Hypertherm HyPerformance Plasma HPR400 Instruction Manual
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Hypertherm HyPerformance Plasma HPR400 Instruction Manual

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HyPerformance
Plasma
®
HPR400
XD
®
Auto gas
Instruction manual
806160 – Revision 4

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Summary of Contents for Hypertherm HyPerformance Plasma HPR400

  • Page 1 HyPerformance Plasma ® HPR400 ® Auto gas Instruction manual 806160 – Revision 4...
  • Page 2 Register your new Hypertherm system Register your product on-line 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 Revision 4 – June, 2015 Hypertherm Inc. Hanover, NH USA www.hypertherm.com © 2015 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 55 11 2409 2636 Tel 55 11 2408 0462 Fax Hypertherm (S) Pte Ltd. 82 Genting Lane Media Centre Hypertherm México, S.A. de C.V. Annexe Block #A01-01 Avenida Toluca No. 444, Anexo 1, Singapore 349567, Republic of Singapore Colonia Olivar de los Padres 65 6841 2489 Tel Delegación Álvaro Obregón...

  • Page 5: Electromagnetic Compatibility (Emc)

    The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The Hypertherm’s CE-marked equipment is built in compliance with surrounding area may extend beyond the boundaries of the premises.
  • Page 6 ElEctRoMAgNEtIc coMPAtIbIlIty (EMc) Earthing of the workpiece Where the workpiece is not bonded to earth for electrical safety, nor connected to earth because of its size and position, for example, ship’s hull or building steel work, a connection bonding the workpiece to earth may reduce emissions in some, but not all instances.

  • Page 7: Warranty

    Except only in cases of products not manufactured by Hypertherm or herein and as follows: if Hypertherm is notified of a defect (i) with manufactured by a person other than Hypertherm not in strict conformity respect to the plasma power supply within a period of two (2) years with Hypertherm’s specifications and in cases of designs, processes,...
  • Page 8 At all times you will have and maintain insurance in such quantities and types, and with coverage sufficient and appropriate to defend and to hold Hypertherm harmless in the event of any cause of action arising from the use of the products.

  • Page 9: Table Of Contents

    Table of ConTenTs ElEctRoMAgNEtIc coMPAtIbIlIty (EMc) ......................EMc-1 wARRANty ....................................w-1 Section 1 SAFEty ....................................Sc-1 Recognize safety information ................................SC-2 Follow safety instructions ..................................SC-2 Inspect equipment before using .................................SC-2 Responsibility for safety ..................................SC-2 A plasma arc can damage frozen pipes ............................SC-2 Static electricity can damage printed circuit boards ........................SC-2 Grounding safety....................................SC-3 Electrical hazards ....................................SC-3 Electric shock can kill ....................................SC-3...
  • Page 10 Table of ConTenTs Symbols and Marks ....................................2-14 Section 3 INStAllAtIoN ..................................3-1 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...
  • Page 11 Table of ConTenTs Torch lead junction box (Optional)..............................3-36 Install the junction box ................................. 3-37 Connect the leads ..................................3-38 Work lead ......................................... 3-42 Torch connections ....................................3-43 Connect the torch to the torch lead assembly ........................3-43 Connect the torch to the quick-disconnect ........................... 3-47 Torch mounting and alignment ................................
  • Page 12 Table of ConTenTs Standard cutting (0°) ................................... 4-10 Bevel cutting (0° to 45°) ................................4-10 Marking ......................................4-10 Consumables for mirror-image cutting ............................ 4-10 SilverPlus electrodes ................................... 4-10 Mild steel ......................................4-11 Stainless steel ....................................4-12 Aluminum ......................................4-13 Mild steel bevel cutting ................................4-14 Mild steel, thick piercing, bevel cutting ...........................
  • Page 13 Coolant flow tests ....................................5-36 Before testing ....................................5-36 Bypass valve verification ................................5-37 Using the Hypertherm flow meter (128933) .......................... 5-37 Manual pump operation ................................5-38 Test 1 – return line ..................................5-39 Test 2 – supply line at ignition console ..........................5-39 Test 3 –...
  • Page 14 Table of ConTenTs Gas leak tests ......................................5-43 Leak test 1 (inlet leak test) ................................. 5-43 Leak test 2 (system leak test) ..............................5-44 Leak test 3 (proportional valve test in the metering console) .................... 5-44 Power supply control board PCB3..............................5-45 Power supply power distribution board PCB2 ..........................
  • Page 15 Introduction .........................................7-1 Wiring diagram symbols ...................................7-1 Discrete output functionality ..................................7-5 Appendix A HyPERtHERM toRcH coolANt SAFEty DAtA ......................A-1 1 – Identification of the substance/mixture and of the company undertaking ................a-2 2 – Hazards identification ..................................a-2 3 – Composition/information on ingredients .............................a-3 4 –...
  • Page 16 Table of ConTenTs Checksum ...................................... b-27 Message retries .................................... b-27 Cable shielding ..................................... b-27 Appendix c RobotIc APPlIcAtIoNS ..............................c-1 Components for robotic applications ..............................c-2 Torch leads .......................................c-2 Ohmic contact extension ................................c-2 Rotational mounting sleeve (optional) – 220864 ........................c-3 Leather overwrap – 024866 ...............................c-3 Robotic teaching torch (laser pointer) –...
  • Page 17 Section 1 SAFEty In this section: Recognize safety information ................................SC-2 Follow safety instructions ..................................SC-2 Inspect equipment before using .................................SC-2 Responsibility for safety..................................SC-2 A plasma arc can damage frozen pipes ............................SC-2 Static electricity can damage printed circuit boards ........................SC-2 Grounding safety ....................................SC-3 Electrical hazards ....................................SC-3 Electric shock can kill ....................................SC-3 Cutting can cause fire or explosion ..............................SC-4...

  • Page 18: Safety

    Safety DANgER wARNINg cAUtIoN REcogNIzE SAFEty American National Standards Institute (ANSI) guidelines are used INFoRMAtIoN for safety signal words and symbols. The signal word DANGER or The symbols shown in this section are used to identify potential WARNING is used with a safety symbol. DANGER identifies the most hazards.

  • Page 19: Grounding Safety

    Safety gRoUNDINg SAFEty Input power work lead Attach the work lead securely to the workpiece or the cutting table with good metal-to-metal contact. Do not connect it to • Make sure to connect the power cord ground wire to the ground in the piece that will fall away when the cut is complete.

  • Page 20: Cutting Can Cause Fire Or Explosion

    MAcHINE MotIoN cAN cAUSE INJURy When an original equipment manufacturer (OEM) makes a cutting system by combining Hypertherm equipment with other equipment, the end-use customer and the OEM are responsible for providing protection against the hazardous moving parts of this cutting system. However, we advise the following to prevent operator injury and equipment damage:...

  • Page 21: Compressed Gas Equipment Safety

    Safety coMPRESSED gAS EqUIPMENt gAS cylINDERS cAN EXPloDE SAFEty IF DAMAgED • Never lubricate cylinder valves or regulators with oil or grease. Gas cylinders contain gas under high pressure. If damaged, a cylinder • Use only correct gas cylinders, regulators, hoses, and fittings can explode.

  • Page 22: A Plasma Arc Can Cause Injury And Burns

    Safety A PlASMA ARc cAN cAUSE INJURy AND bURNS Instant-on torches The plasma arc will cut quickly through gloves and skin. • A plasma arc ignites immediately when the torch switch is activated. • Keep away from the torch tip. • Do not hold metal near the cutting path.

  • Page 23: Noise Can Damage Hearing

    Safety NoISE cAN DAMAgE HEARINg Use ear protectors if the noise is disruptive or if there is a risk Cutting with a plasma arc can exceed acceptable noise levels as of hearing damage after all other engineering and administrative defined by local regulations in many applications. Prolonged exposure controls have been implemented.

  • Page 24: Laser Radiation

    Safety lASER RADIAtIoN Exposure to the laser beam from a laser pointer can result in serious eye injury. Avoid direct eye exposure. On products that use a laser pointer for alignment, one of the following laser radiation labels has been applied on the product near where the laser beam exits the enclosure.

  • Page 25: 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 Selection console ....................................2-3 Metering console .....................................2-3 Torch ........................................2-3 Specifications ......................................2-4 System gas requirements ................................2-4 Power supply ....................................2-5 Cooler – 078531 ..................................2-6 Ignition console –...
  • Page 26 SpecificationS HPR400XD Auto Gas – 806160...

  • Page 27: 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. The power supply has a serial interface to provide communication with a CNC controller.

  • Page 28: Specifications

    SpecificationS Specifications System gas requirements gas quality and pressure requirements gas type quality Pressure +/- 10% Flow rate oxygen 99.5% pure 793 kPa / 8 bar 4250 l/h 150 scfh Clean, dry, oil-free 115 psi nitrogen 99.99% pure 793 kPa / 8 bar 11610 l/h 410 scfh Clean, dry, oil-free 115 psi...

  • Page 29: 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) Power supplies will operate between -10° C and +40° C Ambient temperature/Duty cycle (+14° and 104°...

  • Page 30: Cooler - 078531

    SpecificationS cooler – 078531 • T he cooling system can contain up to 34.5 liters (9 gallons) of coolant. • M aximum cable length from the cooler to the power supply is 4.57 meters (15 ft). • M aximum hose length from the cooler to the ignition console is 76.2 meters (250 ft). • Allow 1 m (3 ft) of space on all sides of the cooler for ventilation and service. To the filter on 76 mm the rear of the 3.00”...

  • Page 31: Ignition Console - 078172

    SpecificationS Ignition console – 078172 • T he ignition console can be mounted remotely on the cutting table’s bridge. See Installation section for details. • M aximum cable length from the ignition console to the torch lifter station is 15 m (50 ft). Allow room to remove the top for servicing. • T he ignition console may be mounted horizontally or vertically. 283 mm 11.125” 219 mm 8.625” 194 mm 9.1 kg 7.625” 20 lb 216 mm 8.5” 152 mm 6”...
  • Page 32 SpecificationS Mounted on table Horizontal mounting Vertical mounting HPR400XD Auto Gas – 806160...

  • Page 33: Torch Lead Junction Box (Optional) - 078619

    SpecificationS torch lead junction box (optional) – 078619 • The junction box provides increased installation flexibility by creating a break point in the leads between the ignition console and torch to facilitate easier replacement of torch leads in certain applications. • Maximum combined lead length from the ignition console to the torch must be less than or equal to: • 20 m (65 feet) for HPR130XD / HPR260XD • 15 m (50 feet) for HPR400XD / HPR800XD...

  • Page 34: Selection Console - 078533

    SpecificationS Selection console – 078533 • Maximum cable length from the power supply to the selection console is 75 m (250 ft). • Maximum cable length from the selection console to the metering console is 20 m (65 ft). • M ount the selection console on top of the power supply or near the CNC on the cutting table. Allow room to open the top for servicing. 355.6 mm 285.75 mm 14.00” 11.25” 311.15 mm 12.25” 13.6 kg 30 lb 314.5 mm 12.38” 38.1 mm 1.5” 76.2 mm 254.0 mm 3.0”...

  • Page 35: Metering Console - 078535

    SpecificationS Metering console – 078535 • M aximum cable length from the metering console to the torch lifter station is 1.8 m (6 ft). • M ount the metering console to the torch carriage on larger tables. On smaller tables it can be mounted to a bracket just above the bridge. • The vent hole on the console must be kept clear at all times. 155.58 mm 285.75 mm 6.125” 11.25” 263.53 mm 10.375” Vent hole. Do not block. 153.9 mm 6.1” 122.2 mm 4.8” 76.2 mm 3.0”...

  • Page 36: Torch - 228354

    SpecificationS torch – 228354 • The outside diameter of the torch mounting sleeve is 50.8 mm (2.0 in). • The minimum bend radius for the torch leads is 152.4 mm (6.0 in). 1.8 m 6’ 49 mm 194 mm 1.91” 7.62” 104 mm 4.10” 51 mm 51 mm 57 mm 2.00” 2” 2.25” 95 mm 3.74” 43 ° 346 mm 13.63” 1.9 kg 4.2 lb 2-12 HPR400XD Auto Gas –...

  • Page 37: Iec Symbols

    SpecificationS IEc symbols The following symbols may appear on the power supply data plate, control labels, switches, LEDs, and LCD screen. Power is ON Direct current (DC) Alternating current (AC) Power is OFF An inverter-based power source, either 1-phase or Plasma torch cutting 3-phase Plate metal cutting...

  • Page 38: Symbols And Marks

    SpecificationS Symbols and Marks Your product may have one or more of the following markings on or near the data plate. Due to differences and conflicts in national regulations, not all marks are applied to every version of a product. S mark The S mark indicates that the power supply and torch are suitable for operations carried out in environments with increased hazard of electrical shock according to IEC 60974-1.

  • Page 39: 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...
  • Page 40 InstallatIon Power cable ....................................3-26 Selection console to metering console connections........................3-28 Cable and gas hose assembly ..............................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 ................................

  • Page 41: Upon Receipt

    – 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 42: Installation Requirements

    InstallatIon Installation requirements HPR400XD Auto Gas – 806160...

  • Page 43: System Components

    InstallatIon System components Power supply Ignition console Cooler Metering console Selection console Torch cables and hoses Pilot arc lead Negative lead Ignition console power cable Coolant hoses Cooler control cable Cooler power cable Selection console control cable Selection console power cable Selection console to metering console hose and lead assembly CNC interface cable Optional CNC interface cable for systems with multiple power supplies...

  • Page 44: Recommended Grounding And Shielding Practices

    Note: The grounding practices in this section have been used on many installations with excellent results, and Hypertherm recommends that these practices be a routine part of the installation process. The actual methods used to implement these practices may vary from system to system, but should remain as consistent as possible.
  • Page 45 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) ground on the table. This includes the ignition console, whether it is bolted to the plasma system or to the cutting table.
  • Page 46 InstallatIon The following picture shows an example of a cutting table ground bus. The components shown here may differ from your system. Gantry ground bus Ground rod Plasma system lead (+) Remote high frequency (RHF) console CNC enclosure Torch holder Plasma system chassis The following picture shows an example of a gantry ground bus.

  • Page 47: Grounding Diagram

    InstallatIon Grounding diagram The following diagram shows an example of grounding the components in a plasma cutting system. Grounding diagram Chassis and RFI ground AC earth ground Cutting table 8, 9 System-specific component such as metering console, gas console, or selection console Gantry CNC chassis Plasma system...
  • Page 48 InstallatIon 3-10 HPR400XD Auto Gas – 806160...

  • Page 49: Placement Of The Power Supply

    InstallatIon Placement of the power supply DANgER ElEctRIc SHock cAN kIll Remove all electrical connections to power supply before moving or positioning. transporting unit can cause personal injury and equipment damage. The power supply can be moved by forklift but the forks must be long enough to extend the entire length of the base. Take care when lifting so that the underside of the power supply is not damaged.

  • Page 50: Lifting The Power Supply

    Use appropriate lifting aids and techniques when moving a power supply A strap kit (228336) for lifting the HPR400XD 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 51 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.

  • Page 52: Install The Ignition Console

    InstallatIon Install the ignition console • M ount the ignition console in a vertical or horizontal position. • Allow room to remove the top for servicing 32 mm 184 mm 1.25 in 7.25 in 222.25 mm 8.75 in 32 mm 1.25 in 248 mm 9.75 in...
  • Page 53 InstallatIon Horizontal RHF mounting Vertical RHF mounting HPR400XD Auto Gas – 806160 3-15...

  • Page 54: Placement Of The Cooler

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

  • Page 55: Install The Metering Console

    InstallatIon Install the metering console • M ount the metering console near the torch lifter station. The maximum length of the gas hoses between the metering console and the torch is 1.8 m (6 ft). Metering console grounding Vent hole: Do not block 153.9 mm 6.1 in...

  • Page 56: Placement Of The Selection Console

    InstallatIon Placement of the selection console • M ount the selection 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 selection console is 75 m (250 ft).
  • Page 57 InstallatIon This page is blank intentionally HPR400XD Auto Gas – 806160 3-19...

  • Page 58: 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 59 InstallatIon Pilot arc lead Negative lead Work lead Pilot arc lead Negative lead HPR400XD Auto Gas – 806160 3-21...

  • Page 60: 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 61: Coolant Hoses

    InstallatIon coolant hoses caution: Never use PtFE tape on any joint preparation. green Part no. length Part no. length 128499 1.5 m (5 ft) 128984 20 m (65 ft) 028652 3 m (10 ft) 128078 25 m (85 ft) 028440 4.5 m (15 ft) 028896 35 m (115 ft)

  • Page 62: 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 – power supply to cooler (9-pin DSUB connectors) Power supply end cooler end Pin No.
  • Page 63 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 Auto Gas – 806160 3-25...

  • Page 64: Power Supply To Selection Console Cables

    InstallatIon Power supply to selection 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 65 InstallatIon HPR400XD Auto Gas – 806160 3-27...

  • Page 66: Selection Console To Metering Console Connections

    InstallatIon Selection console to metering console connections cable and gas hose assembly Part no. length 128992 3 m (10 ft) 128993 4.5 m (15 ft) 228338 6 m (20 ft) 128952 7.5 m (25 ft) 128994 10 m (35 ft) 128930 15 m (50 ft) 128995...
  • Page 67 InstallatIon caution: Never use PtFE tape on any joint preparation. HPR400XD Auto Gas – 806160 3-29...

  • Page 68: 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) To J 300...

  • Page 69: 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 70: Examples Of Output Circuits

    InstallatIon Examples of output circuits 1. Logic interface, active-high 5 VDC-24 VDC CNC/PLC (optional) High-impedance (≤10 mA) 2. Logic interface, active-low 5 VDC-24 VDC (optional) CNC/PLC High-impedance (≤10 mA) 3. Relay interface CNC +24 V +24 VDC CNC +24 V °t Install a Jumper...

  • Page 71: 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 100 V 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 72: Remote On/Off Switch (Provided By Customer)

    InstallatIon Remote oN/oFF switch (provided by customer) DANgER 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 73: Torch Lead Assembly

    InstallatIon torch lead assembly Part no. length 228291 2 m (6 ft) 228292 3 m (10 ft) 228293 4.5 m (15 ft) 228294 6 m (20 ft) 228295 7.5 m (25 ft) 228296 10 m (35 ft) 228297 15 m (50 ft) Note: A 20 m (65 ft) torch lead is not available for HPR400XD systems...

  • Page 74: Torch Lead Junction Box (Optional)

    InstallatIon torch lead junction box (optional) Note: See the Parts list for part numbers caution: total lead length from the ignition console to the torch must be less than or equal to: 20 m (65 feet) for HPR130XD / HPR260XD 15 m (50 feet) for HPR400XD / HPR800XD Metering console Ignition console...

  • Page 75: Install The Junction Box

    InstallatIon Install the junction box 1. Remove the cover fom the junction box 2. Mount the junction box near the cutting location. (See Specification – for Junction box mounting dimensions) Note: Allow space to install and remove the cover of the box for servicing. 3.

  • Page 76: Connect The Leads

    InstallatIon connect the leads Note: Do not overtighten the connections Junction box to the ignition console 1. Connect one end of the junction box lead to the junction box. Note: the lead can go in either end of the junction box. From the ignition console Coolant supply hose (green) Pilot arc lead (yellow)
  • Page 77 InstallatIon 2. Connect the other end of the junction box lead to the ignition console. Coolant supply hose (green) Pilot arc lead (yellow) Coolant return hose (red) HPR400XD Auto Gas – 806160 3-39...
  • Page 78 InstallatIon lead from the torch to the junction box 1. Connect the lead from the torch to the junction box. From the ignition console From the torch Coolant supply hose (green) Pilot arc lead (yellow) Coolant return hose (red) 2. Install the junction box cover. 3-40 HPR400XD Auto Gas –...
  • Page 79 InstallatIon 3. Connect the torch hoses to the metering console. Metering console Junction box Plasma gas vent hose (white) Plasma gas hose (black) Shield hose (blue) HPR400XD Auto Gas – 806160 3-41...

  • Page 80: Work Lead

    InstallatIon work lead Work table Power supply 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 81: 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 82 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 83 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 84 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.

  • Page 85: 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 86: 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 87: Torch Lifter Requirement

    5080 mm/min (200 ipm) with positive braking. A unit which drifts through the stop point is not acceptable. HyperNet HyperNet is only used to connect certain Hypertherm components to each other. An HPRXD system can be connected to the ArcGlide ®...

  • Page 88: 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. Recommendations on fuse and circuit breaker sizing are listed below, however actual sizes required will vary based on individual site electrical line conditions (including but not limited to: source impedance, line impedance, and line voltage fluctuation), product inrush characteristics, and regulatory requirements.

  • Page 89: Line Disconnect Switch

    InstallatIon line disconnect switch The line disconnect switch serves as the supply-voltage disconnecting (isolating) device. Install this switch near the power supply for easy access by the operator. Installation must be performed by a licensed electrician and according to applicable national and local codes.

  • Page 90: Connect The Power

    InstallatIon connect the power DANgER ElEctRIc SHock cAN kIll the line disconnect switch must be in the oFF position before making the power cable connections. In the U.S., use a “lock-out/tag-out” procedure until installation is complete. In other countries, follow appropriate national and local safety procedures. 1.

  • Page 91: Torch Coolant Requirements

    Ambient temperature – The temperature of the room in which the chiller is being used. Premixed coolant for standard operating temperatures Use Hypertherm premixed coolant (028872) when operating in an ambient 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 92 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 purifi ed water (see next page for water purity requirements) to achieve the required protection from freezing.

  • Page 93: Custom Coolant Mix For Cold Operating Temperatures

    InstallatIon custom coolant mix for hot operating temperatures custom coolant mix for hot operating temperatures (above 38° c / 100° F) water purity requirements Treated water (with no propylene glycol) can only be used as coolant when ambient temperatures are never below 0° C (32°...

  • Page 94: Fill The Cooler With Coolant

    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.

  • Page 95: 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 selection console. See gas regulators in this section for recommendations. See the Specification section for gas and flow specifications. See Supply gas hoses at the end of this section for recommendations.

  • Page 96: 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 and local codes.

  • Page 97: Supply Gas Plumbing

    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 98: Connect The Supply Gases

    InstallatIon connect the supply gases Connect the supply gases to the selection console. Torch leads must be purged between gas changes. caution: Synthetic lubricants containing esters that are used in some air compressors will damage polycarbonates used in the air regulator bowl. Fitting Size / Ar...

  • Page 99: Supply Gas Hoses

    InstallatIon Supply gas hoses oxygen hose caution: Never use PtFE tape on any joint preparation. 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...
  • Page 100 InstallatIon 3-62 HPR400XD Auto Gas – 806160...

  • Page 101: Operation

    Section 4 oPERAtIoN In this section: Daily start-up .......................................4-3 Check torch ......................................4-3 Power indicators ......................................4-4 General ......................................4-4 Power supply ....................................4-4 Selection console ....................................4-4 Metering console .....................................4-4 CNC controller requirements ..................................4-5 CNC screen examples ....................................4-6 Main (control) screen ..................................4-6 Diagnostic screen ...................................4-7 Test screen .......................................4-8 Cut chart screen ....................................4-9 Consumable selection ...................................
  • Page 102 OperatiOn How to optimize cut quality .................................. 4-22 Tips for table and torch ................................4-22 Plasma set-up tips..................................4-22 Maximize the life of consumable parts ............................. 4-22 Additional factors of cut quality ..............................4-23 Additional improvements ................................4-25 Cut charts ......................................... 4-26 Thin stainless steel with HDi technology ............................

  • Page 103: 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 DANgER ElEctRIc SHock cAN kIll 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 104: Power Indicators

    OperatiOn Power indicators general Power for the system is controlled by the CNC. The power supply, selection console and metering console each have an LED lamp that illuminates when power is supplied to the component. Power supply green indicator Selection console green indicator Metering console HPR400XD Auto Gas –...

  • Page 105: Cnc Controller Requirements

    OperatiOn cNc controller requirements Note: See appendix B, CNC interface protocol, for more detailed information. base required elements The following elements should be able to be displayed and adjusted on the CNC for setup and basic system information. The plasma system needs this group for basic setup and operation capability. 1.

  • Page 106: Cnc Screen Examples

    OperatiOn cNc screen examples The screens shown are for reference. The screens you work with may be different, but should include the functions listed on the previous page. Main (control) screen HPR400XD Auto Gas – 806160...

  • Page 107: Diagnostic Screen

    OperatiOn Diagnostic screen HPR400XD Auto Gas – 806160...

  • Page 108: Test Screen

    OperatiOn test screen HPR400XD Auto Gas – 806160...

  • Page 109: Cut Chart Screen

    OperatiOn cut chart screen HPR400XD Auto Gas – 806160...

  • Page 110: 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 111: Mild Steel

    OperatiOn Mild steel Nozzle water Shield retaining cap Nozzle Electrode tube Shield cap Swirl ring 30 A 220194 220754 220193 220180 220192 50 A 220555 220754 220554 220553 220552 80 A 220747 220189 220756 220188 220179 220187 220340 130 A 220183 220756 220182...

  • Page 112: Stainless Steel

    OperatiOn Stainless steel Nozzle water retaining cap Shield Nozzle Electrode tube Shield cap Swirl ring 45 A 220202 220755 220201 220180 220308 80 A 220338 220755 220337 220179 220339 220747 130 A 220340 220198 220755 (H35) 220197 220179 220307 220756 (N 200 A 220762 220758...

  • Page 113: Aluminum

    OperatiOn Aluminum Nozzle water retaining cap Shield cap Shield Nozzle Electrode Swirl ring tube 45 A 220202 220756 220201 220180 220308 220747 130 A 220307 (H35) 220198 220197 220179 220755 (H35) 220181 (Air) 220756 (Air) 220340 200 A 220759 220762 220346 220342 220307...

  • Page 114: Mild Steel Bevel Cutting

    OperatiOn Mild steel bevel cutting Nozzle Swirl water retaining cap Electrode Shield cap Shield Nozzle ring tube 80 A 220742 220845 220806 220179 220802 220700 130 A 220742 220740 220646 220179 220649 220637 260 A 220741 220740 220542 220436 220541 220571 400 A 220636...

  • Page 115: Stainless Steel Bevel Cutting

    OperatiOn Stainless steel bevel cutting Nozzle Swirl water Shield cap Electrode Shield retaining cap Nozzle ring tube 130 A 220738 220739 220656 220179 220606 260 A 220571 220738 220739 220607 220405 220606 220637 400 A 220707 220712 220708 220405 220709 HPR400XD Auto Gas –...

  • Page 116: 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 117 OperatiOn Inspect consumables Inspect look for Action Shield cap Erosion, missing material Replace shield cap Cracks Replace shield cap Burned surface Replace shield cap Shield general: Erosion or missing material Replace shield Molten material attached Replace shield Blocked gas holes Replace shield center hole: Must be round...
  • Page 118 OperatiOn Inspect Look for Action Swirl ring General: Chips or cracks Replace swirl ring Blocked gas holes Replace swirl ring Dirt or debris Clean and check for damage; replace when damaged O-rings: Damage Replace swirl ring Lubricant Apply a thin film of silicone lubricant if the o-rings are dry Electrode Center surface:...

  • Page 119: 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 120: Torch Connections

    OperatiOn torch connections Plasma vent Shield gas Ohmic Pilot arc contact Coolant return Coolant return Plasma gas Coolant in Coolant in torch quick-disconnect receptacle torch Replace torch water tube 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.

  • Page 121: Common Cutting Faults

    OperatiOn common cutting faults • T orch pilot arc will initiate, but will not transfer. Causes can be: Work cable connection on the cutting table is not making good contact. Malfunction in the system. See Section 5. Torch-to-work distance is too high. •...

  • Page 122: How To Optimize Cut Quality

    Follow carefully each step in the Daily start-up procedure described earlier in this section. Purge the gas lines before cutting. Maximize the life of consumable parts Hypertherm’s LongLife ® process automatically “ramps up” the gas and current flows at the start and ramps them down at the end of each cut, to minimize erosion of the electrode’s center surface.

  • Page 123: Additional Factors Of Cut Quality

    OperatiOn Additional factors of cut quality Additional factors of cut quality cut angle 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 124 OperatiOn Dross Low-speed dross forms when the torch’s cutting speed is too slow and the arc shoots ahead. It forms as a heavy, bubbly deposit at the bottom of the cut and can be removed easily. Increase the speed to reduce the dross. High-speed dross forms when the cutting speed is too fast and the arc lags behind.

  • Page 125: Additional Improvements

    4 seconds to keep the arc transferred to the plate. • D ifferent material chemistries can have an adverse effect on the pierce capability of the system. In particular, high-strength steel and steel with a high manganese or silicon content can reduce the maximum pierce capability. Hypertherm calculates mild steel pierce parameters with certified A-36 plate. • I f the system has difficulty piercing a specific material or thickness, increasing the shield preflow pressure can help in some cases.

  • Page 126: Cut Charts

    Recommendations Hypertherm develops stainless steel processes using SAE grade 304L. When cutting other grades of stainless steel, you may need to adjust the cut chart parameters to obtain optimal cut quality. In order to reduce the amount of dross, the first recommended adjustment is to adjust the cut speed.

  • Page 127: Thick Stainless Steel Piercing Technique

    While the parameters for this moving pierce process are built into Hypertherm’s CNC software and nesting software, the information is available to all HPRXD customers and can be used with other compatible CNCs and nesting software programs.
  • Page 128 OperatiOn wARNINg the “rooster tail” of molten material and hot gases produced by this moving pierce technique can result in injury, fire, and damage to equipment if appropriate precautions are not taken. you may be required to use guards to protect operators and to prevent the molten metal from reaching any flammable materials.

  • Page 129: Fine Feature Cutting

    Hypertherm has developed the following processes specifically for cutting mild steel in the 3 mm to 25 mm (0.135 to 1 inch) range of thicknesses. These cut chart settings offer a set of optimal parameters for each thickness and are designed to achieve: • Minimum angle deviation...

  • Page 130: Bevel Cutting

    HPRXD Bevel Compensation Cut Charts white paper (part number 807830), which can be found in the “Downloads library” on the Hypertherm website at www.hypertherm.com.

  • Page 131: 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 132: Underwater Cut Charts

    Hypertherm has developed underwater cut charts for 80 A, 130 A, 200 A, 260 A, and 400 A mild steel processes. These underwater cut charts are designed to produce optimal results for cutting mild steel up to 75 mm (3 inches) below the surface of the water.
  • Page 133 THC setup parameters. Refer to the instruction manuals for your Hypertherm CNC and THC systems for more details on setting the stall force threshold or on disabling ohmic contact. Alternative CNCs and THC systems can also be set up for underwater cutting.

  • Page 134: 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. N/A = data not available. Metric thickness (mm) Process Mild steel 400A O / Air...
  • Page 135 OperatiOn Metric thickness (mm) Process Aluminum 400A N / Air N/A N/A N/A N/A N/A N/A 3.50 3.60 3.70 3.90 4.00 N/A N/A 4.00 7.60 N/A N/A N/A 400A H35 / N N/A N/A N/A N/A N/A N/A N/A N/A 4.20 4.30 4.30 N/A N/A 4.45 5.40 7.05 8.00 8.15 400A N/A N/A N/A N/A N/A N/A 3.55 3.65 3.80 3.80 4.20 N/A N/A 4.45 4.55 6.15 6.85 7.10 H35 and N...
  • Page 136 OperatiOn English thickness (in) 0.060 0.135 5/16 1-1/4 1-1/2 1-3/4 2-1/4 2-1/2 Process Mild steel 400A O / Air N/A 0.135 0.140 0.145 0.148 0.164 0.183 0.215 0.237 0.250 0.275 0.340 260A O / Air N/A 0.100 0.100 0.100 0.110 0.115 0.135 0.150 0.170 0.175 0.220 0.225 0.240 0.260 N/A 200A O / Air N/A 0.078 0.082 0.086 0.089 0.108 0.116 0.125 0.164 0.192 N/A 0.216 N/A...
  • Page 137 OperatiOn HPR400XD Auto Gas – 806160 4-37...
  • Page 138 OperatiOn 4-38 HPR400XD Auto Gas – 806160...
  • Page 139 OperatiOn HPR400XD Auto Gas – 806160 4-39...
  • Page 140 OperatiOn 4-40 HPR400XD Auto Gas – 806160...
  • Page 141 OperatiOn Mild steel Flow rates – lpm/scfh Plasma / O Shield Preflow 0 / 0 43 / 90 30 A Cutflow 25 / 52 0 / 0 Note: Air must be connected to use this process. It is used as the preflow gas. 220747 220194 220754...
  • Page 142 OperatiOn Mild steel Flow rates – lpm/scfh Plasma / O Shield Preflow 0 / 0 43 / 90 50 A 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 143 OperatiOn Mild steel Flow rates – lpm/scfh Plasma / Air Shield Preflow 0 / 0 76 / 161 80 A Cutflow 23 / 48 41 / 87 220747 220189 220756 220188 220179 220187 220340 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 47 / 100 80 A Cutflow 23 / 48 47 / 100 220637 220742 220845 220806 220179 220802 220700 Metric Equivalent Select Minimum Torch-to-Work Cutting Initial Pierce...
  • Page 145 OperatiOn Flow rates – lpm/scfh Preflow 0 / 0 76 / 161 Mild steel underwater cutting Cutflow 23 / 48 41 / 87 No more than 75 mm (3 in) below the surface of the water Plasma / Air Shield 80 A 220747 220189...
  • Page 146 OperatiOn Mild steel Flow rates – lpm/scfh Plasma / Air Shield Preflow 0 / 0 102 / 215 130 A Cutflow 33 / 70 45 / 96 220747 220183 220756 220182 220179 220181 220340 Metric Select Material Torch-to-Work Cutting Initial Pierce Pierce Delay Gases Preflow...
  • Page 147 OperatiOn Mild steel bevel cutting Flow rates – lpm/scfh Plasma / Air Shield Preflow 0 / 0 64 / 135 130 A Cutflow 33 / 70 45 / 96 220742 220740 220646 220179 220649 220700 220637 Note: Bevel angle range is 0° to 45°. Metric Equivalent Select...
  • Page 148 OperatiOn Flow rates – lpm/scfh Preflow 0 / 0 102 / 215 Mild steel underwater cutting Cutflow 33 / 70 45 / 96 No more than 75 mm (3 in) below the surface of the water Plasma / Air Shield 130 A 220747 220183...
  • Page 149 OperatiOn Mild steel Flow rates – lpm/scfh Plasma / Air Shield Preflow 0 / 0 128 / 270 200 A Cutflow 39 / 82 48 / 101 220637 220761 220757 220354 220353 220352 220340 Metric Select Material Torch-to-Work Cutting Initial Pierce Pierce Delay Gases Preflow...
  • Page 150 OperatiOn Mild steel bevel cutting Flow rates – lpm/scfh Plasma / Air Shield Preflow 0 / 0 114 / 240 200 A Cutflow 43 / 90 49 / 102 220658 220845 220659 220353 220662 220700 220637 Note: For mirror-image cutting, use 220996 (nozzle retaining cap) and 220350 (swirl ring) instead. Metric Equivalent Select...
  • Page 151 OperatiOn Flow rates – lpm/scfh Preflow 0 / 0 128 / 270 Mild steel underwater cutting Cutflow 39 / 82 48 / 101 No more than 75 mm (3 in) below the surface of the water Plasma / Air Shield 200 A Note: Preflow must be on during IHS.
  • Page 152 OperatiOn Mild steel Flow rates – lpm/scfh Plasma / Air Shield Preflow 0 / 0 130 / 275 260 A Cutflow 42 / 88 104 / 220 220637 220764 220760 220439 220436 220435 220340 Metric Select Material Torch-to-Work Cutting Initial Pierce Pierce Delay Gases Preflow...
  • Page 153 OperatiOn Mild steel bevel cutting (standard) Flow rates – lpm/scfh Plasma / Air Shield 260 A Preflow 0 / 0 130 / 275 Cutflow 42 / 88 104 / 220 220637 220741 220740 220542 220436 220541 220571 Metric Equivalent Select Minimum Torch-to-Work Cutting...
  • Page 154 OperatiOn Mild steel bevel cutting (alternate) Flow rates – lpm/scfh thick metal piercing Preflow 0 / 0 85 / 180 Plasma / Air Shield Cutflow 47 / 99 54 / 115 260 A 220637 220897 220896 220898 220436 220899 220571 Metric Equivalent Torch-to-Work...
  • Page 155 OperatiOn Flow rates – lpm/scfh Preflow 0 / 0 130 / 275 Mild steel underwater cutting Cutflow 42 / 88 104 / 220 No more than 75 mm (3 in) below the surface of the water Plasma / Air Shield 260 A Note: Preflow must be on during IHS.
  • Page 156 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 157 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 Select...
  • Page 158 OperatiOn Flow rates – lpm/scfh Preflow 0 / 0 190 / 400 Mild steel underwater cutting Cutflow 66 / 140 137 / 290 No more than 75 mm (3 in) below the surface of the water Plasma / Air Shield 400 A Note: Preflow must be on during IHS.
  • Page 159 OperatiOn Stainless steel Flow rates – lpm/scfh Plasma / N Shield Preflow 24 / 51 45 A 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 Distance...
  • Page 160 OperatiOn Stainless steel Flow rates – lpm/scfh F5 Plasma / N Shield Preflow 0 / 0 43 / 91 45 A Cutflow 8 / 17 65 / 138 220747 220202 220755 220201 220180 220308 220340 Metric Select Material Torch-to-Work Cutting Initial Pierce Pierce Delay Gases...
  • Page 161 OperatiOn Stainless steel HDi Flow rates – lpm/scfh F5 Plasma / N Shield Preflow 0 / 0 76 / 160 60 A Cutflow 20 / 42 58 / 122 220747 220815 220814 220847 220180 220339 220340 Metric Select Material Torch-to-Work Cutting Initial Pierce Pierce Delay...
  • Page 162 OperatiOn Stainless steel Flow rates – lpm/scfh F5 Plasma / N Shield Preflow 0 / 0 67 / 142 80 A Cutflow 31 / 65 87 / 185 220747 220338 220755 220337 220179 220339 220340 Metric Select Material Torch-to-Work Cutting Initial Pierce Pierce Delay Gases...
  • Page 163 OperatiOn Stainless steel Flow rates – lpm/scfh Plasma / N Shield Preflow 97 / 205 130 A 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 Distance...
  • Page 164 OperatiOn Stainless steel Flow rates – lpm/scfh H35 Plasma / N Shield Preflow 0 / 0 76 / 160 130 A Cutflow 26 / 54 68 / 144 220179 220747 220198 220755 220197 220307 220340 Metric Select Material Torch-to-Work Cutting Initial Pierce Pierce Delay Gases...
  • Page 165 OperatiOn Stainless steel Flow rates – lpm/scfh H35 and N Plasma / N Shield Preflow 0 / 0 97 / 205 130 A Cutflow 13 / 28 71 / 150 220179 220747 220198 220755 220197 220307 220340 Metric Pierce Select Material Torch-to-Work Cutting...
  • Page 166 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 167 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 168 OperatiOn Stainless steel bevel cutting Flow rates – lpm/scfh H35 and N Plasma / N Shield Preflow 0 / 0 97 / 205 130 A Cutflow 13 / 28 120 / 250 220637 220738 220739 220656 220179 220606 220571 Note: Bevel angle range is 0° to 45°. Metric Pierce Equivalent...
  • Page 169 OperatiOn Stainless steel Flow rates – lpm/scfh Plasma / N Shield Preflow 111 / 235 200 A 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 Distance...
  • Page 170 OperatiOn Stainless steel Flow rates – lpm/scfh H35 Plasma / N Shield Preflow 0 / 0 116 / 245 200 A Cutflow 30 / 63 104 / 220 220637 220762 220758 220343 220342 220307 220340 Metric Select Material Torch-to-Work Cutting Initial Pierce Pierce Delay Gases...
  • Page 171 OperatiOn Stainless steel Flow rates – lpm/scfh H35 and N Plasma / N Shield Preflow 0 / 0 116 / 245 200 A Cutflow 11 / 24 118 / 250 220637 220762 220758 220343 220342 220307 220340 Metric Pierce Select Material Torch-to-Work Cutting...
  • Page 172 OperatiOn Stainless steel Flow rates – lpm/scfh Plasma / Air Shield Preflow 127 / 270 0 / 0 260 A Cutflow 54 / 114 116 / 245 220637 220763 220758 220406 220405 220307 220340 Metric Select Material Torch-to-Work Cutting Initial Pierce Pierce Delay Gases Preflow...
  • Page 173 OperatiOn Stainless steel Flow rates – lpm/scfh H35 Plasma / N Shield Preflow 0 / 0 127 / 270 260 A Cutflow 40 / 84 122 / 260 220637 220763 220758 220406 220405 220307 220340 Metric Select Material Torch-to-Work Cutting Initial Pierce Pierce Delay Gases...
  • Page 174 OperatiOn Stainless steel Flow rates – lpm/scfh H35 and N Plasma / N Shield Preflow 0 / 0 132 / 280 260 A Cutflow 13 / 27 163 / 345 220637 220763 220758 220406 220405 220307 220340 Metric Pierce Select Material Torch-to-Work Cutting...
  • Page 175 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 Select...
  • Page 176 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 Select...
  • Page 177 OperatiOn Stainless steel bevel cutting Flow rates – lpm/scfh H35 and N Plasma / N Shield Preflow 0 / 0 132 / 280 260 A Cutflow 13 / 27 163 / 345 220637 220738 220739 220607 220405 220606 220571 Note: Bevel angle range is 0° to 45°. Metric Pierce Equivalent...
  • Page 178 OperatiOn Stainless steel Flow rates – lpm/scfh Plasma / Air Shield Preflow 42 / 90 146 / 310 400 A Cutflow 86 / 182 102 / 217 220637 220707 220712 220708 220405 220709 220571 Metric Select Material Torch-to-Work Cutting Initial Pierce Pierce Delay Gases Preflow...
  • Page 179 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 180 OperatiOn Stainless steel Flow rates – lpm/scfh H35 and N Plasma / N Shield Preflow 0 / 0 194 / 410 400 A Cutflow 36 / 77 194 / 410 220637 220707 220712 220708 220405 220709 220571 Metric Pierce Select Material Torch-to-Work Cutting...
  • Page 181 OperatiOn Stainless steel bevel cutting Flow rates – lpm/scfh Plasma / Air Shield Preflow 42 / 90 146 / 310 400 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 182 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 183 OperatiOn Stainless steel bevel cutting Flow rates – lpm/scfh H35 and N Plasma / N Shield Preflow 0 / 0 194 / 410 400 A Cutflow 36 / 77 194 / 410 220637 220707 220712 220708 220405 220709 220571 Note: Bevel angle range is 0° to 45°. Metric Equivalent Pierce...
  • Page 184 OperatiOn 4-84 HPR400XD Auto Gas – 806160...
  • Page 185 OperatiOn Aluminum Flow rates – lpm/scfh Air Plasma / Air Shield Preflow 45 / 95 45 A 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 Distance...
  • Page 186 OperatiOn Aluminum Flow rates – lpm/scfh Air Plasma / Air Shield Preflow 73 / 154 130 A 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 Distance...
  • Page 187 OperatiOn Aluminum Flow rates – lpm/scfh H35 Plasma / N Shield Preflow 0 / 0 76 / 160 130 A Cutflow 26 / 54 68 / 144 220747 220198 220755 220197 220179 220307 220340 Metric Select Material Torch-to-Work Cutting Initial Pierce Pierce Delay Gases Preflow...
  • Page 188 OperatiOn Aluminum Flow rates – lpm/scfh H35 and N Plasma / N Shield Preflow 0 / 0 97 / 205 130 A Cutflow 13 / 28 71 / 150 220747 220198 220755 220197 220179 220307 220340 Metric Pierce Select Material Torch-to-Work Cutting Initial Pierce...
  • Page 189 OperatiOn Aluminum Flow rates – lpm/scfh Plasma / N Shield Preflow 113 / 240 200 A 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 Speed...
  • Page 190 OperatiOn Aluminum Flow rates – lpm/scfh H35 Plasma / N Shield Preflow 0 / 0 113 / 240 200 A Cutflow 34 / 72 90 / 190 220637 220762 220759 220346 220342 220307 220340 Metric Select Material Torch-to-Work Cutting Initial Pierce Pierce Delay Gases Preflow...
  • Page 191 OperatiOn Aluminum Flow rates – lpm/scfh H35 and N Plasma / N Shield Preflow 0 / 0 121 / 256 200 A Cutflow 13 / 27 126 / 267 220637 220762 220759 220346 220342 220307 220340 Metric Pierce Select Material Torch-to-Work Cutting Initial Pierce...
  • Page 192 OperatiOn Aluminum Flow rates – lpm/scfh Plasma / Air Shield Preflow 125 / 265 0 / 0 260 A 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 193 OperatiOn Aluminum Flow rates – lpm/scfh H35 Plasma / N Shield Preflow 0 / 0 127 / 270 260 A Cutflow 33 / 70 118 / 250 220637 220763 220758 220406 220405 220307 220340 Metric Select Material Torch-to-Work Cutting Initial Pierce Pierce Delay Gases Preflow...
  • Page 194 OperatiOn Aluminum Flow rates – lpm/scfh Plasma / Air Shield Preflow 42 / 90 146 / 310 400 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 195 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...
  • Page 196 OperatiOn Aluminum Flow rates – lpm/scfh H35 and N Plasma / N Shield 400 A Preflow 0 / 0 194 / 410 Cutflow 36 / 77 194 / 410 220637 220707 220712 220708 220405 220709 220571 Metric Pierce Select Material Torch-to-Work Cutting Initial Pierce...
  • Page 197 OperatiOn HPR400XD Auto Gas – 806160 4-97...

  • Page 198: Maintenance

    Section 5 MAINtENANcE In this section: Introduction .........................................5-3 Routine maintenance....................................5-3 System description ....................................5-4 Power 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 – error codes 000 to 018 ..................... 5-10 Error code troubleshooting –...
  • Page 199 Coolant flow tests ....................................5-36 Before testing ....................................5-36 Bypass valve verification ................................5-37 Using the Hypertherm flow meter (128933) .......................... 5-37 Manual pump operation ................................5-38 Test 1 – return line ..................................5-39 Test 2 – supply line at ignition console ..........................5-39 Test 3 –...

  • Page 200: 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 201: System Description

    Maintenance System description Power and signal cables Power cable: Provides 120 VAC to the selection console. CAN Bus signal cable: Provides process and status signals between the power supply and the selection console. Power cable: Provides 120 VAC to the ignition console.

  • Page 202: 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 overtemp off Magnetics overtemp off Coolant overtemp off Plasma start off 2.

  • Page 203: Gas System Purge Cycle

    Maintenance gas system purge cycle When the system is turned on, or the operator changes from one cut process to another, the system automatically goes through a purge cycle. The purge cycle has 2 stages; a preflow purge and a cutflow purge. The preflow purge gas flows for 8 seconds with an auto gas console, or 12 seconds with a manual gas console.
  • Page 204 Maintenance F5/N Metering console Selection console control board process control board LED number 38 39 28 37 10 11 12 13 15 16 Preflow Cutflow SV14 H35/N Metering console Selection console control board process control board LED number 38 39 28 37 10 11 12 13 15 16 Preflow...
  • Page 205 Maintenance Marking process The valves that are active when marking are represented by the tables below. The active valves in the metering console will differ depending on what process was used before marking. Valves active when changing from a process that does not use a fuel gas Metering console Selection console control board control board...

  • Page 206: Error Codes

    Maintenance Error codes Error codes are displayed on the CNC screen. The diagnostic screen shown below is for reference. The screens you work with may be different, but should include the functions described in the Operation section of this manual. HPR400XD Auto Gas –...

  • Page 207: Error Code Troubleshooting - Error Codes 000 To 018

    Maintenance Error code troubleshooting – error codes 000 to 018 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 Wait 10 seconds for the flow rate to stabilize.

  • Page 208: Error Code Troubleshooting - Error Codes 020 To 028, 224 To 228

    Maintenance Error code troubleshooting – error codes 020 to 028, 224 to 228 Error code Name Description corrective action number 1. Verify that the consumable parts are in good condition. 2. Verify proper preflow and cut-flow settings. 3. Perform gas leak tests (see Maintenance section). No current detected from 4.

  • Page 209: Error Code Troubleshooting - Error Codes 030 To 042, 231 To 234

    Maintenance Error code troubleshooting – error codes 030 to 042, 231 to 234 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 210: Error Code Troubleshooting - Error Codes 044 To 046

    Maintenance Error code troubleshooting – error codes 044 to 046 Error code Name Description corrective action number Plasma gas pressure under 1. Inspect gas supply pressure and volume of gas remaining lower limit of in supply tanks. 0.34 bar (5 psi) – preflow Low plasma 2.

  • Page 211: Error Code Troubleshooting - Error Codes 047 To 053, 248 To 250

    Maintenance Error code troubleshooting – error codes 047 to 053, 248 to 250 Error code Name Description corrective action number 1. Verify input–line voltage at PCB2 in the power supply and PCB1 in the cooler (HPR400XD only). Voltage needs to be within 10% of nominal (120 VAC).

  • Page 212: Error Code Troubleshooting - Error Codes 054 To 061

    Maintenance Error code troubleshooting – error codes 054 to 061 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 2. Verify pressure settings on gas console with cut chart. upper limit of: shield gas 3.

  • Page 213: Error Code Troubleshooting - Error Codes 062 To 067, 265 To 267

    Maintenance Error code troubleshooting – error codes 062 to 067, 265 to 267 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.

  • Page 214: Error Code Troubleshooting - Error Codes 071 To 075, 273 To 275

    Maintenance Error code troubleshooting – error codes 071 to 075, 273 to 275 Error code Name Description corrective action number 1. Verify that the large fan in the cooler (HPR400XD only) is running. 2. Blow dust out of the coolerr (HPR400XD only), especially from the heat exchanger.

  • Page 215: Error Code Troubleshooting - Error Codes 076 To 101, 276 To 301

    Maintenance Error code troubleshooting – error codes 076 to 101, 276 to 301 Error code Name Description corrective action number Low current A current less than Primary on CS4 10 amps has been See the chopper test later in this section. HPR400XD detected by only...

  • Page 216: Error Code Troubleshooting - Error Codes 102 To 111, 302 To 308

    Maintenance Error code troubleshooting – error codes 102 to 111, 302 to 308 Error code Name Description corrective action number See wiring diagrams in section 7 1. Verify that the voltage at CS1 is correct. Chopper 1 Primary Chopper 1 current signal 2.

  • Page 217: Error Code Troubleshooting - Error Codes 116 To 133, 316

    Maintenance Error code troubleshooting – error codes 116 to 133, 316 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 the rear of the gas console. 2.

  • Page 218: Error Code Troubleshooting - Error Codes 134 To 140, 334 And 338

    Maintenance Error code troubleshooting – error codes 134 to 140, 334 and 338 Error code Name Description corrective action number 1. Verify that the wiring between CS1 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 219: Error Code Troubleshooting - Error Codes 141 To 152, 346 To 351

    Maintenance Error code troubleshooting – error codes 141 to 152, 346 to 351 Error code Name Description corrective action number 1. Verify that transducer P2 in the selection console is Pressure Faulty transducer or working properly. Replace if necessary. transducer control board in the 2.

  • Page 220: Error Code Troubleshooting - Error Codes 153 To 156, 354 To 356

    Maintenance Error code troubleshooting – error codes 153 to 156, 354 to 356 Error code Name Description corrective action number EEPROM memory on PS EEPROM power supply control Replace the control board. error board not working. 1. Verify that the wiring between CS3 and PCB3 is correct and not damaged.

  • Page 221: Error Code Troubleshooting - Error Codes 157 To 159, 357 To 359

    Maintenance Error code troubleshooting – error codes 157 to 159, 357 to 359 Error code Name Description corrective action number See wiring diagrams in section 7 Chopper 3 1. Verify that the voltage at CS3 is correct. current at Primary Chopper 3 current signal 2.

  • Page 222: Error Code Troubleshooting - Error Codes 160 To 180

    Maintenance Error code troubleshooting – error codes 160 to 180 Error code Name Description corrective action number Communication between the control board (PCB3 1. Verify that the cable connections from the power supply to HPR cooler’s in the power supply) and the cooler are good.

  • Page 223: Error Code Troubleshooting - Error Code 181, 182, 298, And 383

    Maintenance Error code troubleshooting – error code 181, 182, 298, and 383 Error code Name Description corrective action number 1. Verify that the power supply-to-metering console CONTROL and POWER cables are not damaged and are properly connected to PCB3, and the rear of the metering console.

  • Page 224: Power Supply States

    Maintenance Power supply states Power supply states are displayed on the CNC screen. The diagnostic screen shown below is for reference. State State Name Name code code Power-up (idle) Cycle complete (auto off) Purge Test cutflow Ready for start (idle2) Shutdown Preflow Reset...

  • Page 225: Plasma System Operation With Pump Time-Out

    Maintenance Plasma system operation with pump time-out Purge cycle begins, NOT power supply READY FOR START power-up signal is active Error output Purge timer done PLASMA START signal active System is in IDLE state waiting for a START signal, NOT READY FOR START signal is inactive START signal removed...

  • Page 226: Cnc Operation With Pump Time-Out

    Maintenance cNc operation with pump time-out Assert the PLASMA User presses START and HOLD START on signals to all plasma systems Is the NOT READY FOR Remove the START signal active on START and any plasma system? HOLD signals Apply the START signal and remove the HOLD signal Complete the...

  • Page 227: Initial Checks

    Maintenance Initial checks Before trouble-shooting, 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 228: Power Measurement

    Maintenance Power measurement DANgER SHock HAzARD 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. Main power in Ground Note: Check lines in the following order:...

  • Page 229: 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 230: 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 231: 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 232 Maintenance HPR400XD Auto Gas – 806160 5-35...

  • Page 233: 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 234: 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 235: Manual Pump Operation

    Maintenance Manual pump operation 1. Go to the CNC screen that turns on the pump manually (refer to the operation instructions for the CNC being used). If the selection console shows coolant flow error 093, the pump must be turned on manually within 8 seconds of turning on the power supply, or the power will have to be turned off and then on again.

  • Page 236: 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 237: 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 238: 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 using the manual pump control button on your CNC screen (see step 1 under “Manual pump operation”).

  • Page 239: 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 240: Gas Leak Tests

    Maintenance gas leak tests Notes: The CNC screen shown below is from a Hypertherm Automation controller, using version 6 software, and is for reference only. Other controllers should have a test screen similar to the one shown. Contact the original equipment manufacturer for instructions on how to access the test screen needed.

  • Page 241: Leak Test 2 (System Leak Test)

    Maintenance leak test 2 (system leak test) Purpose: Tests for leaks to the atmosphere from the gas system. Test description: The gas for the process selected is purged through the gas system. The metering console valves (B1-B4), and the inlet valves (for the selected process) in the selection console are closed. Gas pressure is now trapped in the system.

  • Page 242: Power Supply Control Board Pcb3

    Maintenance Power supply control board Pcb3 +3.3V TP213 TP214 TP210 TP211 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 243: 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 –...

  • Page 244: 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 245 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.

  • Page 246: Pilot Arc Current Levels

    Maintenance Pilot arc current levels The pilot arc current level will vary according to the arc current selected, and the process. 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 80-amps...

  • Page 247: 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 248: Cooler Power Distribution Board Pcb1

    Maintenance cooler power distribution board Pcb1 gas console control board lED list Signal name Color SV16 + 5 VDC Green HPR400XD Auto Gas – 806160 5-51...

  • Page 249: Cooler Sensor Board Pcb2

    Maintenance cooler sensor board Pcb2 TP21 TP22 – PWR GND TP18 RESET TP17 TP23 TP16 TP10 TP15 gas console control board lED list Signal name Color + 5 VDC + 3.3 VDC Green CAN TX CAN RX control Pcb test points Test point Test point number...

  • Page 250: Selection Console Control Board Pcb2

    Maintenance Selection console control board Pcb2 control Pcb2 firmware list Note: CAN termination resistor. The jumper must be removed. Item Part number 081110 EVEN 081110 gas console control board lED list Signal name Color + 3.3 VDC Green + 5 VDC Green CAN –...

  • Page 251: Selection Console Power Distribution Board Pcb1

    Maintenance Selection console power distribution board Pcb1 gas console control board lED list Signal name Color SV16 + 5 VDC Green 5-54 HPR400XD Auto Gas – 806160...

  • Page 252: Selection Console, Ac Valve-Driver Board Pcb3

    Maintenance Selection console, Ac valve-driver board Pcb3 Signal name Color Signal name Color SV11 SV12 SV13 SV14 (not used) Metering console vent solenoid MV1 close MV1 open MV2 close SV10 MV2 open SV14 SV 7 SV13 SV15 SV12 SV11 SV10 HPR400XD Auto Gas –...

  • Page 253: Metering Console Control Board Pcb2

    Maintenance Metering console control board Pcb2 Note: CAN termination resistor. The jumper control Pcb2 firmware list must be installed. Item Part number 081110 EVEN 081110 gas console control board lED list Signal name Color + 3.3 VDC Green + 5 VDC Green P5 (not visible) CAN –...

  • Page 254: Metering Console Power Distribution Board Pcb1

    Maintenance Metering console power distribution board Pcb1 gas console control board lED list Signal name Color SV16 + 5 VDC Green HPR400XD Auto Gas – 806160 5-57...
  • Page 255 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. Never discharge any capacitor with a screwdriver or other implement…...
  • Page 256 2, if chopper 3 is faulty. If the error does not move, 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.

  • Page 257: 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 or 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 258: Torch Lead Test

    Maintenance wARNINg 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 259: Preventive Maintenance

    See the HPR400XD Auto Gas Preventive Maintenance Program Instruction Manual (808660) for part numbers. If you have questions about how to maintain your plasma system, contact your OEM or regional Hypertherm Technical Service team. You can find contact information for each regional office at www.hypertherm.com/global...
  • Page 260 Section 6 PartS LiSt In this section: Power supply ......................................6-2 Cooler ...........................................6-6 Ignition console ......................................6-8 Torch lead junction box (Optional).................................6-9 Ignition console to junction box leads ............................. 6-10 Selection console ....................................6-11 Metering console ....................................6-13 HyPerformance torch ..................................... 6-14 Torch assembly .....................................

  • Page 261: Power Supply

    Parts List Power supply Note: The Hypernet option is currently used with the Power supplies ArcGlide ® torch height control. See the ArcGlide without with Voltage instruction manual (806450) for more information. Hypernet Hypernet (Ac) 078523 078570 200/208 078524 078571 078525 078572 078526...
  • Page 262 Parts List Power supply Part Item Number Description Designator qty. 229214* Terminal block: Input power 229033** Terminal block: Input power 229195 EMI filter (400 volt power supply only) 428064 Kit: HPR400/800 inrush circuit 129792 Chopper assembly 129792 Chopper assembly 129792 Chopper assembly 129792 Chopper assembly...
  • Page 263 Parts List Power supply Part Item Number Description Designator qty. 108847* Fuse: 7.5 amp, 600 volt, high surge F1, F2 008709** Fuse: 20 amp, 500 volt, slow blow F1, F2 229213 PCB: I/O 003149*** Relay: Pilot arc, 120 VAC 229238 Start circuit assembly PCB1 109004...
  • Page 264 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...

  • Page 265: 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 Auto Gas – 806160...
  • Page 266 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...

  • Page 267: Ignition Console

    Parts List Ignition console Part Item Number Description Designator qty. 078172 Ignition console 129831 Coil assembly 041817 HF/HV Ignition PCB PCB IGN 129854 Transformer 009045 EMI filter HPR400XD Auto Gas – 806160...

  • Page 268: Torch Lead Junction Box (Optional)

    Parts List torch lead junction box (optional) Item Part Number Description qty. 078619 HPRXD junction box 015007 Coolant fitting 104763 Pilot arc fitting 104762 Coolant block HPR400XD Auto Gas – 806160...

  • Page 269: Ignition Console To Junction Box Leads

    Parts List Ignition console to junction box leads caution: total lead length from the ignition console to the torch must be less than or equal to: 20 m (65 feet) for HPR130XD / HPR260XD 15 m (50 feet) for HPR400XD / HPR800XD Part no.

  • Page 270: Selection Console

    Parts List Selection console Part Item Number Description Designator qty. 078533 Selection console 129633 Green power lamp 011109 Filter assembly 011110 Filter element 228069 Kit: Control PCB PCB2 005263 Pressure sensor P1 – P4 123780 Pressure sensor wire harness P1 – P4 228984 Solenoid valve SV3 and SV10...
  • Page 271 Parts List Selection console Part Item Number Description Designator qty. 041822 Valve driver PCB PCB3 008756 Fuse: 5 A, 250V, slow-blow 129999 Motor valve assembly MV1, MV2 229217 Selection console wire harness 228347 Hose kit 6-12 HPR400XD Auto Gas – 806160...

  • Page 272: Metering Console

    Parts List Metering console Part Item Number Description Designator qty. 078535 Metering console 129633 Green power lamp 041897 Power distribution PCB PCB1 008756 Fuse: 5 amp, 250 volt (slow-blow) 228069 Kit: Control PCB PCB2 006077 Check valves 006109 Solenoid valve SV16 006112 Replacement solenoid coil...

  • Page 273: Hyperformance Torch

    Parts List HyPerformance torch torch assembly Part Item Number Description 228354 HPR400XD 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 274: Torch Leads

    Parts List torch leads Part no. Description 228291 2 m (6 ft) 228292 3 m (10 ft) 228293 4.5 m (15 ft) 228294 6 m (20 ft) 228295 7.5 m (25 ft) 228296 10 m (35 ft) 228297 15 m (50 ft) Note: A 20 m (65 ft) torch lead is not available for HPR400XD systems ohmic contact wire (Not part of the HPR400XD system.

  • Page 275: Consumable Parts Kits

    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: 0.208” X 0.070” 027055 Lubricant: Silicone 1/4-oz tube 044028 O-ring: 1.364” X 0.070” 104119 Tool: Consumable removal / replacement 104269...
  • Page 276 Parts List Stainless steel and aluminum parts kit – 228368 Part Number Description qty. 026009 O-ring: 0.208” X 0.070” 027055 Lubricant: Silicone 1/4-oz tube 044028 O-ring: 1.364” X 0.070” 104119 Tool: Consumable removal / replacement 104269 Wrench: Spanner 220179 Swirl ring: 80 A/130 A mild steel 220180 Swirl ring: 30 A mild steel 220181...

  • Page 277: Consumables For Mirror-Image Cutting

    Parts List consumables for mirror-image cutting Straight cutting Mild steel Nozzle water Shield cap Shield retaining cap Nozzle Electrode tube Swirl ring 30 A 220194 220810 220193 220306 220192 50 A 220555 220810 220554 220549 220552 220747 80 A 220189 220755 220188 220305...
  • Page 278 Parts List Stainless steel Nozzle water retaining cap Nozzle Shield cap Shield Swirl ring Electrode tube 45 A 220202 220756 220201 220306 220308 60 A 220815 420337 220847 220306 220339 80 A 220338 220756 220337 220305 220339 220747 130 A 220340 220198 220197...

  • Page 279: Bevel Cutting

    Parts List bevel cutting Mild steel Nozzle Swirl water retaining cap Shield cap Electrode Shield Nozzle ring tube 80 A 220742 220996 220806 220305 220802 220700 130 A 220742 220794 220646 220305 220649 220637 260 A 220741 220794 220542 220442 220541 220571 400 A...
  • Page 280 Parts List Stainless steel Nozzle Swirl water Shield cap Electrode Shield retaining cap Nozzle ring tube 130 A 220738 420336 220656 220305 220606 260 A 220571 220738 420336 220607 420330 220606 220637 400 A 220707 220885 220708 420330 220709 HPR400XD Auto Gas – 806160 6-21...

  • Page 281: 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 282 Parts List Selection and metering consoles Part Number Description Designator qty. 228069 Kit: Control PCB PCB2 041897 Power distribution PCB PCB1 008756 Fuse: 5 amp, 250 volt (slow-blow) 041822 Valve driver PCB PCB3 008756 Fuse: 5 amp, 250 volt (slow-blow) 228984 Solenoid valve SV3 and SV10...

  • Page 283: Warning Label - 110647

    Button shirt collar. Protect ears from noise. Use welding helmet with the correct shade of filter. 6. Become trained. Only qualified 110647 Rev. B www.hypertherm.com/weee personnel should operate this equipment. Use torches specified in the manual. Keep non-qualified personnel and children away.
  • Page 284 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: • S heet numbers are located in the lower right-hand corner.
  • Page 285 Wiring Diagrams HPR400XD Auto Gas – 806160...
  • Page 286 Wiring Diagrams HPR400XD Auto Gas – 806160...
  • Page 287 Discrete output functionality HPR400XD Auto Gas – 806160...
  • Page 288 Cooler Power Cable 12x1 3 Phase Unit 7 Power Cooler w/ Ground 1x12 Torch Lead Assembly Negative Lead Unit M HF/PS Cable Unit 2 Torch Atm Vent Unit 3 Unit 4 72" Lifter Ignition Console Cut Gas 1 Plasma Pilot Arc Lead Selection Console Metering Console (Optional Unit)
  • Page 289 SHEET 2-A4 SHEET SHEET SHEET SHEET 3-D4 CON 2 4-B2 4-B3 3-C1 DRV A SHEET 10-A4 SHEET 2-A4 JA.1 JA.6 CON 3 SEE SHEET 12 OF 14 FOR SHEET ALL SUPPLY VOLTAGE 18-C2 (-)NEGATIVE 800A Connection INPUT WIRING CHOPPER SA CABLE: 123666 POINT J4.4...
  • Page 290 SHEET J2.15 2-D3 PCB2 SHEET POWER DISTRIBUTION PHASE LOSS INPUT J8 J2.8 PHASE LOSS 5-D1 041802 PHASE LOSS OUTPUT SHEET 11-D4 SHEET J2.4 J2.A J2.B J4 2-A4 PUMP MOTOR DRIVE SHEET J11 J2.11 POWER 7-D4 YEL 24VAC 24VAC YEL 24VAC 240VAC HOT RED 120VAC 120VAC...
  • Page 291 PCB2 POWER DISTRIBUTION 041802 SHEET J2.5 J5 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:HPR400XD POWER SUPPLY W/AUTO SHEET 18-D3 013374...
  • Page 292 PCB3 J308 J3.308 SHEET PILOT ARC ENABLE 2-A1 PA-C POWER SUPPLY CONTROL PA-E 141030 SHEET PHASE LOSS 3-D1 PHASE LOSS SHEET J3.202 J202 D107 +5V D320 CONTACTOR 2-A3 FA+3.3V D108 +3.3V D321 PA RELAY CHOPPER A TEMP SENSOR D110 TXLED D322 HF J307 J3.307...
  • Page 293 PCB3 SHEET 3-C4 POWER SUPPLY CONTROL J3.100 J100 +24V 141030 PUMP ENABLE/ALARM PWR GND SHEET 7-D1 J306 J3.306 PUMP ENABLE\ - C PUMP ENABLE\ - A +15V FAULTOUT\ -15V F+5V TP200 TP202 TP204 TP206 J106 TRST\ TP214 JTAG EMU0 EMU1 J108 J102 J103...
  • Page 294 PUMP ENABLE/ALARM SHEET PCB7 6-D1 SHEET J7.10 3-D1 J7.8 J8 PUMP MOTOR DRIVE CONTROLLER PUMPEN\ - C ACIN1 141027 PUMPEN\ - A ACIN2 FAULTOUT\ F+5V +15V +3.3V TRST\ OUTPUT OVER CURRENT PUMPAC1 HEAT SINK OVERTEMP PUMPAC2 JTAG IPM ALARM EMU0 PUMP EMU1 A+3.3V...
  • Page 295 480/60 440/50 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 296 240/60 600/60 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 297 CABLE: 123760 THC OPTION PCB3 COMMAND PLASMA INTERFACE POWER SUPPLY CONTROL 041842 141030 J12.2B J3.303A 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 MOTION 3-E MOTION 3-C MOTION 4-E TO COMMAND CONTROL MODULE MOTION 4-C...
  • Page 298 THC OPTION CABLE: 123760 PCB3 ARCGLIDE ETHERNET INTERFACE POWER SUPPLY CONTROL 141162 141030 J13.5 J3.303B J13.7 RED/BLK 24VAC RTN 422 GND 24VAC MOTION IN MOTION 1-E MOTION 1-C ERROR IN ERROR-E ERROR-C RAMPDOWN ERROR IN RDERR-E RDERR-C NOT READY IN NOT READY-E NOT READY-C MOTION 2-E...
  • Page 299 PCB1 J1.3 AC IN RED/BLK HPR AUTO GAS J1.6 120V HOT RED/BLK 120V RTN SELECTION CONSOLE 120VAC POWER DISTRIBUTION 041897 J1.4 +24V +24V COM GAS CONSOLE DC POWER +5V COM J1.5 SHEET 13-D3 +15V SV16 +15V COM D4 120VAC SHEET D2 SV16 ENABLED RED/BLK AC IN...
  • Page 300 MV1 POT MV2 POT POT 1 POT 2 J2.2 J2.9 SHEET 12-C4 J2.11 J11 +24V PWR GND +15V SV16 -15V LINE FREQ. PCB2 HPR AUTO GAS SELECTION CONSOLE CONTROL 041828 POWER INDICATORS TRST\ D45 +24V D40 +15V D18 +5V D17 +3.3V 422B JTAG RS-422...
  • Page 301 RED/BLK SV1.A J3.1 J3.3 SV1.B RED/BLK RED/BLK PCB2 120V HOT SV4.A SHEET RED/BLK SV2.A RED/BLK 120V RTN HPR AUTO GAS 12-C1 SV3.A SV2.B RED/BLK SELECTION CONSOLE SV2.A RED/BLK RED/BLK SV1.A CONTROL SV3.A RED/BLK PCB3 SV5.A 041828 SV3.B HPR AUTO GAS 120V RTN SV1.B RED/BLK...
  • Page 302 PCB1 J1.3 HPR AUTO GAS RED/BLK AC IN J1.6 120V HOT METERING CONSOLE POWER IN RED/BLK 120V RTN POWER POWER DISTRIBUTION 120VAC INDICATOR 041897 J1.4 +24V +24V COM GAS CONSOLE DC POWER +5V COM J1.5 RED/BLK +15V SV16 SV16 +15V COM D4 120VAC RAMPDOWN VALVE OUTPUT...
  • Page 303 J2.9 SHEET SHEET 15-C4 J2.11 J11 15-C4 +24V PWR GND J2.1 POWER IN +15V SV16 METERING VALVE -15V PRESSURE INPUTS LINE FREQ. POT FEEDBACK INPUTS PCB2 RAMPDOWN VALVE HPR AUTO GAS CONTROL OUTPUT METERING CONSOLE CONTROL 041828 POWER INDICATORS D45 +24V TRST\ D40 +15V D18 +5V...
  • Page 304 PCB2 HPR AUTO GAS METERING CONSOLE CONTROL 041828 NOT USED NOT USED NOT USED J2.12 J12 +24V SPARE 4 BURKERT 4 PWM4 SPARE 3 SPARE 2 SPARE 1 BURKERT 3 PWM3 SV20 SV19 SV18 BURKERT 2 PWM2 SV17 SV16 BURKERT 1 PWM1 SV15 SV14...
  • Page 305 CABLE: 123670 SHEET 4-B2 SHEET CATHODE 2-D1 FLTR 009045 BLOCK CABLE: 123666 HPR HFHV IGNITION 041817 TORCH PILOT ARC 0.22uF 1kVDC 009224 129854 0.22uF 1kVDC COIL SECONDARY IN 009224 1400pF 20kV COIL PRIMARY 2 009975 109344 1400pF 20kV 009975 109344 009793 1400pF 20kV 009975...
  • Page 306 COOLING SYSTEM 229235 FLOW SENSOR PCB1 141033 Cooler Sensor Board SHEET 12X2 J1.5 6-A3 +24V +24V CANL FLOW SENSOR S2-1 FA+3.3V COOLANT TEMP CANH +24V FLOW CHILLER FLOW Cooler +24V CHECK VALVE PRESS SENSOR N.O. J18.3 LINE VOLT IN FLOW SENSOR FILTER HEAT EXCHANGER +24V...
  • Page 307 Air N2 H5 H35 F5 torch connections 5 Micron Filter Shield gas Plasma vent Pilot arc Selection Ohmic contact pin Console Plasma gas Coolant return Coolant in Cut Gas 1 Cut Gas 2 Metering Console Vent Shield Plasma Vent HPR400 Auto Torch Gas Schematic ELEC SCH:HPR400XD POWER SUPPLY W/AUTO...
  • Page 308 (Customer Supplied) termination jumpers must be installed/set at the CNC for each of the RS-422 RX and TX signal pairs. 3) If a Hypertherm Automation Controller is being used, and there are intermittent communication failures ELEC SCH:HPR400XD POWER SUPPLY W/AUTO...
  • Page 309 S301 J300 3 2 1 * If a Hypertherm Automation controller is being used, and there are intermittent communication Gas Power Cable failures (PS Link Failure), try removing the jumnpers on J104 and J105 on the control board, and the 1 2 3 4 5 6 7 8 termination jumper (J6 or J8) on the serial isolation board in the controler.
  • Page 310 6) The CNC will need a dedicated I/O port for each Command THC. 1 2 3 4 5 6 7 8 7) If a Hypertherm Automation controller is being used, and there are intermittent communication ELEC SCH:HPR400XD POWER SUPPLY W/AUTO...
  • Page 311 Optional ArcGlide/EdgePro Multi-System Interface Unit 1 Unit 2 Unit 3 Unit 4 HPR PAC HPR PAC HPR PAC HPR PAC Dry Cutting System Dry Cutting System Dry Cutting System Dry Cutting System 141030 141030 141030 141030 CONTROL BOARD CONTROL BOARD CONTROL BOARD CONTROL BOARD J104...
  • Page 312 Appendix A HyPERtHERM toRcH coolANt SAFEty DAtA In this section: 1 – Identification of the substance/mixture and of the company undertaking ................a-2 2 – Hazards identification ..................................a-2 3 – Composition/information on ingredients .............................a-3 4 – First aid measures ....................................a-3 5 – Fire-fighting measures ..................................a-3 6 –...
  • Page 313 Details of the supplier of the safety data sheet Company Identification – Hypertherm Telephone – +1 (603) 643-5638 (USA), +31 (0) 165 596 907 (Europe) E-Mail (competent person) – technical.service@Hypertherm.com Address – P.o. box 5010, Hanover, NH 03755 USA (USA), Vaartveld 9, 4704 SE Roosendaal, Nederlands (Europe) Emergency telephone number –...
  • Page 314 A self contained breathing apparatus and suitable protective clothing should be worn in fire conditions 6 – AccIDENtAl RElEASE MEASURES Personal Precautions Put on protective clothing Environmental Exposure controls Absorb spillages onto sand, earth or any suitable adsorbent material other None Hypertherm Plasma systems 12/15/2010...
  • Page 315 Decomposition Temperature (°C) – Not available Evaporation rate – Not available Viscosity (mPa.s) – Not available Flammability (solid, gas) – Non-flammable Explosive properties – Not explosive Explosive limit ranges – Not available Oxidizing properties – Not oxidizing Other information – None Hypertherm Plasma systems 12/15/2010...
  • Page 316 Do not let this chemical/product enter the environment. Persistence and degradability Biodegradable bioaccumulative potential None anticipated Mobility in soil The product is predicted to have moderate mobility in soil Results of Pbt and vPvb assessment None assigned other adverse effects None anticipated Hypertherm Plasma systems 12/15/2010...
  • Page 317 State Right to Know Lists – cAS No. 95-14-7 listed in MA, NJ, PA. canada WHMIS Classification (Canada) – Not classified. CANADA INGREDIENT DISCLOSURE LIST – Not applicable. Canada (DSL/NDSL) – listed. EINECS (Europe) – listed. Wassergefährdungsklasse (Germany) – None. Hypertherm Plasma systems 12/15/2010...
  • Page 318 Information contained in this publication or as otherwise supplied to Users is believed to be accurate and is given in good faith, but it is for the Users to satisfy themselves of the suitability of the product for their own particular purpose. Hypertherm gives no warranty as to the fitness of the product for any particular purpose and any implied warranty or condition (statutory or otherwise) is excluded except to the extent that exclusion is prevented by law.
  • Page 319 Date SAFETY DATA SHEET Revision 6 Dec 2010 2.01CLP Torch Coolant 30% PG Mixture °c °F % of Propylene glycol Freezing Point of Propylene glycol Solution Hypertherm Plasma systems 12/15/2010...
  • Page 320 Appendix b cNc INtERFAcE PRotocol In this section Interface hardware .....................................b-2 Signal list........................................b-2 Signals .......................................b-2 Hardware ......................................b-3 Multi-drop wiring ....................................b-4 Multi-drop addressing ..................................b-5 Serial commands .......................................b-5 Format ........................................b-5 Framing ......................................b-5 Commands ......................................b-5 Command table (1 of 14) ..................................b-6 Error responses .................................... b-20 Calculating checksums ................................

  • Page 321: Interface Hardware

    Appendix B – CnC interfACe protoCol Interface hardware • T he interface will use a combination of discrete signals (5 inputs, 3 outputs, and 24 VDC active low) and an addressable RS422 interface. • T he hardware will provide 4 unique addresses, which allows 4 systems to be connected to one serial port on the CNC. The addressing mechanism will be inside the power supply, on a PC board (Note: A total of 32 I/O points [20 Inputs, 12 Outputs] will be required for 4 systems). • T he RS422 hardware will have tri-stateable transmitter to disconnect itself from the line when not communicating.

  • Page 322: Hardware

    Appendix B – CnC interfACe protoCol Signal list (continued) Signal name type Description Pierce Complete Input When active, the system will use shield preflow gases during piercing. When the signal is removed, the system will switch to shield cutflow gases. The signal should be applied at the same time the start signal is applied.
  • Page 323 Appendix B – CnC interfACe protoCol Multi-drop wiring Plasma start Hold ignition ––DB37 Pierce complete Corner current Machine motion 1 Machine motion 2 Machine motion 3 Machine motion 4 System error Rampdown error RS422 serial Remote power “ON/OFF” HPR system 1 Remote power “ON/OFF”...

  • Page 324: Multi-Drop Addressing

    Appendix B – CnC interfACe protoCol Multi-drop addressing The power supply control has DIP switches to set the power supply ID. DIP switches 2, 3, 4 are used to set the ID. Reserved Reserved Reserved Reserved Systems with ID 0 power-up with the serial interface enabled. Systems with any other ID power-up with the serial interface disabled.

  • Page 325: Command Table (1

    Appendix B – CnC interfACe protoCol command table (1 of 14) command System Description 000 HELLO Manual gas system Establish communications with the plasma system. Use this command Auto gas system to determine if the system is configured as an 800XD or 400XD. This command will return “HPR800XD”...
  • Page 326 Appendix B – CnC interfACe protoCol command table (2 of 14) command System Description 028 READ_PLASMA_AMPS Manual gas system Read actual power supply current. Auto gas system Data: None Return value: Power supply current in amps Sample: >0289A< >02801305E< (130 amps) 058 SET_NOMINAL_AMPS Auto gas system Set the power supply current in amps.
  • Page 327 Appendix B – CnC interfACe protoCol command table (3 of 14) command System Description SYSTEM_RESET Manual gas system Clear error conditions and resume operation. Only accepted Auto gas system if system is in a shutdown error condition (Error code > 79 and State = 14).
  • Page 328 Appendix B – CnC interfACe protoCol command table (4 of 14) command System Description 074 GET_IO_STATUS Manual gas system Read the status of the I/O ports of the DSP. Refer to I/O Auto gas system listing for description of each bit in Ports A-F. Data: None Return value:...
  • Page 329 Appendix B – CnC interfACe protoCol command table (5 of 14) command System Description 079 GET_PS_INFO Manual gas system Returns pressures, system state, and system error, Auto gas system space-delimited Data: None Return value: Plasma cutflow pressure (0044 = 44 psi) Plasma preflow pressure (0044 = 44 psi) Shield cutflow pressure (0044 = 44 psi) Shield preflow pressure (0044 = 44 psi)
  • Page 330 Appendix B – CnC interfACe protoCol command table (6 of 14) command System Description 087 BROADCAST MODE Manual gas system Tell all systems to listen but not respond. Auto gas system Data: None Return value: None Sample: >0879F< no response 094 READ_GAS_PRESSURES Manual gas system Read the gas pressures.
  • Page 331 Appendix B – CnC interfACe protoCol command table (7 of 14) command System Description 096 SET_INLET_GASES Auto gas system Set inlet gases for auto console. If inlet gases change, the power supply will enter the purge state. gas type changes are not allowed when the system is cutting (state 4 –...
  • Page 332 Appendix B – CnC interfACe protoCol command table (8 of 14) command System Description 100 GET_CONTROL_DATA Manual gas system Read internal control data: Auto gas system Chopper A used in HPR130/HPR260 Chopper B used in HPR260 Return string is the same whether the system is an HPR130 or HPR260.
  • Page 333 Appendix B – CnC interfACe protoCol command table (9 of 14) command System Description 102 SET_GAS_IO_FROM_PS Manual gas system This command will allow the user to turn on or off each output Auto gas system of the processor. After sending this command, the SYSTEM_ RESET command must be issued to restore the processor state.
  • Page 334 Appendix B – CnC interfACe protoCol command table (10 of 14) command System Description 114 READ_INPUTS Manual gas system This command will return the status of inputs to the PC board. Auto gas system Data: None Return value: 1 = on, 0 = off Power Supply Serial program Plasma start...
  • Page 335 Appendix B – CnC interfACe protoCol command table (11 of 14) command System Description 121 LEAK_CHECK_MODE Manual gas system This command will put the system into leak mode. There are Auto gas system 3 modes, mode #1 is the inlet leak check mode. This is used to see if the inlet solenoids are allowing gas to pass through the valve even when they are closed.
  • Page 336 Appendix B – CnC interfACe protoCol command table (12 of 14) command System Description 122 READ_GAS_SWITCH Manual gas system This command will return data that shows the actual position of the rotary switches used to set the inlet gas type. The difference between this command and 098 is that this command returns the values set by the position of the switch.
  • Page 337 Appendix B – CnC interfACe protoCol command table (13 of 14) command System Description 126 GET_INFO2 Auto gas control See 079 board only 127 GET_INFO3 Auto gas control See 079 board only 131 CLEAR WARNINGS Manual gas system This command will clear error codes less than #43. Auto gas system Sample: >13195<...
  • Page 338 Appendix B – CnC interfACe protoCol command table (14 of 14) command System Description 136 SERIAL_RESPONSE_DELAY All HPR systems Used when a CNC serial port can only support a half-duplex connection. The HPR power supply will reduce its response speed. Data: None Return value:...

  • Page 339: Error Responses

    Appendix B – CnC interfACe protoCol Error responses If there is a problem with the serial command, the module will return an error. bad checksum Return ID: 500 Description: The serial command received does not have the correct checksum. Sample: >00091< – checksum should be 90, not 91 >50095<...

  • Page 340: Error Codes

    Appendix B – CnC interfACe protoCol Error codes Name Description NO ERROR System is ready to run. When the pump is restarted after a pump timeout (30 minutes FLOW SWITCH TEST without a start signal) the system will test the flow switch to make sure there is sufficient flow before firing the torch.
  • Page 341 Appendix B – CnC interfACe protoCol Name Description HIGH SHIELD GAS PRESSURE Gas pressure is over upper limit of 7.58 bar (110 psi). Motor valve 1 inlet pressure is less than 3.45 bar (50 psi) or MV 1 INLET PRESSURE greater than 9.65 bar (140 psi).
  • Page 342 Appendix B – CnC interfACe protoCol Name Description 106 Primary CURRENT TOO LOW ON LEM A current less than 10 amps has been detected by current sensor 306 Secondary 107 Primary CURRENT TOO HIGH ON LEM A current greater than 35 amps has been detected by current 307 Secondary sensor 3.
  • Page 343 Appendix B – CnC interfACe protoCol Name Description 156 Primary CHOPPER 2 CURRENT AT INIT Chopper 2 current signal is active on power-up 356 Secondary 157 Primary CHOPPER 3 CURRENT AT INIT Chopper 3 current signal is active on power-up 357 Secondary 158 Primary CHOPPER 4 CURRENT AT INIT...

  • Page 344: Status Codes

    Appendix B – CnC interfACe protoCol Status codes Name IDLE PURGE IDLE2 PREFLOW PILOT ARC TRANSFER RAMP-UP STEADY STATE RAMP-DOWN FINAL RAMP-DOWN AUTO OFF TEST CUTFLOW SHUTDOWN RESET MAINTENANCE TEST PREFLOW MANUAL PUMP CONTROL INLET LEAK CHECK SYSTEM LEAK CHECK BURKERT FLOW CHECK gas type codes gas type...

  • Page 345: Cnc Requirements

    Appendix B – CnC interfACe protoCol cNc requirements Auto gas console Below is a list of functionality that CNCs must offer for the automatic gas console version of the HPR system. In this system configuration there is no local control of the plasma system. All settings and diagnostic information will be under CNC control.

  • Page 346: Serial Interface Guidelines

    Serial interface guidelines checksum The protocol used for the serial interface between the Hypertherm system and the CNC contains a checksum on the message being sent. The checksum should be validated for each message to ensure the information is not corrupted.
  • Page 347 Appendix B – CnC interfACe protoCol b-28 HPR400XD Auto Gas – 806160...
  • Page 348 Appendix c RobotIc APPlIcAtIoNS In this section: Components for robotic applications ..............................c-2 Torch leads .......................................c-2 Ohmic contact extension ................................c-2 Rotational mounting sleeve (optional) – 220864 ........................c-3 Leather overwrap – 024866 ...............................c-3 Robotic teaching torch (laser pointer) – 228394........................c-3 Torch and rotational mounting sleeve dimensions........................c-3 Rotational mounting sleeve clamp dimensions.........................c-4 HPR400XD Auto Gas –...
  • Page 349 Appendix C – robotiC AppliCAtions components for robotic applications torch leads The torch leads listed below have been designed to withstand the added stresses found in robotic, or bevel, applications. They are available with 2 m (6 ft), or 2.5 m (8 ft) gas leads. Note: Consumable life will be reduced if the 2.5 m (8 ft) gas leads are used.
  • Page 350 Appendix C – robotiC AppliCAtions Rotational mounting sleeve (optional) – 220864 The rotational sleeve is designed for use in applications where the torch leads are twisted repeatedly. It is an optional component, and does not need to be used to use the torch leads listed above. The length of the rotational sleeve is 114.3 mm (4.5 in).
  • Page 351 Appendix C – robotiC AppliCAtions Rotational mounting sleeve clamp dimensions 73.7 mm 50.8 mm (2.9 (2.0 73.7 mm (2.9 in.) 55.9 mm (2.2 in.) 57.4 mm (2.26 in.) HPR400XD Auto Gas – 806160...
  • Page 352 Updated information about noise levels. A generic statement pointing customers to information on the Hypertherm web site will be added to all Mechanized manuals over time. Added a paragraph before the bullet points with some details about moving the power supply with 3-11 a fork lift.
  • Page 353 changed Page Description of change for revision 2 (date of revision - 9/2011) 4-20 Added Torch quick disconnect receptacle graphic. Added “(for example: 30 amp O and 50 amp O processes). The pierce complete signal must be turned off for processes with shield gas preflow pressures that are lower than the cutflow pressures (for example: 600 amp and 800 amp processes).”...
  • Page 354 All sheets updated from revision C to revision E. Appendix A Updated to the latest information and formatting for the Hypertherm torch coolant data (MSDS) Added the secondary error code ID numbers after the primary error code ID number, for all Appendix B applicable error codes.
  • Page 355 HPR400XD Auto Gas – 806160...

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