Hypertherm HyPerformance HPR400XD Manuals

Manuals and User Guides for Hypertherm HyPerformance HPR400XD. We have 3 Hypertherm HyPerformance HPR400XD manuals available for free PDF download: Instruction Manual, Manual

Hypertherm HyPerformance HPR400XD Instruction Manual (355 pages)

Brand: Hypertherm | Category: Welding System | Size: 40.05 MB

Table of Contents

9
Section 2 Specifications

25
- Specifications
  25
- Cooler
  27
- General
  27
- Ignition Console
  27
- Metering Console
  27
- Power Supply
  27
- Selection Console
  27
- System Description
  27
- Torch
  27
- Specifications
  28
- System Gas Requirements
  28
- Power Supply
  29
- Cooler - 078531
  30
- Ignition Console - 078172
  31
- Torch Lead Junction Box (Optional) - 078619
  33
- Selection Console - 078533
  34
- Metering Console - 078535
  35
- Torch - 228354
  36
- IEC Symbols
  37
- Symbols and Marks
  38
Section 3 Installation

39
- Installation
  39
- Claims
  41
- Installation Requirements
  41
- Noise Levels
  41
- Placement of System Components
  41
- Torque Specifications
  41
- Upon Receipt
  41
- Installation Requirements
  42
- Cables and Hoses
  43
- Customer-Supplied Power Cable
  43
- Supply Gas Hoses
  43
- System Components
  43
- Grounding Practices
  44
- Introduction
  44
- Recommended Grounding and Shielding Practices
  44
- Types of Grounding
  44
- Grounding Diagram
  47
- Placement of the Power Supply
  49
- Lifting the Power Supply
  50
- Install the Ignition Console
  52
- Placement of the Cooler
  54
- Install the Metering Console
  55
- Placement of the Selection Console
  56
- Negative Lead
  58
- Pilot Arc Lead
  58
- Power Supply to Ignition Console Leads
  58
- Ignition Console Power Cable
  60
- Coolant Hoses
  61
- Control Cable
  62
- Power Cable
  62
- Power Supply to Cooler Cables
  62
- Control Cable
  64
- Power Cable
  64
- Power Supply to Selection Console Cables
  64
- Cable and Gas Hose Assembly
  66
- Selection Console to Metering Console Connections
  66
- Optional Multi-System CNC Interface Cable
  68
- Power Supply to CNC Interface Cable
  68
- Notes to CNC Interface Cable Run List
  69
- Examples of Output Circuits
  70
- Examples of Input Circuits
  71
- Remote ON/OFF Switch (Provided by Customer)
  72
- Torch Lead Assembly
  73
- Torch Lead Junction Box (Optional)
  74
- Install the Junction Box
  75
- Connect the Leads
  76
- Work Lead
  80
- Connect the Torch to the Torch Lead Assembly
  81
- Torch Connections
  81
- Connect the Torch to the Quick-Disconnect
  85
- Mounting the Torch
  86
- Torch Alignment
  86
- Torch Mounting and Alignment
  86
- Hypernet
  87
- Torch Lifter Requirement
  87
- General
  88
- Power Requirements
  88
- Line Disconnect Switch
  89
- Main Power Cable
  89
- Connect the Power
  90
- Premixed Coolant for Standard Operating Temperatures
  91
- Torch Coolant Requirements
  91
- Custom Coolant MIX for Cold Operating Temperatures
  93
- Custom Coolant MIX for Hot Operating Temperatures
  93
- Water Purity Requirements
  93
- Fill the Cooler with Coolant
  94
- Gas Requirements
  95
- Setting the Supply Regulators
  95
- Gas Regulators
  96
- Supply Gas Plumbing
  97
- Connect the Supply Gases
  98
- Supply Gas Hoses
  99
Section 4 Operation

101
- Operation
  101
- Check Torch
  103
- Daily Start-Up
  103
- General
  104
- Metering Console
  104
- Power Indicators
  104
- Power Supply
  104
- Selection Console
  104
- CNC Controller Requirements
  105
- CNC Screen Examples
  106
- Main (Control) Screen
  106
- Diagnostic Screen
  107
- Test Screen
  108
- Cut Chart Screen
  109
- Bevel Cutting (0° to 45°)
  110
- Consumable Selection
  110
- Consumables for Mirror-Image Cutting
  110
- Marking
  110
- Silverplus Electrodes
  110
- Standard Cutting (0°)
  110
- Mild Steel
  111
- Stainless Steel
  112
- Aluminum
  113
- Mild Steel Bevel Cutting
  114
- Mild Steel, Thick Piercing, Bevel Cutting
  114
- Stainless Steel Bevel Cutting
  115
- Install and Inspect Consumables
  116
- Maintenance Kit
  119
- Quick-Disconnect Maintenance
  119
- Routine Maintenance
  119
- Torch Maintenance
  119
- Replace Torch Water Tube
  120
- Torch Connections
  120
- Common Cutting Faults
  121
- How to Optimize Cut Quality
  122
- Maximize the Life of Consumable Parts
  122
- Plasma Set-Up Tips
  122
- Tips for Table and Torch
  122
- Additional Factors of Cut Quality
  123
- Additional Improvements
  125
- Cut Charts
  126
- Overview
  126
- Thin Stainless Steel with Hdi Technology
  126
- Overview
  127
- Thick Stainless Steel Piercing Technique
  127
- Fine Feature Cutting
  129
- Overview
  129
- Bevel Compensation Tables
  130
- Bevel Cutting
  130
- Consumables
  130
- Bevel Cutting Definitions
  131
- Overview
  132
- Underwater Cut Charts
  132
- Estimated Kerf-Width Compensation
  134
Section 5 Maintenance

198
Section 6 Parts List

260
- Power Supply
  261
- Cooler
  265
- Ignition Console
  267
- Torch Lead Junction Box (Optional)
  268
- Ignition Console to Junction Box Leads
  269
- Selection Console
  270
- Metering Console
  272
- Hyperformance Torch
  273
- Torch Assembly
  273
- Ohmic Contact Wire
  274
- Torch Leads
  274
- Consumable Parts Kits
  275
- Consumables for Mirror-Image Cutting
  277
- Mild Steel
  277
- Straight Cutting
  277
- Bevel Cutting
  279
- Recommended Spare Parts
  281
- Warning Label - 110647
  283
Appendix B Cnc Interface Protocol

320
- Interface Hardware
  321
- Signal List
  321
- Signals
  321
- Hardware
  322
- Commands
  324
- Format
  324
- Framing
  324
- Multi-Drop Addressing
  324
- Serial Commands
  324
- Command Table (1
  325
- Calculating Checksums
  339
- Error Responses
  339
- Error Codes
  340
- Gas Type Codes
  344
- Status Codes
  344
- Auto Gas Console
  345
- CNC Requirements
  345
- Cable Shielding
  346
- Checksum
  346
- Message Retries
  346
- Serial Interface Guidelines
  346

Hypertherm HyPerformance HPR400XD Instruction Manual (283 pages)

Brand: Hypertherm | Category: Cutter | Size: 25.64 MB

English

10
- Electromagnetic Compatibility (EMC
  
  5
- Warranty
  
  7
  - Table of Contents
    10
- Safety
  
  17
Français

28
- Sécurité
  28
Español

39
- Seguridad
  
  39
- Specifications
  
  50
  - Section 2 SPECIFICATIONS
    50
  - System Description
    52
    
    General
    52
    
    Power Supply
    52
    
    Cooler
    52
    
    Ignition Console
    52
    
    Gas Console
    52
    
    Off-Valve
    52
    
    Torch
    52
  - Specifications
    53
    
    System Gas Requirements
    53
    
    Power Supply
    54
    
    Cooler - 078531
    55
    
    Ignition Console - 078172
    56
    
    Gas Console - 078532
    58
    
    Off-Valve - 078534
    59
    
    Torch - 228354
    60
- Installation
  
  61
  - Section 3 INSTALLATION
    61
  - Upon Receipt
    63
  - Claims
    63
  - Installation Requirements
    63
  - Noise Levels
    63
  - Placement of System Components
    63
    
    Torque Specifications
    63
  - Installation Requirements
    64
    
    System Components
    65
    
    Cables and Hoses
    65
    
    Supply Gas Hoses
    65
    
    Customer Supplied Power Cable
    65
  - Recommended Grounding and Shielding Practices
    66
  - Introduction
    66
    
    Types of Grounding
    66
    
    Steps to Take
    67
    
    Grounding Diagram
    70
    
    Placement of the Power Supply
    71
    
    Lifting the Power Supply
    72
    
    Install the Ignition Console
    74
    
    Placement of the Cooler
    76
  - Power Supply to Ignition Console Leads
    80
    
    Pilot Arc Lead
    80
    
    Negative Lead
    80
    
    Ignition Console Power Cable
    82
  - Coolant Hoses
    83
  - Power Supply to Cooler Cables
    84
    
    Control Cable
    84
    
    Power Cable
    84
  - Power Supply to Gas Console Cables
    86
    
    Control Cable
    86
    
    Power Cable
    86
  - Gas Console to Off-Valve Connections
    88
    
    Cable and Gas Hose Assembly
    88
    
    Gas Console to Off-Valve Cable
    88
    
    Off-Valve Cable
    88
  - Power Supply to CNC Interface Cable
    90
    
    Optional Multi-System CNC Interface Cable
    90
    
    Notes to CNC Interface Cable Run List
    91
    
    Examples of Output Circuits
    92
    
    Examples of Input Circuits
    93
  - Remote On/Off Switch
    94
  - Torch Lead Assembly
    95
  - Work Lead
    96
  - Torch Connections
    97
    
    Connect the Torch to the Torch Lead Assembly
    97
    
    Connect the Torch to the Quick-Disconnect
    101
  - Torch Mounting and Alignment
    102
    
    Mounting the Torch
    102
    
    Torch Alignment
    102
  - Torch Lifter Requirement
    102
  - Power Requirements
    103
    
    General
    103
    
    Line Disconnect Switch
    103
    
    Power Cable
    103
  - Connect the Power
    104
  - Torch Coolant Requirements
    105
  - Water Purity Requirements
    107
  - Gas Requirements
    109
    
    Setting the Supply Regulators
    109
  - Gas Regulators
    110
  - Supply Gas Plumbing
    111
    
    Connect the Supply Gases
    112
  - Supply Gas Hoses
    113
- Operation
  
  114
  - Section 4 OPERATION
    114
  - Daily Start-Up
    115
    
    Check Torch
    115
  - Controls and Indicators
    116
    
    General
    116
    
    Main Power Switch
    116
    
    Power Indicators
    116
    
    Manual Gas Console Operation
    117
  - Consumable Selection
    118
    
    Standard Cutting
    118
    
    Bevel Cuting
    118
    
    Marking
    118
    
    Consumables for Mirror-Image Cutting
    118
    
    Silverplus Electrodes
    118
    
    Mild Steel
    119
    
    Stainless Steel
    120
    
    Aluminum
    121
    
    Mild Steel Bevel Cutting
    122
    
    Stainless Steel Bevel Cutting
    122
  - Install and Inspect Consumables
    123
  - Torch Maintenance
    125
  - Torch Connections
    126
  - Replace Torch Water Tube
    126
  - Common Cutting Faults
    127
  - How to Optimize Cut Quality
    128
    
    Tips for Table and Torch
    128
    
    Plasma Set-Up Tips
    128
    
    Maximize the Life of Consumable Parts
    128
    
    Additional Factors of Cut Quality
    129
    
    Additional Improvements
    130
  - Cut Charts
    131
    
    Bevel Cut Charts
    131
  - Bevel Cutting Definitions
    132
  - Estimated Kerf-Width Compensation
    133
- Maintenance
  
  171
  - Section 5 MAINTENANCE
    171
  - Introduction
    173
  - Routine Maintenance
    173
  - System Description
    174
    
    Control and Signal Cables
    174
  - Sequence of Operation
    175
  - Gas System Purge Cycle
    176
  - Gas System Valve Usage
    176
    
    Marking Process
    178
  - Error Codes
    179
    
    Error Code Troubleshooting - 1 of 16
    180
    
    Error Code Troubleshooting - 2 of 16
    181
    
    Error Code Troubleshooting - 3 of 16
    182
    
    Error Code Troubleshooting - 4 of 16
    183
    
    Error Code Troubleshooting - 5 of 16
    184
    
    Error Code Troubleshooting - 6 of 16
    185
    
    Error Code Troubleshooting - 7 of 16
    186
    
    Error Code Troubleshooting - 8 of 16
    187
    
    Error Code Troubleshooting - 9 of 16
    188
    
    Error Code Troubleshooting - 10 of 16
    189
    
    Error Code Troubleshooting - 11 of 16
    190
    
    Error Code Troubleshooting - 12 of 16
    191
    
    Error Code Troubleshooting - 13 of 16
    192
    
    Error Code Troubleshooting - 14 of 16
    193
    
    Error Code Troubleshooting - 15 of 16
    194
    
    Error Code Troubleshooting - 16 of 16
    195
  - Power Supply States
    196
  - Plasma System Operation with Pump Time-Out
    197
  - CNC Operation with Pump Time-Out
    198
  - Initial Checks
    199
  - Power Measurement
    200
  - Air Filter Element Replacement
    201
  - Coolant System Servicing
    202
    
    Draining the Coolant System
    202
  - Coolant System Filter
    203
    
    Filter Replacement
    203
  - Coolant Flow Tests
    205
    
    Before Testing
    205
    
    Bypass Valve Verification
    206
    
    Using the Hypertherm Flow Meter (128933)
    206
    
    Manual Pump Operation
    207
    
    Test 1 - Return Line
    208
    
    Test 2 - Supply Line at Ignition Console
    208
    
    Test 3 - Change the Torch
    209
    
    Test 4 - Supply Line to the Torch Receptacle
    209
    
    Test 5 - Return Line from the Torch Receptacle
    209
    
    Test 6 - Bucket Test at the Pump
    210
    
    Pump and Motor Troubleshooting
    211
    
    Testing the Flow Sensor
    211
  - Gas Leak Tests
    212
  - Power Supply Control Board PCB3
    213
  - Power Supply Power Distribution Board PCB2
    214
  - Start Circuit PCB1
    215
    
    Operation
    215
    
    Start Circuit Functional Schematic
    215
    
    Start Circuit Troubleshooting
    215
    
    Pilot Arc Current Levels
    217
  - Pump Motor Drive Board PCB7
    218
  - Cooler Power Distribution Board PCB1
    219
  - Cooler Sensor Board PCB2
    220
  - Gas Console Control Board PCB2
    221
  - Gas Console Power Distribution Board PCB1
    222
  - Gas Console AC Valve-Driver Board PCB3
    223
  - Chopper Tests
    224
  - Phase-Loss Detection Test
    226
  - Torch Lead Test
    227
  - Preventive Maintenance
    228
  - Cooling System
    229
  - Power Supply
    232
  - Section 6 PARTS LIST
    235
  - Power Supply
    236
  - Cooler
    240
  - Ignition Console
    242
  - Gas Console
    243
  - Off-Valve
    244
  - Hyperformance Torch
    245
    
    Torch Assembly
    245
    
    Torch Leads
    245
  - Consumables for Mirror-Image Cutting
    248
  - Recommended Spare Parts
    249
- Wiring Diagrams
  
  251
  - Introduction
    251
  - Section 7 WIRING DIAGRAMS
    251
- Appendix A BENZOTRIAZOLE / PROPYLENE GLYCOL SAFETY DATA
  
  275
  - Section 1 Chemical Product and Company Identification
    275
  - Section 2 Composition / Information on Ingredients
    275
  - Section 3 Hazards Identification
    275
  - Chemical Product and Company Identification
    275
  - Information on Ingredients
    275
  - Hazards Identification
    275
  - Section 4 First Aid Measures
    276
  - Section 5 Fire Fighting Measures
    276
  - Section 6 Accidental Release Measures
    276
  - Section 7 Handling and Storage
    276
  - First Aid Measures
    276
  - Fire Fighting Measures
    276
  - Accidental Release Measures
    276
  - Handling and Storage
    276
  - Section 8 Exposure Controls / Personal Protection
    277
  - Section 9 Physical and Chemical Properties
    277
  - Section 10 Stability and Reactivity
    277
  - Section 11 Toxicological Information
    277
  - Exposure Controls / Personal Protection
    277
  - Physical and Chemical Properties
    277
  - Stability and Reactivity
    277
  - Toxicological Information
    277
  - Section 12 Ecological Information
    278
  - Section 13 Disposal Considerations
    278
  - Section 14 Transport Information
    278
  - Section 15 Regulatory Information
    278
  - Section 16 Other Information
    278
  - Ecological Information
    278
  - Disposal Considerations
    278
  - Transport Information
    278
  - Regulatory Information
    278
  - Other Information
    278
  - Freezing Point of Propylene Glycol Solution
    279
- Functional Description of Software
  
  280

Hypertherm HyPerformance HPR400XD Manual (17 pages)

plasma cutting systems

Brand: Hypertherm | Category: Cutter | Size: 0.52 MB

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Hypertherm HyPerformance HPR400XD Manuals

Hypertherm HyPerformance HPR400XD Instruction Manual (355 pages)

Table of Contents

Table of Contents

Section 2 Specifications

Section 3 Installation

Section 4 Operation

Section 5 Maintenance

Section 6 Parts List

Appendix B Cnc Interface Protocol

Hypertherm HyPerformance HPR400XD Instruction Manual (283 pages)

Table of Contents

English

Electromagnetic Compatibility (EMC

Warranty

Safety

Français

Español

Seguridad

Specifications

Installation

Operation

Maintenance

Wiring Diagrams

Appendix A BENZOTRIAZOLE / PROPYLENE GLYCOL SAFETY DATA

Functional Description of Software

Hypertherm HyPerformance HPR400XD Manual (17 pages)

Table of Contents

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