Hypertherm HT400 Quick start guide

HT400
Flow Switch Upgrade
Instructions
801220 - Rev. 1

Revision 1 June 2000
HT400
Flow Switch Upgrade
Instructions
IM-122
(P/N 801220)
Hypertherm, Inc.
Hanover, NH USA
http://www.hypertherm.com
email:[email protected]
© Copyright 2000 Hypertherm, Inc.
All Rights Reserved
Hypertherm and HT are trademarks of Hypertherm, Inc.,
and may be registered in the United States and/or other countries

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5/00

Page 1
UPGRADE INSTRUCTIONS
HT400 FLOW SWITCHES
Purpose
The HT400 flow switch upgrade instructions provide the necessary information to allow the
removal of the existing flow switches and replacing them with the Kobold flow switch manifold
subassembly.
Customer Supplied Tools
Drill
3/16" (0.187)/4.762mm drill bit
Straight blade screwdriver
7/16" (11.11 mm) open-end wrench
9/16" (14.29 mm) open-end wrench
11/16" (17.46 mm) open-end wrench
1/4" (6.35 mm) hex wrench
Flow Switch Assembly Upgrade Kit (# 028484)
Part No. Description Qty.
029546 Kobold flow switch manifold SA 1
005139 Flow switch, 0.25 GPM
005140 Flow switch, 1.20 GPM
004456 Flow switch manifold
074005 Cable Tie 5
075040 M/S:10-32 X 5/8 3
075186 Lock washer:#10 Intl-T 3
Procedure
Remove Existing Flow Switches
To remove the existing flow switches, refer to the following procedure and the figures called out
from the HT400 Plasma Arc Cutting System Instruction Manual IM-54 (P/N 800540).
1. Shut the power supply down at the front panel and turn off power at the disconnect box.
Disconnect the gas supply to the power supply. Disconnect the water supply to the power
supply.
2. Remove the top cover and the left side cover to access the flow switches on the center wall.
Refer to Figure 38.
3. Remove the tyraps from around the flow switches leads which are connected to the terminal
strip located on the opposite side of the wall..
4. Disconnect the 4 switch leads (red) from the terminal strip. These leads are marked 4 (2), 5,
and 6.
5. Disconnect the input water hose (left side) from flow switch 2FLS (005053). Refer to Figure
38. Disconnect the other end of the hose from the water manifold (top hose) at rear panel.
Refer to Figure 39. Remove the plug from the upgrade kit and screw into the manifold where
the hose was disconnected. Refer to Figure 1 in this upgrade instruction.

Page 2
UPGRADE INSTRUCTIONS
HT400 FLOW SWITCHES
6. Disconnect and tag the remaining hoses at the flow switches.
7. Remove the bolts, washers, and screws to remove the flow switches.
Install Upgrade Kit
To install the Kobold flow switch manifold subassembly upgrade kit, refer to Figures 1 and 2 and
perform the following procedure.
1. Refer to Figure 1
2. On the side of the wall with the terminal strip, position the template as indicated. Remove
any leads from the terminal strip that interfere with drilling.
3. Drill the three holes.
4. Align the three holes in the manifold (004456) with the holes on the wall.
5. On the terminal strip side of the wall, install the screws with lockwashers through the wall and
into the manifold subassembly.
6. Route the flow switch leads to the terminal strip on the opposite side of the wall. Connect
leads to the terminal strip as shown.
7. Replace ties to secure flow switch leads.
8. To connect the water hose assemblies, proceed as follows:
•Connect the WATER IN hose assembly (024102) from the manifold at the rear panel
to the manifold (004456).
•Connect the WATER OUT - ELECTRODE hose assembly (024138) to flow switch
1FLS (005140/1.20 GPM).
•Connect the hose assembly (024139) from the WATER flow meter on the front panel to
flow switch 2FLS (005139/.25 GPM).
6-00

Page 3
UPGRADE INSTRUCTIONS
HT400 FLOW SWITCHES
Approximate hole locations
Drill 3/16" (0.187)/4.762mm
Dia. Holes (3 places)
Figure 1 Mounting Holes

Page 4
UPGRADE INSTRUCTIONS
HT400 FLOW SWITCHES
Figure 2 HT400 Upgrade Kit Installation
Flow Switch Subassembly
Plug
015561 Manifold
WATER OUT-
ELECTRODE Hose
024138
WATER Flow Meter Hose
024139
Flow Switch Leads (4)
Rear Panel Terminal Strip
Flow Switch 1FLS
(1.20 gpm) 005140
Flow Switch 2FLS
(0.25 gpm) 005139
Manifold
004456
WATER IN Hose
024102
Mounting Screw
Holes
Attach manifold to
center wall with mount-
ing screws and washers
from far side of wall.
6-00
(3)