Chapters
Table of Contents
Troubleshooting
Related Manuals for Hypertherm HyPerformance HPR400XD
Summary of Contents for Hypertherm HyPerformance HPR400XD
- Page 1 HyPerformance Plasma ® HPR400 ® Manual gas Instruction manual 806170 – Revision 0...
- Page 2 Register your new Hypertherm system Register your product online at www.hypertherm.com/registration for easier technical and warranty support. You can also receive updates on new Hypertherm products and a free gift as a token of our appreciation. For your records Serial number:...
- Page 3 0 – December, 2008 Hypertherm, Inc. Hanover, NH USA www.hypertherm.com © Copyright 2008 Hypertherm, Inc. All Rights Reserved Hypertherm, HyPerformance, HyDefinition, LongLife and CommandTHC are trademarks of Hypertherm, Inc. and may be registered in the United States and/or other countries.
- Page 4 Hypertherm, Inc. Hypertherm (Shanghai) Trading Co., Ltd. Etna Road, P.O. Box 5010 Unit A, 5th Floor, Careri Building Hanover, NH 03755 USA 432 West Huai Hai Road 603-643-3441 Tel (Main Office) Shanghai, 200052 603-643-5352 Fax (All Departments) PR China info@hypertherm.com (Main Office Email)
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Page 5: Electromagnetic Compatibility (Emc
Immunity of other equipment in the en viron ment. User shall ensure that other equip ment being used in the Hypertherm’s CE-marked equipment is built in compliance environment is com pat i ble. This may require ad di tion al with standard EN60974-10. - Page 6 Screening and shielding Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of in ter fer ence. Screening of the entire plasma cutting installation may be con sid ered for special applications. Hypertherm 4-08...
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Page 7: Warranty
Hypertherm repair facility, all costs, insurance and freight needed to comply with the European EMC Directive are pre paid. Hypertherm shall not be liable for any repairs, incorporated within versions of the power supply with a replacement, or adjustments of Products covered by this CE Marking. - Page 8 A higher-level system with hazardous moving parts may constitute industrial machinery or robotic In no event shall Hypertherm be liable to any person equipment, in which case the OEM or end-use customer or entity for any incidental, consequential, indirect,...
- Page 9 National and Local codes governing plumbing and electrical installation shall take precedent over any instructions contained in this manual. In no event shall Hypertherm be liable for injury to persons or property damage by reason of any code violation or poor work practices.
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Page 10: Table Of Contents
TABLE OF CONTENTS Electromagnetic Compatibility (EMC) ...........................i Warranty......................................ii Section 1 SAFETY ................................1-1 Recognize safety information...................................1-2 Follow safety instructions ..................................1-2 Cutting can cause fire or explosion................................1-2 Electric shock can kill ....................................1-3 Static electricity can damage circuit boards............................1-3 Toxic fumes can cause injury or death..............................1-4 A plasma arc can cause injury and burns .............................1-5 Arc rays can burn eyes and skin ................................1-5 Grounding safety......................................1-6... - Page 11 TABLE OF CONTENTS Electricidad estática puede dañar tablillas de circuito........................1b-3 Humos tóxicos pueden causar lesiones o muerte ...........................1b-4 El arco de plasma puede causar lesiones y quemaduras ......................1b-5 Los rayos del arco pueden producir quemaduras en los ojos y en la piel .................1b-5 Seguridad de toma a tierra ..................................1b-6 Seguridad de los equipos de gas comprimido ..........................1b-6 Los cilindros de gas pueden explotar si están dañados.........................1b-6...
- Page 12 TABLE OF CONTENTS Steps to take .....................................3-7 Grounding diagram ..................................3-10 Placement of the power supply..............................3-11 Lifting the power supply................................3-12 Install the ignition console ................................3-14 Placement of the cooler ................................3-16 Install the metering console ................................3-17 Placement of the selection console ............................3-18 Power supply to ignition console leads ..............................3-20 Pilot arc lead....................................3-20 Negative lead....................................3-20...
- Page 13 TABLE OF CONTENTS Water purity requirements..................................3-47 Fill the power supply with coolant................................3-48 Gas requirements ....................................3-49 Setting the supply regulators ..............................3-49 Gas regulators......................................3-50 Supply gas plumbing ....................................3-51 Connect the supply gases ................................3-52 Supply gas hoses ....................................3-53 Section 4 OPERATION................................4-1 Daily start-up........................................4-2 Check torch.......................................4-2 Controls and indicators.....................................4-3 General.......................................4-3...
- Page 14 Coolant flow troubleshooting chart ..............................5-34 Coolant flow tests....................................5-35 Before testing....................................5-35 Bypass valve verification................................5-36 Using the Hypertherm flow meter (128933) ..........................5-36 Manual pump operation ................................5-37 Test 1 – return line..................................5-38 Test 2 – supply line at ignition console ..........................5-38 Test 3 – change the torch.................................5-39 Test 4 –...
- Page 15 TABLE OF CONTENTS Gas leak tests......................................5-42 Power supply control board PCB3 ..............................5-43 Power supply power distribution board PCB2..........................5-44 Start circuit PCB1 ....................................5-45 Operation ......................................5-45 Start circuit functional schematic ..............................5-45 Start circuit troubleshooting ...............................5-45 Pilot arc current levels ..................................5-47 Pump motor drive board PCB7................................5-48 Cooler power distribution board PCB1 .............................5-49 Cooler sensor board PCB2 ..................................5-50 Gas console control board PCB2 ...............................5-51...
- Page 16 TABLE OF CONTENTS 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 Freezing point of Propylene Glycol solution............................a-6 Appendix B FUNCTIONAL DESCRIPTION OF SOFTWARE ..................b-1 HPR400XD Manual Gas Instruction Manual xiii...
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Page 17: Safety
Gas cylinders can explode if damaged ..............................1-6 Noise can damage hearing..................................1-7 Pacemaker and hearing aid operation ..............................1-7 A plasma arc can damage frozen pipes ..............................1-7 Additional safety information..................................1-8 Symbols and markings ....................................1-8 Warning labels ......................................1-9 Dry dust collection information ................................1-11 Hypertherm 11/08... -
Page 18: Recognize Safety Information
WARNING CAUTION The symbols shown in this section are used to identify Hypertherm uses American National Standards Institute potential hazards. When you see a safety symbol in this guidelines for safety signal words and symbols. A signal manual or on your machine, understand the potential for... -
Page 19: Electric Shock Can Kill
This switch allows grounding conductor first. the operator to turn off the power supply quickly in • Each Hypertherm plasma system is designed to be an emergency situation. used only with specific Hypertherm torches. Do not •... -
Page 20: Toxic Fumes Can Cause Injury Or Death
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. Hypertherm 11/08... -
Page 21: A Plasma Arc Can Cause Injury And Burns
Less than 40 A 41 to 60 A 61 to 80 A 81 to 125 A 126 to 150 A 151 to 175 A 176 to 250 A 251 to 300 A 301 to 400 A 401 to 800 A Hypertherm 11/08... -
Page 22: Grounding Safety
• 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. Hypertherm 11/08... -
Page 23: Noise Can Damage Hearing
• Do not wrap or drape the torch lead or work cable around your body. Frozen pipes may be damaged or can burst if you attempt to thaw them with a plasma torch. • Keep as far away from the power supply as possible. Hypertherm 11/08... -
Page 24: Additional Safety Information
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. -
Page 25: Warning Labels
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). Hypertherm 11/08... - Page 26 6. Become trained. Only qualified personnel should operate this equipment. Use torches specified in the manual. Keep non-qualified personnel and children away. Do not remove, destroy, or cover this label. Replace if it is missing, damaged, or worn. 1-10 Hypertherm 11/08...
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Page 27: Dry Dust Collection Information
Note 2 – Users of Hypertherm manuals should consult and comply with all applicable federal, state, and local laws and regulations. Hypertherm does not, by the publication of any Hypertherm manual, intend to urge action that is not in compliance with all applicable regulations and standards, and this manual may never be construed as doing so. -
Page 28: Section 1A
Les bouteilles de gaz comprimé peuvent exploser en cas de dommages .................1a-6 Le bruit peut provoquer des problèmes auditifs ..........................1a-7 Pacemakers et prothèses auditives ..............................1a-7 Un arc plasma peut endommager les tuyaux gelés..........................1a-7 Symboles et marquage ...................................1a-8 Étiquettes de sécurité .....................................1a-9 Information sur le dépoussiérage...............................1a-11 Hypertherm 1a-1 11/08... -
Page 29: Dentifier Les Consignes De Sécurité
IDENTIFIER LES CONSIGNES DANGER AVERTISSEMENT ATTENTION DE SÉCURITÉ Hypertherm adopte les lignes directrices de l’American Les symboles indiqués dans cette section sont utilisés pour National Standards Institute relativement aux termes, aux identifier les risques éventuels. Si vous trouvez un symbole de symboles et à... -
Page 30: Les Chocs Électriques Peuvent Être Fatals
Prévention des chocs électriques de courant. Tous les systèmes plasma Hypertherm utilisent des hautes • Ne jamais contourner ou court-circuiter les verrouillages tensions pour le coupage (souvent de 200 à 400 V). -
Page 31: Les Vapeurs Toxiques Peuvent Provoquer Des Blessures Ou La Mort
Le niveau de qualité de l’air dans tout lieu de travail dépend du site afin d’assurer une qualité de l’air sûre. 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. 1a-4 Hypertherm 11/08... -
Page 32: L'arc Plasma Peut Provoquer Des Blessures Ou Des Brûlures
Moins de 40 A 41 à 60 A 61 à 80 A 81 à 125 A 126 à 150 A 151 à 175 A 176 à 250 A 251 à 300 A 301 à 400 A 401 à 800 A Hypertherm 1a-5 11/08... -
Page 33: Mise À La Masse Et À La Terre
• 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. 1a-6 Hypertherm 11/08... -
Page 34: Le Bruit Peut Provoquer Des Problèmes Auditifs
• Ne pas s’enrouler le faisceau de la torche ou le câble de retour autour du corps. Les tuyaux gelés peuvent être endommagés ou éclater si l'on essaie de les dégeler avec une torche plasma. • Se tenir le plus loin possible de la source de courant. Hypertherm 1a-7 11/08... -
Page 35: Symboles Et Marquage
La marque CE signifie la déclaration de conformité du fabricant aux directives et normes européennes applicables. Seules les versions des produits Hypertherm portant la marque CE placée sur la plaque signalétique ou à proximité ont été mises à l’essai de conformité à la directive européenne sur la basse tension et la compatibilité électromagnétique européenne (CEM). -
Page 36: Étiquettes De Sécurité
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). Hypertherm 1a-9 11/08... -
Page 37: Étiquettes De Sécurité
Le personnel non qualifié et les enfants doivent se tenir à l’écart. Ne pas enlever, détruire ni couvrir cette étiquette. La remplacer si elle est absente, endommagée ou usée (PN 110584 Rev C). 1a-10 Hypertherm 11/08... -
Page 38: Information Sur Le Dépoussiérage
à tous les systèmes de dépoussiérage. Note 2 – Les utilisateurs des manuels d’Hypertherm doivent consulter tous les règlements et lois fédéraux et locaux applicables et s’y conformer. Hypertherm n’a pas l’intention, en publiant un manuel d’Hypertherm, de demander des mesures qui ne sont pas conformes aux règlements et normes applicables et ce manuel ne peut jamais être interprété... -
Page 39: Seguridad
Los cilindros de gas pueden explotar si están dañados.........................1b-6 El ruido puede deteriorar la audición..............................1b-7 Operación de marcapasos y de audífonos ............................1b-7 Un arco plasma puede dañar tubos congelados..........................1b-7 Símbolos y marcas ....................................1b-8 Etiquetas de advertencia..................................1b-9 Información sobre la colección de polvo seco ..........................1b-11 Hypertherm 1b-1 11/08... -
Page 40: Reconocimiento De Información De Seguridad
RECONOCIMIENTO DE PELIGRO ADVERTENCIA PRECAUCIÓN INFORMACIÓN DE SEGURIDAD Hypertherm usa las directivas del Instituto Americano de Los símbolos que se muestran en esta sección se utilizan para Normas Nacionales (American National Standards Institute) identificar los posibles peligros. Cuando vea un símbolo de para las palabras y símbolos que señalan seguridad. -
Page 41: El Choque Eléctrico Puede Provocar La Muerte
Prevención ante el electrochoque Deje la pieza en su lugar o sobre la mesa de trabajo con Todos los sistemas por plasma de Hypertherm usan alto el cable de trabajo conectado en todo momento. voltaje en el proceso de corte (son comunes los voltajes CD •... -
Page 42: Humos Tóxicos Pueden Causar Lesiones O Muerte
• Diseño de mesa (mojada, seca, bajo agua). • La composición del material, el acabado de la superficie, y la composición de los recubrimientos. • Volumen que se quita del material. 1b-4 Hypertherm 11/08... -
Page 43: El Arco De Plasma Puede Causar Lesiones Y Quemaduras
Menos de 40 A 41 a 60 A 61 a 80 A 81 a 125 A 126 a 150 A 151 a 175 A 176 a 250 A 251 a 300 A 301 a 400 A 401 a 800 A Hypertherm 1b-5 11/08... -
Page 44: Seguridad De Toma A Tierra
• No exponga nunca los cilindros a calor excesivo, chispas, escorias o llamas. • No emplee nunca martillos, llaves u otro tipo de herramientas para abrir de golpe la válvula del cilindro. 1b-6 Hypertherm 11/08... -
Page 45: El Ruido Puede Deteriorar La Audición
Se puede hacer daño a los tubos congelados, o se los puede • Manténgase tan lejos de la fuente de energía como reventar, si uno trata de descongelarlos con una antorcha por sea posible. plasma. Hypertherm 1b-7 11/08... -
Page 46: Símbolos Y Marcas
SÍMBOLOS Y MARCAS Su producto de Hypertherm puede tener una o más de las marcas que siguen en, o cerca de la placa de datos. Debido a diferencias y conflictos en reglamentos nacionales, no todas las marcas se aplican a toda versión del producto. -
Page 47: Etiquetas De Advertencia
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). Hypertherm 1b-9 11/08... - Page 48 Proteja su cuerpo completamente. Antes de trabajar en la máquina o de proceder a cortar, capacítese y lea las instrucciones completamente. No retire las etiquetas de advertencia ni las cubra con pintura. 1b-10 Hypertherm 11/08...
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Page 49: Información Sobre La Colección De Polvo Seco
Kst, índice de deflagración” y otros términos. Nota 1 – La interpretación de Hypertherm de estos nuevos requisitos es que, a no ser que se haya completado una evaluación específica del sitio para determinar que todo polvo generado no es combustible, la edición del 2007 de la NFPA 68 requiere el uso de respiraderos de explosión diseñados para el peor caso del valor Kst (vea anexo F) que... -
Page 50: Specifications
Section 2 SPECIFICATIONS In this section: System description ....................................2-3 General.......................................2-3 Power supply ....................................2-3 Cooler .........................................2-3 Ignition console ....................................2-3 Gas console ......................................2-3 Off-valve ......................................2-3 Torch ........................................2-3 Specifications......................................2-4 System gas requirements ................................2-4 Power supply ....................................2-5 Cooler – 078531 .....................................2-6 Ignition console – 078172 ................................2-7 Gas console –... - Page 51 SPECIFICATIONS HPR400XD Manual Gas Instruction Manual...
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Page 52: System Description
SPECIFICATIONS System description General HyPerformance plasma systems are designed to cut a wide range of thicknesses of mild steel, stainless steel and aluminum. Power supply The power supply is a 400-amp, 200-VDC constant-current supply. It contains the circuitry to ignite a torch, a heat exchanger and pump to cool the torch. -
Page 53: Specifications
SPECIFICATIONS Specifications System gas requirements Gas quality and pressure requirements Gas type Quality Pressure +/- 10% Flow rate oxygen* 99.5% pure 827 kPa / 8.3 bar 4250 l/h 150 scfh Clean, dry, oil-free 115 psi nitrogen* 99.99% pure 827 kPa / 8.3 bar 11610 l/h 410 scfh Clean, dry, oil-free 115 psi... -
Page 54: Power Supply
SPECIFICATIONS Power supply General Maximum OCV (U 360 VDC Maximum output current (I 400 Amps Output voltage (U 50 – 200 VDC Duty cycle rating (X) 100% @ 80 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) 0.98 @ 400 ADC output Cooling... -
Page 55: Cooler - 078531
SPECIFICATIONS Cooler – 078531 • The cooling system can contain up to 34.5 liters (9 gallons) of coolant. • Maximum cable length from the cooler to the power supply is 4.57 meters (15 ft). • Maximum hose length from the cooler to the ignition console is 76.2 meters (250 ft). •... -
Page 56: Ignition Console - 078172
SPECIFICATIONS Ignition console – 078172 • The ignition console can be mounted remotely on the cutting table’s bridge. See Installation section for details. • Maximum cable length from the ignition console to the torch lifter station is 15 m (50 ft). Allow room to remove the top for servicing. - Page 57 SPECIFICATIONS Mounted on table Horizontal mounting Vertical mounting HPR400XD Manual Gas Instruction Manual...
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Page 58: Gas Console - 078532
SPECIFICATIONS Gas console – 078532 • Maximum cable length from the power supply to the gas console is 75 m (250 ft). • Maximum cable length from the gas console to the off-valve assembly is 20 m (65 ft). • Mount the gas console on top of the power supply or near the CNC on the cutting table. Allow room to open the top for servicing. -
Page 59: Off-Valve - 078534
SPECIFICATIONS Off-valve – 078534 • Maximum cable length from the off-valve to the torch lifter station is 1.8 m (6 ft). • Mount the off-valve assembly to the torch carriage on larger tables. On smaller tables it can be mounted to a bracket just above the bridge. -
Page 60: Torch - 228354
SPECIFICATIONS Torch – 228354 • The outside diameter of the torch mounting sleeve is 50.8 mm (2.0 in). • The maximum bend radius for the torch leads is 152.4 mm (6.0 in). 1.8 m 49 mm 194 mm 1.91" 7.62" 104 mm 4.10"... -
Page 61: Installation
Section 3 INSTALLATION In this section: Upon receipt........................................3-3 Claims ...........................................3-3 Installation requirements...................................3-3 Noise levels........................................3-3 Placement of system components .................................3-3 Torque specifications ..................................3-3 Installation requirements...................................3-4 System components..................................3-5 Cables and hoses ....................................3-5 Supply gas hoses ....................................3-5 Customer supplied power cable ..............................3-5 Recommended grounding and shielding practices..........................3-6 Introduction........................................3-6 Types of grounding ..................................3-6 Steps to take .....................................3-7... - Page 62 INSTALLATION Cable and gas hose assembly ..............................3-28 Gas console to off-valve cable ..............................3-28 Off-valve cable ....................................3-28 Power supply to CNC interface cable ..............................3-30 Optional multi-system CNC interface cable ...........................3-30 Notes to CNC interface cable run list ............................3-31 Examples of output circuits.................................3-32 Examples of input circuits................................3-33 Remote on/off switch....................................3-34 Torch lead assembly....................................3-35...
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Page 63: Upon Receipt
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. -
Page 64: Installation Requirements
INSTALLATION Installation requirements 10 11 HPR400XD Manual Gas Instruction Manual... -
Page 65: System Components
INSTALLATION System components Power supply Ignition console Cooler Off-valve Gas console Torch Cables and hoses Pilot arc lead Negative lead Ignition console power cable Coolant hoses Cooler control cable Cooler power cable Gas console control cable Gas console power cable Gas console to off-valve hose and lead assembly CNC interface cable Optional CNC interface cable for systems with multiple power supplies... -
Page 66: Recommended Grounding And Shielding Practices
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. -
Page 67: Steps To Take
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. - Page 68 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).
- Page 69 INSTALLATION Cable to ground Component bus on the 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.
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Page 70: Grounding Diagram
INSTALLATION Grounding diagram (some systems will not include all the components shown) 3-10 HPR400XD Manual Gas Instruction Manual... -
Page 71: Placement Of The Power Supply
INSTALLATION Placement of the power supply DANGER ELECTRICAL SHOCK CAN KILL Remove all electrical connections to power supply before moving or positioning. Transporting unit can cause personal injury and equipment damage. • Place the power supply in an area that is free of excessive moisture, has proper ventilation, and is relatively clean. -
Page 72: Lifting The Power Supply
A strap kit (228336) for lifting the HPR400 is available from Hypertherm. The strap kit should only be used to lift the HPR400 as outlined herein. Before using the strap kit, the customer understands and assumes exclusive responsibility for supplying personnel trained and qualified to operate forklifts, cranes, hoists and other lifting devices to lift or move the power supply. - Page 73 OSHA regulations, you should consult appropriate legal counsel. Hypertherm slings are not for sale In Europe, where locally purchased slings are required to have “CE Marking. ” In the UK the interpretation of the European Directives translated into the following UK Statutory Instruments (SI): SI 2306 PUWER, The Provision and Use of Work Equipment Regulations and SI 2307 LOLER, Lifting Operations Lifting Equipment Regulations.
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Page 74: Install The Ignition Console
INSTALLATION Install the ignition console • Mount the ignition console in a vertical or horizontal position. • Allow room to remove the top for servicing. 32 mm 184 mm 1.25" 7.25" 216 mm 8.50" 32 mm 1.25" 248 mm 9.75" 279 mm 7 mm 11.00"... - Page 75 INSTALLATION Horizontal RHF mounting Vertical RHF mounting HPR400XD Manual Gas Instruction Manual 3-15...
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Page 76: Placement Of The Cooler
INSTALLATION Placement of the cooler • Place the cooler in an area that is free of excessive moisture, has proper ventilation, and is relatively clean. Allow 1 m (3 ft) of space on all sides of the power supply for ventilation and service. •... - Page 77 INSTALLATION Install the off-valve • Mount the off-valve assembly near the torch lifter station. The maximum length of the gas hoses between the off-valve assembly and the torch is 1.8 m (6 ft). Off-valve grounding A - A 157 mm 6.18"...
- Page 78 INSTALLATION Placement of the gas console • Mount the gas console near the cutting table. Allow room to remove the top and right side cover for servicing. Preferred orientation is shown in the figure below. The maximum length of cables between the power supply and gas console is 75 m (250 ft).
- Page 79 INSTALLATION This page is blank intentionally HPR400XD Manual Gas Instruction Manual 3-19...
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Page 80: Power Supply To Ignition Console Leads
INSTALLATION Power supply to ignition console leads Pilot arc lead I/O board Ignition console Part no. Length Part no. Length 123820 3 m (10 ft) 123735 25 m (82 ft) 123821 4.5 m (15 ft) 123668 35 m (115 ft) 123666 7.5 m (25 ft) 123669... - Page 81 INSTALLATION Pilot arc lead Negative lead Work lead Pilot arc lead Negative lead HPR400XD Manual Gas Instruction Manual 3-21...
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Page 82: Ignition Console Power Cable
INSTALLATION Ignition console power cable Female end to ignition console Part no. Length Part no. Length Cable signal list – power supply to ignition console 123419 3 m (10 ft) 123425 22.5 m (75 ft) Power supply end Ignition console end 123834 4.5 m (15 ft) 123736... -
Page 83: Coolant Hoses
INSTALLATION Coolant hoses Green Part no. Length 128499 1.5 m (5 ft) 028652 3 m (10 ft) 028440 4.5 m (15 ft) Green HPR400XD Manual Gas Instruction Manual 3-23... -
Page 84: Power Supply To Cooler Cables
INSTALLATION Power supply to cooler cables Control cable Female end to cooler Part no. Length 123844 1.5 m (5 ft) 123784 3 m (10 ft) 123839 4.5 m (15 ft) Cable signal list – 9-pin DSUB connectors Power supply end Cooler end Pin # Wire color Description... - Page 85 INSTALLATION See note below Note: The inductor on the pump motor drive board makes a noise during operation that has been described as a “hum”, “sing”, and “click”. This is normal and can be disregarded. HPR400XD Manual Gas Instruction Manual 3-25...
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Page 86: Power Supply To Gas Console Cables
INSTALLATION Power supply to gas console cables Control cable Part no. Length Part no. Length 123784 3 m (10 ft) 123841 20 m (65 ft) 123839 4.5 m (15 ft) 123737 25 m (82 ft) 123963 6 m (20 ft) 123738 35 m (115 ft) 123691... - Page 87 INSTALLATION HPR400XD Manual Gas Instruction Manual 3-27...
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Page 88: Gas Console To Off-Valve Connections
INSTALLATION Gas console to off-valve connections Cable and gas hose assembly Part no. Length 128989 3 m (10 ft) 128990 4.5 m (15 ft) 228339 6 m (20 ft) 128782 7.5 m (25 ft) 128967 10 m (35 ft) 128786 15 m (50 ft) 128991 20 m (65 ft) - Page 89 INSTALLATION HPR400XD Manual Gas Instruction Manual 3-29...
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Page 90: Power Supply To Cnc Interface Cable
INSTALLATION Power supply to CNC interface cable Part no. Length Part no. Length Part no. Length 123210 3 m (10 ft) 123216 13.5 m (45 ft) 123742 35 m (115 ft) 123211 4.5 m (15 ft) 123023 15 m (50 ft) 123219 37.5 m (125 ft) 123212... -
Page 91: Notes To Cnc Interface Cable Run List
INSTALLATION Notes to CNC interface cable run list Note 1. Inputs are optically isolated. They require 24 VDC at 7.3 mA, or dry-contact closure. 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 Note 2. -
Page 92: Examples Of Output Circuits
INSTALLATION Examples of output circuits 1. Logic interface, active-high 5VDC-24VDC CNC/PLC – (optional) High-impedance (≤10mA) 2. Logic interface, active-low 5VDC-24VDC (optional) CNC/PLC – High-impedance (≤10mA) 3. Relay interface CNC +24V +24VDC CNC +24V °t Install a Jumper J304 108056 CNC/PLC –... -
Page 93: Examples Of Input Circuits
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 (See note 4 on page 3-31) Output from CNC/PLC External relay (AC or DC) -
Page 94: Remote On/Off Switch
INSTALLATION Remote ON/OFF switch (provided by customer) WARNING ELECTRIC SHOCK CAN KILL Disconnect electrical power before performing any maintenance. See the Safety section in this manual for more safety precautions. 1. Locate terminal block 2 (TB2) in the power supply. TB2 location 2. -
Page 95: Torch Lead Assembly
INSTALLATION Torch lead assembly Part no. Length 128986 2 m (6 ft) 128935 3 m (10 ft) 128934 4.5 m (15 ft) 128784 7.5 m (25 ft) 128987 10 m (35 ft) 128785 15 m (50 ft) 128988 20 m (65 ft) Blue Black Plasma-gas vent... -
Page 96: Work Lead
INSTALLATION Work lead Power supply Work table Part no. Length Part no. Length 123418 3 m (10 ft) 123996 25 m (82 ft) 023382 4.5 m (15 ft) 123997 35 m (115 ft) 023078 7.5 m (25 ft) 023081 45 m (150 ft) 123994 10 m (35 ft) 023188... -
Page 97: Torch Connections
INSTALLATION Torch connections Connect the torch to the torch lead assembly 1. Uncoil the first 2 meters (6.5 ft) of the leads on a flat surface. 2. Hold the torch assembly in place with the spanner wrench (104269) and remove the mounting sleeve from the torch assembly. - Page 98 INSTALLATION 5. Connect the pilot arc lead (yellow). Insert the connector into the torch receptacle and turn it by hand until it is tight. 6. Connect the optional ohmic contact wire. 6a. Route the ohmic contact wire through the opening in the braided cover and the torch sleeve. Sleeve Braided cover 6b.
- Page 99 INSTALLATION 7. Connect the plasma-gas vent hose (white). Note: The connectors in steps 7–10 are push-to-connect fittings. To make a connection, push the hose fitting into the appropriate connector until it stops, 13 mm (0.5 in.). connector-collar 8. Connect the coolant supply hose (green). To disconnect a fitting, push the connector-collar toward the torch, and pull the hose...
- Page 100 INSTALLATION 11. Slide the torch sleeve over the connections and screw it onto the torch assembly. 12. Slide the braided cover up to the torch sleeve. Make sure that the plasma, shield and vent hoses are routed through the hole in the braided cover. Loosen the hose clamp on the braided cover, slide the braided cover and clamp over the sleeve and tighten the clamp.
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Page 101: Connect The Torch To The Quick-Disconnect
INSTALLATION Connect the torch to the quick-disconnect Apply a thin film of silicone lubricant to each o-ring Torch body Torch quick-disconnect receptacle 220706 220705 Installation note Align the torch body to the torch leads and secure by screwing completely together. Be certain that there is no space between the torch body and the o-ring on the torch leads. -
Page 102: Torch Mounting And Alignment
INSTALLATION Torch mounting and alignment Mounting the torch Installation Install the torch (with torch leads attached) in the torch mounting bracket. Upper torch sleeve Position the torch below mounting bracket, so that the bracket is around the lower portion of the torch sleeve Torch mounting touching the torch quick-disconnect. -
Page 103: Power Requirements
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. Note: The main feed protection device (Circuit Breaker or Fuse) must be sized to handle all branch-feed loads for both inrush and steady-state current. -
Page 104: Connect The Power
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 local safety procedures. -
Page 105: Torch Coolant Requirements
Premixed coolant for standard operating temperatures Use Hypertherm premixed coolant (028872) when operating in a temperature range of -12° C to 40° C (10° F to 104° F). Refer to the custom coolant mix recommendations, if temperatures during operation are ever outside of this range. - Page 106 Use the chart below to determine what percentage of propylene glycol to use in the mixture. Mix 100% glycol (028873) with the premixed Hypertherm coolant (028872) to increase the percentage of glycol. The 100% glycol solution can also be mixed with purified water (see next page for water purity requirements) to achieve the required protection from freezing.
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Page 107: Water Purity Requirements
INSTALLATION Custom Coolant mix for hot operating temperatures (above 38° C / 100° F) Treated water (with no propylene glycol) can only be used as coolant when operating temperatures are never below 0° C (32° F). For operations in very warm temperatures treated water will provide the best cooling properties. Treated water refers to a mixture of purified water, that meets the specifications below, and 1 part benzotriazole (BZT) to 300 parts of water. - Page 108 INSTALLATION Fill the cooler with coolant The cooling system’s capacity is 15.5 to 34.5 liters (4 to 9 gallons) of coolant, depending on the length of the torch leads and coolant hoses. Caution: Using the wrong coolant can cause damage to the system. Refer to torch coolant requirements in this section for more information.
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Page 109: Gas Requirements
INSTALLATION Gas requirements The customer must furnish all gases and gas-supply regulators for the system. Use a high-quality, 2-stage pressure regulator located within 3 m (10 ft) of the gas console. See gas regulators in this section for recommendations. See the Specification section for gas and flow specifications. -
Page 110: Gas Regulators
Use a high-quality, 2-stage, gas regulator 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 or local codes. -
Page 111: Supply Gas Plumbing
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. -
Page 112: Connect The Supply Gases
INSTALLATION Connect the supply gases Connect the supply gases to the gas console. Torch leads must be purged between gas changes. Fitting Size 5/8 – 18, RH, internal (Inert Gas) “B” 9/16 – 18, JIC, #6 H35 / H5 9/16 – 18 LH, (Fuel Gas) “B”... -
Page 113: Supply Gas Hoses
INSTALLATION Supply gas hoses Oxygen hose Part no. Length Part no. Length 024607 3 m (10 ft) 024738 25 m (82 ft) 024204 4.5 m (15 ft) 024450 35 m (115 ft) 024205 7.5 m (25 ft) 024159 45 m (150 ft) 024760 10 m (35 ft) 024333... -
Page 114: Operation
Section 4 OPERATION In this section: Daily start-up........................................4-2 Check torch.......................................4-2 Controls and indicators.....................................4-3 General.......................................4-3 Main power switch...................................4-3 Power indicators ....................................4-3 Manual gas console operation..............................4-4 Consumable selection....................................4-5 Standard cutting ....................................4-5 Bevel cuting.......................................4-5 Marking.......................................4-5 Consumables for mirror-image cutting............................4-5 SilverPlus electrodes..................................4-5 Mild steel......................................4-6 Stainless steel....................................4-7 Aluminum ......................................4-8 Mild steel bevel cutting...................................4-9... -
Page 115: Daily Start-Up
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 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. -
Page 116: Controls And Indicators
OPERATION Controls and indicators General The main power switch for the HyPerformance plasma system is located on the gas console. There is no power switch on the power supply. The gas console controls all systems functions. Error codes are shown in the LED display over the current select knob. -
Page 117: Manual Gas Console Operation
OPERATION Manual gas console operation The term “position number” refers to the numbers on the front panel of the gas console. 3-digit display* Position number 1. Turn ON the power. 2. Follow instructions below using the settings provided in the Cut charts. Position # Instruction Select PLASMA GAS. -
Page 118: Consumable Selection
OPERATION Consumable selection Standard cutting (0°) Most of the consumables on the following pages are designed for standard (straight) cutting, when the torch is perpendicular to the workpiece. Bevel cutting (0° to 45°) Consumables for 130 amp and 260 amp bevel cutting are specifically designed for bevel cutting. 400 amp consumables can be used for standard cutting and bevel cutting, but bevel-specific, 400 amp cut charts are provided for convenience. -
Page 119: Mild Steel
OPERATION Mild steel Nozzle Water Shield retaining cap Nozzle Electrode tube Shield cap Swirl ring 220194 220754 220193 220180 220192 220555 220754 220554 220553 220552 220747 220189 220756 220188 220179 220187 220340 130A 220183 220756 220182 220179 220181* 200A 220761 220757 220354 220353... -
Page 120: Stainless Steel
OPERATION Stainless steel Water Nozzle Shield Nozzle Electrode tube Shield cap retaining cap Swirl ring 220202 220755 220201 220180 220308 220338 220755 220337 220179 220339 220747 130A 220340 220198 220755 (H35) 220197 220179 220307 220756 (N 200A 220762 220758 220343 220342 220307 260A... -
Page 121: Aluminum
OPERATION Aluminum Nozzle Water Shield cap Shield retaining cap Nozzle Electrode Swirl ring tube 220202 220756 220201 220180 220308 220747 130A 220307 (H35) 220198 220197 220179 220755 (H35) 220181 (Air) 220756 (Air) 220340 200A 220762 220759 220346 220342 220307 260A 220763 220758 220406... -
Page 122: Mild Steel Bevel Cutting
OPERATION Mild steel bevel cutting Nozzle Swirl Water Shield cap Shield Nozzle Electrode ring retaining cap tube 130A 220700 220742 220740 220646 220179 220649 260A 220741 220740 220542 220436 220541 220637 220571 400A 220636 220635 220632 220631 220629 Stainless steel bevel cutting Nozzle Swirl Water... -
Page 123: Install And Inspect Consumables
OPERATION Install and Inspect consumables WARNING The system is designed to go into an idle mode if the retaining cap is removed. However, DO NOT CHANGE CONSUMABLE PARTS WHILE IN THE IDLE MODE. Always disconnect power to the power supply before inspecting or changing torch consumable parts. Use gloves when removing consumables. - Page 124 OPERATION Inspect consumables Inspect Look for Action Erosion, missing material Replace shield cap Shield cap Cracks Replace shield cap Burned surface Replace shield cap General: Erosion or missing material Replace shield Molten material attached Replace shield Blocked gas holes Replace shield Shield Center hole: Must be round...
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Page 125: Torch Maintenance
Maintenance kit Even with proper care, the o-rings at the rear of the torch will need to be replaced periodically. Hypertherm provides a kit (128879) of replacement parts. Kits should be kept in stock and be used as part of your routine maintenance schedule. -
Page 126: Torch Connections
OPERATION Torch connections Shield gas Plasma vent Pilot arc Ohmic contact pin Plasma gas Coolant return Coolant in Replace torch water tube WARNING The system is designed to go into an idle mode if the retaining cap is removed. However, DO NOT REMOVE CONSUMABLE PARTS WHILE IN THE IDLE MODE. -
Page 127: Common Cutting Faults
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. •... -
Page 128: How To Optimize Cut Quality
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. -
Page 129: Additional Factors Of Cut Quality
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. -
Page 130: Additional Improvements
Hypertherm calculates mild steel pierce parameters with certified A-36 plate. • If the system has difficulty piercing a specific material or thickness, increasing the shield preflow pressure can help in some cases. -
Page 131: Cut Charts
OPERATION Cut charts The following Cut charts show the consumable parts, cutting speeds 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. -
Page 132: Bevel Cutting Definitions
OPERATION Bevel cutting definitions Bevel angle The angle between the center line of the torch and a line that is perpendicular to the workpiece. If the torch is perpendicular to the workpiece, the bevel angle is zero. The maximum bevel angle is 45°. Nominal thickness The vertical thickness of the workpiece. -
Page 133: Estimated Kerf-Width Compensation
OPERATION Estimated kerf-width compensation The widths in the chart below are for reference. Differences between installations and material composition may cause actual results to vary from those shown in the table. Metric Thickness (mm) Mild steel 400A O / Air 3.40 3.50 3.68 3.76 4.06 4.88 5.94 6.60 7.80 9.10... - Page 134 OPERATION Estimated kerf-width compensation – continued English Thickness (in.) .060 .135 1-1/4 1-1/2 1-3/4 2-1/4 2-1/2 Mild steel 400A O / Air .135 .140 .145 .148 .164 .183 .215 .237 .250 .275 .340 260A O / Air .100 .110 .135 .150 .170 .175...
- Page 135 OPERATION Mild steel Flow rates – lpm/scfh Plasma / O Shield Preflow 0 / 0 46 / 97 30 A Cutting Cutflow 22 / 46 0 / 0 Note: Air must be connected to use this process. It is used as the preflow gas 220747 220194 220754...
- Page 136 OPERATION Mild steel Flow rates – lpm/scfh Plasma / O Shield Preflow 0 / 0 43 / 90 50 A Cutting Cutflow 25 / 52 0 / 0 Note: Air must be connected to use this process. It is used as the preflow gas 220747 220555 220754...
- Page 137 OPERATION Mild steel Flow rates – lpm/scfh Plasma / Air Shield Preflow 0 / 0 76 / 161 80 A Cutting Cutflow 23 / 48 41 / 87 220747 220189 220756 220188 220179 220187 220340 Metric Select Material Torch-to-Work Cutting Initial Pierce Pierce Delay Gases...
- Page 138 OPERATION Mild steel Flow rates – lpm/scfh Plasma / Air Shield Preflow 0 / 0 102 / 215 130 A Cutting Cutflow 33 / 70 45 / 96 220747 220183 220756 220182 220179 220181 220340 Metric Select Material Torch-to-Work Cutting Initial Pierce Pierce Delay Gases...
- Page 139 OPERATION Mild steel bevel cutting Flow rates – lpm/scfh Plasma / Air Shield Preflow 0 / 0 64 / 135 130 A Cutflow 33 / 70 45 / 96 220637 220742 220740 220646 220179 220649 220700 Note: Bevel angle range is 0° to 45° Metric Equivalent Select...
- Page 140 OPERATION Mild steel Flow rates – lpm/scfh Plasma / Air Shield Preflow 0 / 0 128 / 270 200 A Cutting Cutflow 39 / 82 48 / 101 220637 220761 220757 220354 220353 220352 220340 Metric Select Torch-to-Work Cutting Initial Pierce Pierce Delay Material Gases...
- Page 141 OPERATION Mild steel Flow rates – lpm/scfh Plasma / Air Shield Preflow 0 / 0 130 / 275 260 A Cutting Cutflow 42 / 88 104 / 220 220637 220764 220760 220439 220436 220435 220340 Metric Select Torch-to-Work Cutting Initial Pierce Pierce Delay Material Gases...
- Page 142 OPERATION Mild steel bevel cutting Flow rates – lpm/scfh Plasma / Air Shield Preflow 0 / 0 130 / 275 260 A Cutflow 42 / 88 104 / 220 220637 220741 220740 220542 220436 220541 220571 Metric Equivalent Minimum Select Torch-to-Work Cutting Initial Pierce...
- Page 143 OPERATION Mild steel Flow rates – lpm/scfh Plasma / Air Shield Preflow 0 / 0 190 / 400 400 A Cutflow 66 / 140 137 / 290 220637 220636 220635 220632 220631 220629 220571 Metric Select Material Torch-to-Work Cutting Initial Pierce Pierce Delay Gases Preflow...
- Page 144 OPERATION Mild steel bevel cutting Flow rates – lpm/scfh Plasma / Air Shield Preflow 0 / 0 190 / 400 400 A Cutflow 66 / 140 137 / 290 220637 220636 220635 220632 220631 220629 220571 Note: Bevel angle range is 0° to 45° Metric Equivalent Minimum...
- Page 145 OPERATION Stainless steel Flow rates – lpm/scfh Plasma / N Shield Preflow 24 / 51 45 A Cutting Cutflow 75 / 159 220747 220202 220755 220201 220180 220308 220340 Metric Select Material Torch-to-Work Cutting Initial Pierce Pierce Delay Gases Preflow Cutflow Thickness Voltage...
- Page 146 OPERATION Stainless steel Flow rates – lpm/scfh F5 Plasma / N Shield Preflow 0 / 0 43 / 91 45 A Cutting Cutflow 8 / 17 65 / 138 220747 220202 220755 220201 220180 220308 220340 Metric Select Torch-to-Work Cutting Initial Pierce Pierce Delay Material...
- Page 147 OPERATION Stainless steel Flow rates – lpm/scfh F5 Plasma / N Shield Preflow 0 / 0 67 / 142 80 A Cutting Cutflow 31 / 65 55 / 116 220747 220338 220755 220337 220179 220339 220340 Metric Select Material Torch-to-Work Cutting Initial Pierce Pierce Delay...
- Page 148 OPERATION Stainless steel Flow rates – lpm/scfh Plasma / N Shield Preflow 97 / 205 130 A Cutting Cutflow 79 / 168 220179 220747 220198 220756 220197 220307 220340 Metric Select Material Torch-to-Work Cutting Initial Pierce Pierce Delay Gases Preflow Cutflow Thickness Voltage...
- Page 149 OPERATION Stainless steel Flow rates – lpm/scfh H35 Plasma / N Shield Preflow 0 / 0 76 / 160 130 A Cutting Cutflow 26 / 54 68 / 144 220179 220747 220198 220755 220197 220307 220340 Metric Select Material Torch-to-Work Cutting Initial Pierce Pierce Delay...
- Page 150 OPERATION Stainless steel bevel cutting Flow rates – lpm/scfh Plasma / N Shield Preflow 97 / 205 130 A Cutflow 125 / 260 220637 220738 220739 220656 220179 220606 220571 Note: Bevel angle range is 0° to 45° Metric Equivalent Select Minimum Torch-to-Work...
- Page 151 OPERATION Stainless steel bevel cutting Flow rates – lpm/scfh H35 Plasma / N Shield Preflow 0 / 0 90 / 190 130 A Cutflow 26 / 54 114 / 240 220637 220738 220739 220656 220179 220606 220571 Note: Bevel angle range is 0° to 45° Metric Equivalent Select...
- Page 152 OPERATION Stainless steel Flow rates – lpm/scfh Plasma / N Shield Preflow 111 / 235 200 A Cutting Cutflow 137 / 290 220637 220762 220758 220343 220342 220307 220340 Metric Select Material Torch-to-Work Cutting Initial Pierce Pierce Delay Gases Preflow Cutflow Thickness Voltage...
- Page 153 OPERATION Stainless steel Flow rates – lpm/scfh H35 Plasma / N Shield Preflow 0 / 0 116 / 245 200 A Cutting Cutflow 30 / 63 104 / 220 220637 220762 220758 220343 220342 220307 220340 Metric Select Material Torch-to-Work Cutting Initial Pierce Pierce Delay...
- Page 154 OPERATION Stainless steel Flow rates – lpm/scfh Plasma / Air Shield Preflow 127 / 270 0 / 0 260 A Cutting Cutflow 54 / 114 116 / 245 220637 220763 220758 220406 220405 220307 220340 Metric Select Material Torch-to-Work Cutting Initial Pierce Pierce Delay Gases...
- Page 155 OPERATION Stainless steel Flow rates – lpm/scfh H35 Plasma / N Shield Preflow 0 / 0 127 / 270 260 A Cutting Cutflow 40 / 84 122 / 260 220637 220763 220758 220406 220405 220307 220340 Metric Select Material Torch-to-Work Cutting Initial Pierce Pierce Delay...
- Page 156 OPERATION Stainless steel bevel cutting Flow rates – lpm/scfh H35 Plasma / N Shield Preflow 0 / 0 127 / 270 260 A Cutflow 40 / 84 122 / 260 220637 220738 220739 220607 220405 220606 220571 Notes: Bevel angle range is 0° to 45°. Metric Equivalent Minimum...
- Page 157 OPERATION Stainless steel bevel cutting Flow rates – lpm/scfh Plasma / Air Shield Preflow 127 / 270 0 / 0 260 A Cutflow 54 / 114 116 / 245 220637 220738 220739 220607 220405 220606 220571 Note: Bevel angle range is 0° to 45° Metric Equivalent Minimum...
- Page 158 OPERATION Stainless steel Flow rates – lpm/scfh Plasma / Air Shield Preflow 190 / 400 0 / 0 400 A Cutflow 86 / 182 102 / 217 220637 220707 220712 220708 220405 220709 220571 Metric Select Torch-to-Work Cutting Initial Pierce Pierce Delay Material Gases...
- Page 159 OPERATION Stainless steel Flow rates – lpm/scfh H35 Plasma / N Shield Preflow 0 / 0 189 / 400 400 A Cutflow 86 / 182 123 / 260 220637 220707 220712 220708 220405 220709 220571 Metric Select Material Torch-to-Work Cutting Initial Pierce Pierce Delay Gases...
- Page 160 OPERATION Stainless steel bevel cutting Flow rates – lpm/scfh Plasma / Air Shield Preflow 190 / 400 0 / 0 400 A Cutflow 86 / 182 102 / 217 220637 220707 220712 220708 220405 220709 220571 Note: Bevel angle range is 0° to 45° Metric Equivalent Select...
- Page 161 OPERATION Stainless steel bevel cutting Flow rates – lpm/scfh H35 Plasma / N Shield Preflow 0 / 0 189 / 400 400 A Cutflow 86 / 182 123 / 260 220637 220707 220712 220708 220405 220709 220571 Note: Bevel angle range is 0° to 45° Metric Equivalent Select...
- Page 162 OPERATION Aluminum Flow rates – lpm/scfh Air Plasma / Air Shield Preflow 45 / 95 45 A Cutting Cutflow 78 / 165 220747 220202 220756 220201 220180 220308 220340 Metric Select Material Torch-to-Work Cutting Initial Pierce Pierce Delay Gases Preflow Cutflow Thickness Voltage...
- Page 163 OPERATION Aluminum Flow rates – lpm/scfh Air Plasma / Air Shield Preflow 73 / 154 130 A Cutting Cutflow 78 / 165 220747 220198 220756 220197 220179 220181 220340 Metric Select Material Torch-to-Work Cutting Initial Pierce Pierce Delay Gases Preflow Cutflow Thickness Voltage...
- Page 164 OPERATION Aluminum Flow rates – lpm/scfh H35 Plasma / N Shield Preflow 0 / 0 76 / 160 130 A Cutting Cutflow 26 / 54 68 / 144 220747 220198 220755 220197 220179 220307 220340 Metric Select Material Torch-to-Work Cutting Initial Pierce Pierce Delay Gases...
- Page 165 OPERATION Aluminum Flow rates – lpm/scfh Plasma / N Shield Preflow 113 / 240 200 A Cutting Cutflow 135 / 287 220637 220762 220759 220346 220342 220307 220340 Metric Select Material Torch-to-Work Cutting Initial Pierce Pierce Delay Gases Preflow Cutflow Thickness Voltage Distance...
- Page 166 OPERATION Aluminum Flow rates – lpm/scfh H35 Plasma / N Shield Preflow 0 / 0 113 / 240 200 A Cutting Cutflow 34 / 72 90 / 190 220637 220762 220759 220346 220342 220307 220340 Metric Select Material Torch-to-Work Cutting Initial Pierce Pierce Delay Gases...
- Page 167 OPERATION Aluminum Flow rates – lpm/scfh Plasma / Air Shield Preflow 125 / 265 0 / 0 260 A Cutting Cutflow 50 / 105 113 / 240 220637 220763 220758 220406 220405 220307 220340 Metric Select Material Torch-to-Work Cutting Initial Pierce Pierce Delay Gases Preflow...
- Page 168 OPERATION Aluminum Flow rates – lpm/scfh H35 Plasma / N Shield Preflow 0 / 0 127 / 270 260 A Cutting Cutflow 33 / 70 118 / 250 220637 220763 220758 220406 220405 220307 220340 Metric Select Material Torch-to-Work Cutting Initial Pierce Pierce Delay Gases...
- Page 169 OPERATION Aluminum Flow rates – lpm/scfh Plasma / Air Shield Preflow 190 / 400 0 / 0 400 A Cutflow 68 / 144 103 / 219 220637 220707 220712 220708 220405 220709 220571 Metric Select Material Torch-to-Work Cutting Initial Pierce Pierce Delay Gases Preflow...
- Page 170 OPERATION Aluminum Flow rates – lpm/scfh H35 Plasma / N Shield Preflow 0 / 0 189 / 400 400 A Cutflow 86 / 182 123 / 260 220637 220707 220712 220708 220405 220709 220571 Metric Select Material Torch-to-Work Cutting Initial Pierce Pierce Delay Gases Preflow...
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Page 171: Maintenance
Section 5 MAINTENANCE In this section: 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 Gas system valve usage ...................................5-6 Marking process....................................5-8 Error codes ........................................5-9 Error code troubleshooting – 1 of 16 ............................5-10 Error code troubleshooting –... - Page 172 MAINTENANCE Using the Hypertherm flow meter (128933) ..........................5-36 Manual pump operation ................................5-37 Test 1 – return line..................................5-38 Test 2 – supply line at ignition console ..........................5-38 Test 3 – change the torch.................................5-39 Test 4 – supply line to the torch receptacle .........................5-39 Test 5 –...
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Page 173: Introduction
MAINTENANCE Introduction Hypertherm assumes that the service personnel performing the troubleshooting testing 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. -
Page 174: System Description
MAINTENANCE System description Control and signal cables Power cable: Provides 120 VAC to the gas console. CAN Bus signal cable: Provides process and status signals between the power supply and the gas console. Power cable: Provides 120 VAC to the ignition console. -
Page 175: Sequence Of Operation
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. -
Page 176: Gas System Purge Cycle
MAINTENANCE Gas system purge cycle When the system is turned on, or the operator changes from one process to another, the system automatically goes through a purge process. The purge process has 2 stages; a preflow purge and a cutflow purge. The preflow purge gas is turned on for 8 seconds with an auto gas console, or 12 seconds with a manual gas console. - Page 177 MAINTENANCE Gas console AC valve driver board – LEDs process Valve Gas console Off-valve location number Preflow SV11 SV17 SV18 Cutflow SV11 SV14 SV16 SV19 F5/N Gas console AC valve driver board – LEDs process Valve Gas console Off-valve location number Preflow SV12...
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Page 178: Marking Process
MAINTENANCE Marking process The valves that are active when marking are represented by the tables below. The active valves in the gas console will differ, depending on what process was used before marking. Valves active when changing from a non-fuel gas process Gas console AC valve driver board –... -
Page 179: Error Codes
MAINTENANCE Error codes HyPerformance plasma system error codes Error codes are displayed in the 3-digit LED display on the gas console. HPR400XD Manual Gas Instruction Manual... -
Page 180: Error Code Troubleshooting - 1 Of 16
MAINTENANCE Error code troubleshooting – 1 of 16 Error code Name Description Corrective action number No error System is ready to run. None needed. The flow switch is tested when the pump restarts after a pump timeout Flow switch (30 minutes without a start Wait 10 seconds for the flow rate to stabilize. -
Page 181: Error Code Troubleshooting - 2 Of 16
MAINTENANCE Error code troubleshooting – 2 of 16 Error code Name Description Corrective action number No current detected on 1. Verify proper pierce height. No arc work lead 500 2. Verify proper preflow and cut-flow settings. transfer milli-seconds after pilot arc 3. -
Page 182: Error Code Troubleshooting - 3 Of 16
MAINTENANCE Error code troubleshooting – 3 of 16 Error code Name Description Corrective action number 1. Verify that cable number 5 (power supply-to-gas console control cable) is not damaged and is properly connected to PCB3 and to the rear of the gas console. 2. -
Page 183: Error Code Troubleshooting - 4 Of 16
MAINTENANCE Error code troubleshooting – 4 of 16 Error code Name Description Corrective action number Plasma gas pressure under 1. Inspect gas supply pressure and volume of gas remaining in lower limit of supply tanks. 0.34 bar (5 psi) – preflow Low plasma 2. -
Page 184: Error Code Troubleshooting - 5 Of 16
MAINTENANCE Error code troubleshooting – 5 of 16 Error code Name Description Corrective action number 1. Verify input-line voltage at PCB2 in the power supply and PCB1 in the cooler. Voltage needs to be within 10 % of nominal (120 VAC). 2. -
Page 185: Error Code Troubleshooting - 6 Of 16
MAINTENANCE Error code troubleshooting – 6 of 16 Error code Name Description Corrective action number 1. Verify gas supply regulator settings. See Setting the supply regulators (Installation section). Shield gas pressure is over High shield 2. Verify pressure settings on gas console with cut chart. upper limit of: 3. -
Page 186: Error Code Troubleshooting - 7 Of 16
MAINTENANCE Error code troubleshooting – 7 of 16 Error code Name Description Corrective action number 1. Auto gas - the process parameters may not have been downloaded. Verify that the process information can be Manual gas - The gas viewed on the CNC screen. console control board is 2. -
Page 187: Error Code Troubleshooting - 8 Of 16
MAINTENANCE Error code troubleshooting – 8 of 16 Error code Name Description Corrective action number 1. Verify that the large fan in the cooler is running. 2. Blow dust out of the cooler, especially from the heat exchanger. 3. Verify that the voltage on the rear side of J1.5 pins 6 and 8, is equal to or lower than 2.8 VDC. -
Page 188: Error Code Troubleshooting - 9 Of 16
MAINTENANCE Error code troubleshooting – 9 of 16 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. No coolant Coolant flow signal was 3. -
Page 189: Error Code Troubleshooting - 10 Of 16
MAINTENANCE Error code troubleshooting – 10 of 16 Error code Name Description Corrective action number A current less than Low current 10 amps has been See the chopper test later in this section. on CS2 detected by current sensor 2. A current greater than High current 35 amps has been... -
Page 190: Error Code Troubleshooting - 11 Of 16
MAINTENANCE Error code troubleshooting – 11 of 16 Error code Name Description Corrective action number 1. Verify that LED D19 or D20 is illuminating on the AC valve MV2 error Motor valve 2 did not driver PCB in the selection console. If either illuminates, Auto Gas move into position within replace the motor valve. -
Page 191: Error Code Troubleshooting - 12 Of 16
MAINTENANCE Error code troubleshooting – 12 of 16 Error code Name Description Corrective action number 1. Verify that the wiring between CS2 and PCB3 is correct and not damaged. 2. Measure voltage across current sensor. a) Red to black = +15 VDC, Green to black = -15 VDC, white to black = 0 VDC at idle and varies with current output (4 VDC = 100 amps). -
Page 192: Error Code Troubleshooting - 13 Of 16
MAINTENANCE Error code troubleshooting – 13 of 16 Error code Name Description Corrective action number Internal flash Communication problem to the flash chip on error 1. Replace the control board. Manual Gas the gas console control Only board. Internal flash Communication problem error to the flash chip on... -
Page 193: Error Code Troubleshooting - 14 Of 16
MAINTENANCE Error code troubleshooting – 14 of 16 Error code Name Description Corrective action number 1. Verify that the wiring between CS4 and PCB3 is correct and not damaged. 2. Measure voltage across current sensor. a) Red to black = +15 VDC, Green to black = -15 VDC, white to black = 0 VDC at idle and varies with current output (4 VDC = 100 amps). -
Page 194: Error Code Troubleshooting - 15 Of 16
MAINTENANCE Error code troubleshooting – 15 of 16 Error code Name Description Corrective action number 1. Verify that the circuit breaker on PCB7 has not tripped. If it has tripped, reset the breaker by pressing the button until it is even with the top of the circuit breaker. If the circuit breaker is not tripped and there is no power to PCB7, verify that the fuse on PCB2 in the power supply is good. -
Page 195: Error Code Troubleshooting - 16 Of 16
MAINTENANCE Error code troubleshooting – 16 of 16 Error code Name Description Corrective action number 1. Verify that the power supply-to-selection console CONTROL and POWER cables are not damaged and are properly connected to PCB3, and the rear of the selection console. -
Page 196: Power Supply States
MAINTENANCE Power supply states Set switch 8 on the gas console to the status position to view ID numbers. State Name code Power-up (idle) Purge Ready for start (idle2) Preflow Pilot arc Transfer Ramp-up Steady state Ramp-down Final ramp-down Cycle complete (auto off) Test cutflow Shutdown Reset... -
Page 197: Plasma System Operation With Pump Time-Out
MAINTENANCE Plasma system operation with pump timeout HPR400XD Manual Gas Instruction Manual 5-27... -
Page 198: Cnc Operation With Pump Time-Out
MAINTENANCE CNC operation with pump timeout 5-28 HPR400XD Manual Gas Instruction Manual... -
Page 199: Initial Checks
MAINTENANCE Initial checks Before troubleshooting, do a visual check and verify that proper voltages are present at the power source, transformers and power distribution board. DANGER SHOCK HAZARD: Always use caution when servicing a power supply when plugged in and the covers are removed. -
Page 200: Power Measurement
MAINTENANCE Power measurement DANGER There is line voltage at the contactor and the power distribution board (PCB2) when the line disconnect switch is ON. Use extreme care when measuring primary power in these areas. Voltages present at the terminal block and contactors can cause injury or death. Ground Note: Check lines in the following order:... -
Page 201: Air Filter Element Replacement
MAINTENANCE Air filter element replacement 1. Turn OFF all electrical power and disconnect the air hose from the filter. 2. Remove the filter bowl by turning it counter clockwise until it releases. 3. Pull the clear filter housing down firmly to remove it. The filter housing has an o-ring around the top. Apply a thin film of silicone lubricant on the o-ring to extend it’s life. -
Page 202: Coolant System Servicing
MAINTENANCE Coolant system servicing Draining the coolant system 1. Turn OFF all power to the system. 2. Remove the return coolant hose (red washer on the cooler fitting) from the rear of the cooler and put it in a 20 liter (5 gallon) container. -
Page 203: Coolant System Filter
MAINTENANCE Caution: Coolant will flow from the filter when its housing is removed. Drain coolant before servicing the filter. Coolant system filter Filter replacement 1. Turn OFF all power to the system. 2. Remove housing. 3. Remove and discard filter element. 4. - Page 204 MAINTENANCE 5-34 HPR400XD Manual Gas Instruction Manual...
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Page 205: Coolant Flow Tests
An in-line flow meter is the most accurate way to measure the flow rate, but can not be used with all the tests described without custom fittings. An in-line flow meter (part number 128933) is available from Hypertherm. The following “bucket”... -
Page 206: Bypass Valve Verification
Right side orifice Filler cap Bypass valve Using the Hypertherm flow meter (128933) Use the steps below to get an accurate reading from the flow meter. 1. Hold the flow meter upright. Square in both axis. 2. Take your reading from the edge shown below. -
Page 207: Manual Pump Operation
MAINTENANCE Manual pump operation If the LED display on the gas console shows coolant flow error 093, the pump must be turned on manually within 12 seconds of turning on the power supply, or the power will have to be turned off and then on again. 1. -
Page 208: Test 1 - Return Line
1. Turn OFF the power. Remove the supply coolant line (blue hose with green tape) from the RHF/LHF console, and place it in a 3.8 liter (1 gallon) container. A Hypertherm coolant container works well. 2. Measure how long it takes to fill the container. Turn ON the power. -
Page 209: Test 3 - Change The Torch
1. Turn OFF the power. Remove the return coolant line (blue hose with red tape) from the RHF/LHF console, and place it in a 3.8 liter (1 gallon) container. A Hypertherm coolant container works well. 2. Measure how long it takes to fill the container. Turn ON the power. -
Page 210: Test 6 - Bucket Test At The Pump
1. Turn OFF the power. Remove the pump outlet, coolant line, and place it in a 3.8 liter (1 gallon) container. A Hypertherm coolant container works well. 2. Measure how long it takes to fill the container. Turn ON the power. Turn ON the pump manually (see step 1 under “Manual pump operation”). -
Page 211: Pump And Motor Troubleshooting
MAINTENANCE Pump and motor troubleshooting Is the motor LED illuminated on the control board? Is the motor on? If the LED is illuminated, but the pump is not running, turn the pump on manually. If the motor will not turn on, verify that the fuse is OK, and make sure there is power to the motor. If you are still not getting flow from the pump, verify that the solenoid valve and relief valve are working correctly. -
Page 212: Gas Leak Tests
MAINTENANCE Gas leak tests The system has two automatic leak test modes. The leak test mode is activated by changing the shield gas selector switch (2) to the TEST position and then changing the RUN/SET switch (7) to either SET PREFLOW or SET CUTFLOW to begin the leak test. -
Page 213: Power Supply Control Board Pcb3
MAINTENANCE Power supply control board PCB3 +3.3V TP214 TP210 TP211 TP213 TP114 D329 D107 TP212 D108 TP113 TP104 TP102 TP112 TP100 TP203 D317 TP208 TP110 TP202 TP106 TP101 TP118 SPARE D316 TP200 TP109 TP201 PILOT ARC PHASE LOST TP107 D324 MOTION Rd ERROR TP103... -
Page 214: Power Supply Power Distribution Board Pcb2
MAINTENANCE Power supply power distribution board PCB2 Power distribution PC board LED list Output Color Contactor Pilot arc relay 120 VAC (switched) Green HF ignition Surge select 24 VAC (switched) Green 240 VAC (switched) Green + 24 VDC Pump motor Green + 5 VDC - 15 VDC... -
Page 215: Start Circuit Pcb1
MAINTENANCE Start-circuit PCB1 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. - Page 216 MAINTENANCE D2 should always be illuminated. D1 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 will not illuminate. If there is no arc at the torch or if the arc will not transfer: 1.
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Page 217: Pilot Arc Current Levels
MAINTENANCE 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 30-amps 45-amps 50-amps 80-amps 130-amps 200-amps 260-amps 400-amps Transfer current Plasma gas 30-amps 45-amps 50-amps... -
Page 218: Pump Motor Drive Board Pcb7
MAINTENANCE Pump motor drive board PCB7 Note: The inductor on the pump motor-drive board makes a noise during operation that has been described as a “hum”, “sing”, and “click”. This is normal and can be disregarded. TP10 TP12 Control PCB LED list Description Status + 15 V OK... -
Page 219: Cooler Power Distribution Board Pcb1
MAINTENANCE Cooler power distribution board PCB1 Signal name Color SV16 + 5 VDC Green HPR400XD Manual Gas Instruction Manual 5-49... -
Page 220: Cooler Sensor Board Pcb2
MAINTENANCE Cooler sensor board PCB2 TP21 TP22 – PWR GND TP18 RESET TP17 TP23 TP16 TP10 TP15 Signal name Color + 5 VDC + 3.3 VDC Green CAN TX CAN RX Control PCB test points Test point Test point number Description number Description... -
Page 221: Gas Console Control Board Pcb2
MAINTENANCE Gas console control board PCB2 Control PCB2 firmware list Item Part Number 081109 ODD 081109 EVEN Gas console control board LEDN list Gas console control board LED list LEDN Signal name Color Signal name Color LEDN1 Plasma preflow, left digit + 5 VDC Green LEDN2... -
Page 222: Gas Console Power Distribution Board Pcb1
MAINTENANCE Gas console power distribution board PCB1 Signal Name Color 120 VAC (switched) Green + 5 VDC + 24 VDC 5-52 HPR400XD Manual Gas Instruction Manual... -
Page 223: Gas Console Ac Valve-Driver Board Pcb3
MAINTENANCE Gas console, AC valve-driver board PCB3 Signal Name Color Signal Name Color SV11 SV12 SV13 SV14 SV15 (not used) SV16 SV17 SV18 SV19 SV10 SV20 SV14 SV13 SV12 SV19 SV18 SV10 SV20 SV16 SV17 SV11 Off-valve HPR400XD Manual Gas Instruction Manual 5-53... -
Page 224: Chopper Tests
MAINTENANCE 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. - Page 225 2, if chopper 3 is faulty. If the error does not change, or you measure an OCV of about 360 VDC for chopper 3, contact Hypertherm Technical Service at 800-643-9878 Note: Return switch 5 on S301 to the OFF position before returning to normal cutting operations.
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Page 226: Phase-Loss Detection Test
MAINTENANCE Phase-loss detection test 1. Turn OFF all power to the system and remove the cover from CON1. 2. Inspect the condition of the 3 contacts for excessive wear. If one of more of the contacts are worn excessively, replace CON1 and restart the system. If the error remains, perform the following steps. Excessive wear 3. -
Page 227: Torch Lead Test
MAINTENANCE DANGER SHOCK HAZARD: Always use caution when servicing a power supply when 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. -
Page 228: Preventive Maintenance
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 HyPerformance 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. -
Page 229: Cooling System
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 7. - Page 230 MAINTENANCE 16. If the gas line pressures hold steady, perform a system gas leak test as specified in this manual. 17. 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.
- Page 231 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 March April June July Sept • Clean power supply with dry, oil free compressed air, or a vacuum cleaner. •...
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Page 232: Power Supply
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 – continued 1. Inspect for particulates and blow out 16. - Page 233 MAINTENANCE Service parts replacement schedule – 1 of 2 228369 – annual preventive maintenance parts kit (200-240 volt) 228370 – annual preventive maintenance parts kit (380-600 volt) The kits include all the parts in the shaded boxes below Timeline Component Part number Qty.
- Page 234 MAINTENANCE Service parts replacement schedule – 2 of 2 Timeline Component Part number Qty. 027664 Coolant filter element 028872 Coolant solution 70/30 003217 Main contactor 220162 Torch main body 003149 Pilot arc relay 4 Years or 2400 arc hours 228171 Coolant pump kit System dependant Torch leads...
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Page 235: Section 6 Parts List
Section 6 PARTS LIST In this section: Power supply .......................................6-2 Cooler ...........................................6-6 Ignition console ......................................6-8 Gas console ........................................6-9 Off-valve ........................................6-10 HyPerformance torch ....................................6-11 Torch assembly ....................................6-11 Torch leads......................................6-11 Consumable parts kit – 228027 ...............................6-12 Consumables for mirror-image cutting ...............................6-14 Recommended spare parts ...................................6-15 HPR400XD Manual Gas Instruction Manual... -
Page 236: Power Supply
PARTS LIST Power supply Part Item Number Description Designator Qty. 078523 HyPerformance Plasma power supply: 200/208 volt 078524 HyPerformance Plasma power supply: 220 volt 078525 HyPerformance Plasma power supply: 240 volt 078526 HyPerformance Plasma power supply: 380 volt 078527 HyPerformance Plasma power supply: 400 volt 078528 HyPerformance Plasma power supply: 440 volt 078529... - Page 237 PARTS LIST Power supply Part Item Number Description Designator Qty. 003232* Contactor CON1 003228** Contactor CON1 229195 EMI filter (400 volt power supply only) 027079 10" fan: 450-550 CFM, 120 VAC 50-60 HZ 129792 Chopper assembly 129792 Chopper assembly 129792 Chopper assembly 129792 Chopper assembly...
- Page 238 PARTS LIST Power supply Part Item Number Description Designator Qty. 008551 Fuse: 7.5 amp, 600 volt F1, F2 229213 PCB: I/O 003149* Relay: Pilot arc, 120 VAC 229238 Start circuit assembly PCB1 109004 Current sensor: Hall 100 amp, 4 volt 109004 Current sensor: Hall 100 amp, 4 volt 109004...
- Page 239 PARTS LIST Power supply Part Item Number Description Designator Qty. 141027 PCB: Pump motor drive PCB7 229212 Inductor: 5 amp, 1.4 mH 041802 PCB: Power distribution PCB2 108028 Fuse: 3 amp, 250 volt F5, F6, F7 108075 Fuse: 6.3 amp, 250 volt (slow-blow) F1, F2, F3 108709 Fuse: 10 amp, 250 volt...
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Page 240: Cooler
PARTS LIST Cooler Part Item Number Description Designator Qty. 078531 Cooler 101022 Panel: Right side 127014 Filler cap 228366 Panel: Top, with labels 110507 Panel: Left side 027634 Filter housing 027664 Filter element HPR400XD Manual Gas Instruction Manual... - Page 241 PARTS LIST Cooler Part Item Number Description Designator Qty. 006113 Check valve 229235 Flow sensor: 23 lpm (6 gpm) 141033 PCB: Cooler sensor 009040 EMI filter: 250 VAC, 2 amp, 1 phase 041897 PCB: Console power distribution 008756 Fuse: 5 amp, 250 volt (slow-blow) 027658 Fan: 240 volt, 240 watt, 2910 cfm 229224...
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Page 242: Ignition Console
PARTS LIST Ignition console Part Item Number Description Designator Qty. 078172 Ignition Console 129831 Coil assembly 041817 HFHV Ignition PCB PCB IGN 129854 Transformer 009045 EMI filter HPR400XD Manual Gas Instruction Manual... -
Page 243: Gas Console
PARTS LIST Gas console Part Item Number Description Designator Qty. 078532 Gas Console 041805 Power distribution PCB PCB1 041822 Valve driver PCB PCB3 005263 Pressure sensor PT1-PT4 006109 Solenoid valve SV2, SV3, SV4, SV6, SV8-SV14 006112 Replacement solenoid coil 006136 Solenoid valve SV1, SV5, SV7 005262... -
Page 244: Off-Valve
PARTS LIST Gas console – 2 of 2 Part Item Number Description Designator Qty. 041912 Control PCB PCB2 229128 Regulator assembly with elbow fitting PR3, PR4 011109 Air filter housing 011110 Air filter element 229129 Regulator assembly with elbow and tee fitting PR1, PR2 Off-valve Part... -
Page 245: Hyperformance Torch
PARTS LIST HyPerformance torch Torch assembly Part Item Number Description 228354 machine torch assembly 220706 Quick-disconnect torch 220571 Water tube 220705 Quick-disconnect receptacle 220789 Torch mounting sleeve assembly: Standard, 181 mm (7 in) 220788 Torch mounting sleeve assembly: Short, 114 mm (4.5 in) 220790 Torch mounting sleeve assembly: Long, 248 mm (9.75 in) 104269... - Page 246 PARTS LIST Consumable parts kits Note: See Consumable selection or Cut charts in section 4 for specific applications Mild steel parts kit – 228367 Part Number Description Qty. 026009 O-ring: .208" X .070" 027055 Lubricant: Silicone 1/4-oz tube 044028 O-ring: 1.364" X .070" 104119 Tool: Consumable removal / replacement 104269...
- Page 247 PARTS LIST Stainless steel and aluminum parts kit – 228368 Part Number Description Qty. 026009 O-ring: .208" X .070" 027055 Lubricant: Silicone 1/4-oz tube 044028 O-ring: 1.364" X .070" 104119 Tool: Consumable removal / replacement 104269 Wrench: Spanner 220747 Shield cap 220202 Shield 220755...
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Page 248: Consumables For Mirror-Image Cutting
PARTS LIST Consumables for mirror-image cutting Mild steel Nozzle Water Shield cap Shield retaining cap Nozzle Swirl ring Electrode tube 220194 220810 220193 220306 220192 220555 220810 220554 220549 220552 220747 220189 220755 220188 220305 220187 220340 130A 220183 220755 220182 220305 220181... -
Page 249: Recommended Spare Parts
PARTS LIST Recommended spare parts Power supply Part Number Description Designator Qty. 129633 Green power lamp assembly 129792 Chopper assembly CH1, CH2, CH3, CH4 127039 6" fan: 230 CFM, 115 VAC 50-60 HZ 027079 10" fan: 450-550 CFM, 120 VAC 50-60 HZ 003149 Relay: Pilot arc, 120 VAC 229213... - Page 250 PARTS LIST Gas console Part Number Description Designator Qty. 041805 Power distribution PCB PCB1 041822 Valve driver PCB PCB3 005263 Pressure sensor PT1-PT4 006109 Solenoid valve SV2, SV3, SV4, SV6, SV8-SV14 006136 Solenoid valve SV1, SV5, SV7 005262 Illuminated power switch 011109 Air filter housing (on the rear panel of the selection console) 011110...
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Page 251: Wiring Diagrams
Section 7 WIRING DIAGRAMS Introduction This section contains the wiring diagrams for the system. When tracing a signal path or ref er enc ing with the Parts List or Troubleshooting sections, please be aware of the following format to assist you in un der stand ing the wiring diagrams' organization: •... - Page 252 Battery Fuse Push Button, Normally Closed Push Button, Ground Clamp Cap, polarized Normally Open Receptacle Ground, Chassis Cap, non-polarized Relay, Coil Ground, Earth Cap, feed-thru Relay, Normally Closed IGBT Circuit breaker Relay, Normally Open Inductor Coax shield Relay, Solid State, AC Current Sensor Relay, Solid State, DC Lamp...
- Page 253 Time Delay Open, Switch, Flow Torch Symbols NC/On 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, Triac...
- Page 255 Cooler Power Cable 12x1 3 Phase Unit 7 Power with Ground Cooler 1x12 Torch Lead Assembly Negative Lead HF/PS Cable Unit M Atm Vent Unit 2 Oxygen Plasma Preflow Torch Unit 4 72" N2/Ar Unit 3 Ignition Console Lifter Shield Preflow Pilot Arc Lead Plasma Off Valve...
- Page 256 SHEET SHEET SHEET SHEET SHEET 3-D4 3-C1 4-B2 4-B3 10-A4 DRV A JA.1 JA.6 SEE SHEET 12 OF 14 FOR SHEET ALL SUPPLY VOLTAGE 14-C2 INPUT WIRING CHOPPER SA CABLE: 123662 129792 J4.4 – 38 Handle CUSTOMER SUPPLIED E-Stop + 39 FUSED DISCONNECT (–)NEGATIVE Fuse...
- Page 257 SHEET 2-D3 J2.15 PCB2 POWER DISTRIBUTION PHASE LOSS INPUT SHEET 041802 J2.8 PHASE LOSS 5-D1 – PHASE LOSS OUTPUT SHEET 2-A4 J2.4 PUMP MOTOR DRIVE SHEET J11 J2.11 POWER 7-D4 24VAC YEL 24VAC 240VAC HOT 120VAC RED 120VAC 240VAC ORN 240VAC 240VAC RTN COOLOANT SOLONOID SHEET...
- Page 258 PCB2 POWER DISTRIBUTION 041802 SHEET J2.5 5-D1 CONTACTOR D1 CONTACTOR PA RELAY D2 PA RELAY HV XFMR D5 HV XFMR MARKING SURGE RELAY D7 MARKING SURGE RELAY 3 4 5 6 J2.3 CABLE: 123670 ELEC SCH:HPR400 PWR SPLY SHEET 14-D3 013373 SHEET 4 OF 19 7-10...
- Page 259 J308 J3.308 SHEET PCB3 PILOT ARC ENABLE 2-A1 POWER SUPPLY CONTROL PA-C 141030 PA-E SHEET PHASE LOSS 3-D1 PHASE LOSS SHEET D320 CONTACTOR J3.202 J202 D107 +5V 2-A3 D108 +3.3V D321 PA RELAY FA+3.3V CHOPPER A TEMP SENSOR D110 TXLED D322 HF J307 J3.307...
- Page 260 PCB3 SHEET POWER SUPPLY CONTROL 3-C4 J3.100 J100 141030 +24V PUMP ENABLE PWR GND SHEET 7-D1 J306 J3.306 PUMP ENABLE\ – C PUMP ENABLE\ – A +15V FAULTOUT\ –15V F+5V J106 TP200 TP202 TP204 TP206 TRST\ TP214 JTAG EMU0 EMU1 J108 J102 J103...
- Page 261 PUMP ENABLE/ALARM PCB7 SHEET SHEET 6-D1 PUMP MOTOR DRIVE CONTROLLER J7.10 3-D1 J7.8 PUMPEN\ – C 141027 ACIN1 PUMPEN\ – A ACIN2 FAULTOUT\ F+5V +15V +3.3V TRST\ OUTPUT OVER CURRENT PUMPAC1 HEAT SINK OVERTEMP PUMPAC2 JTAG IPM ALARM EMU0 EMU1 A+3.3V PUMP THMS–...
- Page 262 480/60 440/50 INPUT POWER INPUT POWER FROM FACILITY FROM FACILITY 440 VAC 480 VAC 3 Phase 3 Phase 50 Hertz 50 Hertz CON1 CON1 0 VAC 0 VAC 400VAC 400/50 CE 380/50 INPUT POWER INPUT POWER FROM FACILITY FROM FACILITY 380 VAC 400 VAC 3 Phase...
- Page 263 240/60 600/60 INPUT POWER INPUT POWER FROM FACILITY FROM FACILITY 600 VAC 240 VAC 3 Phase 3 Phase 60 Hertz 60 Hertz CON1 CON1 0 VAC 0 VAC 600VAC 240VAC 200/50-60 220/50-60 INPUT POWER INPUT POWER FROM FACILITY FROM FACILITY 440 VAC 380 VAC 3 Phase...
- Page 264 CABLE: 123209 THC OPTION COMMAND PLASMA INTERFACE PCB3 041842 POWER SUPPLY CONTROL J12.2B J3.303A 141030 RX– RX– TX– TX– 422 GND MOTION 1-E MOTION 1-C ERROR-E ERROR-C RDERR-E RDERR-C TO POWER SUPPLY NOT READY-E NOT READY-C MOTION 2-E MOTION 2-C PLASMA INTERFACE MOTION 3-E MOTION 3-C...
- Page 265 J1.2 120V RTN PCB1 RED/BLK 120V HOT GAS CONSOLE POWER DISTRIBUTION SHEET 041805 11-B4 J1.1 GAS CONSOLE +24V DC POWER +24V COM J1.6 RED/BLK 120VAC HOT +5V COM D1 120VAC SHEET 12-D4 D7+5V AC VALVE DRIVER POWER D9 +24V SHEET 13-D3 120VAC RTN SHEET...
- Page 266 J2.4 +24V PCB2 +24V COM GAS CSL CONT 041912 RS-232 232 COM +5V COM SHEET 11-C4 J2.8 CABLE: 123691 CABLE: 123692 J2.9 CANL CAN GND CAN A CANH CAN +24V SHIELD TRST\ SHIELD +5V COM CANL CAN GND JTAG SHEET 6-A4 CAN B CANH...
- Page 267 PCB3 SHEET AC VALVE DRIVER 11-C1 J3.1 J3.3 RED/BLK 041822 RED/BLK RED/BLK 120V HOT PCB2 RED/BLK GAS CSL CONT 120V RTN RED/BLK 041912 RED/BLK RED/BLK RED/BLK RED/BLK 120V RTN J2.6 J3.4 J4 120V RTN NOT USED RED/BLK 120V RTN NOT USED RED/BLK NOT USED 120V RTN...
- Page 268 CABLE: 123670 SHEET 4-B2 SHEET CATHODE 009045 FLTR 2-D1 BLOCK CABLE: 123662 HPR HFHV IGNITION 041817 TORCH 0.22uF 1kVDC PILOT ARC 009224 129854 0.22uF 1kVDC COIL SECONDARY IN 009224 1400pF 20kV 009975 COIL PRIMARY 2 109344 1400pF 20kV 009975 109344 1400pF 20kV 009793 009975...
- Page 269 N2/Ar H35/F5 5 Micron Filter Torch connections Shield gas Plasma vent Pilot arc Ohmic contact pin Gas Console Plasma gas Coolant return Coolant in Shield Shield Plasma Plasma Cutflow Cutflow Preflow Preflow Off Valve Manifold Vent Plasma Shield Vent HPR400 Manual Torch Gas Schematic ELEC SCH:HPR400 PWR SPLY...
- Page 270 COOLING SYS. FLOW SENSOR 229235 PCB1 COOLER SENSOR BOARD SHEET 141033 6-A3 12X2 J1.5 +24V +24V CANL S2-1 FLOW SENSOR FA+3.3V COOLANT TEMP CANH +24V V out CHILLER FLOW Cooler +24V CHECK VALVE PRESS SENSOR LINE VOLT IN FLOW SENSOR FILTER HEAT EXCHANGER RESERVOIR...
- Page 271 3) Use only the first four dipswitch settings, they are the same as on the 141030 control board. ELEC SCH:HPR400 PWR SPLY 4) If a Hypertherm Automation controler is being used, and there are intermittent communication Termination Termination failures (PS Link Failure), try removing the jumpers on J104 and J105 on the control board, and the 013373 termination jumper (J6 or J8) on the serial isolation board in the controler.
- Page 272 J105 CONTROL BOARD (contact should be rated for min. 24Vac, 0.5 Amp) * If a Hypertherm Automation controler is being used, and there are intermittent communication failures S301 J300 (PS Link Failure), try removing the jumpers on J104 and J105 on the control board, and the termination 3 2 1 jumper (J6 or J8) on the serial isolation board in the controler.
- Page 273 ELEC SCH:HPR400 PWR SPLY Dipswitch 7) If a Hypertherm Automation controler is being used, and there are intermittent communication failures (PS Link Failure), try removing the jumpers on J104 and J105 on the control board, and the Switch 1 is in the ON position.
- Page 274 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...
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Page 275: Section 1 Chemical Product And Company Identification
MATERIAL SAFETY DATA SHEET SECTION 1 – CHEMICAL PRODUCT AND COMPANY IDENTIFICATION PRODUCT NAME Hypertherm Torch Coolant Latest Revision Nov. 7, 2008 Date EMERGENCY TELEPHONE NUMBERS ISSUE DATE Nov. 7, 2008 Product Information: (603) 643-3441 DISTRIBUTOR: Hypertherm, Inc. 21 Great Hollow Road Hanover, N.H. -
Page 276: Section 4 First Aid Measures
MSDS Page 2 of 4 Product CODE Hypertherm Torch Coolant SECTION 4 – FIRST AID MEASURES Ingestion Seek immediate medical attention. If affected, remove from exposure. Restore breathing. Keep warm and quiet. Seek medical Inhalation attention. Eye Contact Immediately flush eye with cool running water. Remove contact lenses if applicable. Continue flushing with water for at least 15 minutes. -
Page 277: Section 8 Exposure Controls / Personal Protection
MSDS Page 3 of 4 Product CODE Hypertherm Torch Coolant SECTION 8 – EXPOSURE CONTROLS / PERSONAL PROTECTION Hygienic practices Normal procedures for good hygiene. Good general ventilation. Eye wash station in immediate area of use. Engineering controls M.E.L./O.E.S Nil. -
Page 278: Section 12 Ecological Information
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... -
Page 279: Freezing Point Of Propylene Glycol Solution
°C °F % of Propylene Glycol Freezing Point of Propylene Glycol Solution Hypertherm Plasma systems 8/21/08... -
Page 280: Functional Description Of Software
Appendix B FUNCTIONAL DESCRIPTION OF SOFTWARE III. Power-up a. Processor boots in microprocessor mode and begins to execute code in external flash memory. b. Limited initialization of digital-signal processing (DSP) hardware. c. Calculate checksum on external flash and on DSP internal flash. –... - Page 281 SOFTWARE FUNCTIONAL DESCRIPTION • After delay, wait for CAN watchdog message from the gas console. • After CAN watchdog messages have been received, send a CAN reset message to the gas console and go to the Purge state. Error checking •...
- Page 282 SOFTWARE FUNCTIONAL DESCRIPTION • If no chopper current after 10 HF pulses, go to Auto Off state with error code (020), “No pilot arc. ” Error checking • No error checking due to HF noise. 6. Transfer • If work lead current is > transfer reference current, go to Ramp-up state and turn off pilot arc controller and pilot arc relay.
- Page 283 SOFTWARE FUNCTIONAL DESCRIPTION 10. Final ramp-down • Chopper setpoints = 0. Error checking • Check for coolant flow at power-up (093). 11. Auto-off • Turn off pilot arc relay, pilot arc controller, HF, and machine motion outputs. • Preflow gases run for a 10-second postflow period. •...
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