommended.
4. If the plasma system has an air filter in the front panel of the power supply, inspect the air filter and recommend
replacement if dirty.
5. Inspect the pilot arc relay (CR1) for excessive pitting on the contacts, characterized by a roughened, black
surface. Recommend replacement if necessary.