Hypertherm HyPerformance Plasma HPR800XD Manuals

Manuals and User Guides for Hypertherm HyPerformance Plasma HPR800XD. We have 4 Hypertherm HyPerformance Plasma HPR800XD manuals available for free PDF download: Instruction Manual, Manual, Field Service Bulletin

Hypertherm HyPerformance Plasma HPR800XD Instruction Manual (366 pages)

Auto Gas, Plasma Cutting System

Brand: Hypertherm | Category: Cutter | Size: 48 MB

Table of Contents

9
- Electromagnetic Compatibility (Emc)
  5
- Warranty
  7
  - Table of Contents
    9
Table of Contents

15
- Safety
  18
Section 2 Specifications

25
- Specifications
  25
  - System Description
    27
    
    Chiller
    27
    
    Chiller Interface Console
    27
    
    General
    27
    
    Ignition Console
    27
    
    Metering Console
    27
    
    Power Supplies
    27
    
    Selection Console
    27
    
    Torch
    27
  - Specifications
    28
    
    System Gas Requirements
    28
    
    General
    29
    
    Power Supplies
    29
    
    Chiller
    30
    
    Chiller Interface Console - 078537
    31
    
    Ignition Console - 078536
    32
  - Torch Lead Junction Box (Optional) - 078619
    34
    
    Selection Console - 078533
    35
    
    Metering Console - 078535
    36
    
    Torch - 228599
    37
  - IEC Symbols
    38
  - Symbols and Marks
    39
Section 3 Installation

41
- Installation
  41
  - Section 3 Installation
    41
  - Upon Receipt
    43
  - Claims
    43
  - Installation Requirements
    43
  - Noise Levels
    43
  - Placement of System Components
    43
  - Installation Requirements
    44
    
    Cables and Hoses
    45
    
    Customer-Supplied Power Cables
    45
    
    Supply Gas Hoses
    45
    
    System Components
    45
  - Recommended Grounding and Shielding Practices
    46
  - Introduction
    46
    
    Grounding Practices
    46
    
    Types of Grounding
    46
    
    Grounding Diagram
    49
  - Placement of the Primary Power Supply
    51
  - Placement of the Secondary Power Supply
    52
    
    Lifting the Power Supply
    53
  - Install the Ignition Console
    55
  - Placement of the Chiller
    57
  - Install the Chiller Interface Console
    58
  - Install the Metering Console
    59
  - Placement of the Selection Console
    60
  - Primary Power Supply to Secondary Power Supply Cables
    61
    
    Interface (On/Off) Cable
    61
    
    Communication Cable
    62
  - Power Supply to Ignition Console Leads
    63
    
    Negative Leads
    63
    
    Pilot Arc Lead
    63
    
    Coolant Hose Set (Chiller to Chiller-Interface Console)
    66
    
    Coolant Hose Set (Chiller-Interface Console to Ignition Console)
    67
  - Primary Power Supply to Chiller Interface Console
    68
    
    Chiller Interface Power Cable
    68
  - Secondary Power Supply to Chiller Interface Console
    69
    
    Chiller Interface Communication Cable
    69
  - Primary Power Supply to Selection Console Cables
    70
    
    Selection Console Communication Cable
    70
    
    Selection Console Power Cable
    70
  - Selection Console to Metering Console Hose and Lead Assembly
    72
    
    Cable and Gas Hose Assembly
    72
  - Power Supply to CNC Interface Cable
    74
    
    Optional Multi-System CNC Interface Cable
    74
    
    Examples of Output Circuits
    76
    
    Examples of Input Circuits
    77
  - Remote ON/OFF Switch (Provided by Customer)
    78
  - Torch Lead Assembly
    79
  - Torch Lead Junction Box (Optional)
    80
    
    Install the Junction Box
    81
    
    Connect the Leads
    82
  - Work Lead
    86
  - Torch Connections
    87
    
    Connect the Torch to the Torch Lead Assembly
    87
    
    Connect the Torch to the Quick-Disconnect
    91
  - Torch Mounting and Alignment
    92
    
    Mounting the Torch
    92
    
    Torch Alignment
    92
  - Torch Lifter Requirement
    93
  - Hypernet
    93
    
    General
    94
    
    Line Disconnect Switch
    95
  - Main Power Cable (Power Supplies)
    95
  - Main Power Cable (Chiller)
    95
  - Connect the Power
    96
  - Torch Coolant Requirements
    97
    
    Premixed Coolant for Standard Operating Temperatures
    97
    
    Custom Coolant MIX for Cold Operating Temperatures
    98
    
    Custom Coolant MIX for Hot Operating Temperatures
    99
  - Water Purity Requirements
    99
  - Fill the Chiller with Coolant
    100
  - Gas Requirements
    101
    
    Setting the Supply Regulators
    101
  - Gas Regulators
    102
  - Supply Gas Plumbing
    103
    
    Connect the Supply Gases
    104
  - Supply Gas Hoses
    105
Section 4 Operation

107
- Operation
  107
  - Daily Start-Up
    109
    
    Check Torch
    109
  - Power Indicators
    110
    
    Chiller Interface Console
    110
    
    General
    110
    
    Metering Console
    110
    
    Power Supply
    110
    
    Selection Console
    110
  - CNC Controller Requirements
    111
  - CNC Screen Examples
    112
    
    Main (Control) Screen
    112
    
    Diagnostic Screen
    113
    
    Test Screen
    114
    
    Cut Chart Screen
    115
  - Consumable Selection
    116
    
    Bevel Cutting (0° to 45°)
    116
    
    Consumables for Mirror-Image Cutting
    116
    
    Marking
    116
    
    Powerpierce Technology
    116
    
    Silverplus Electrodes
    116
    
    Standard Cutting (0°)
    116
    
    Mild Steel
    117
    
    Stainless Steel
    118
    
    Aluminum
    119
    
    Mild Steel Bevel Cutting
    120
    
    Mild Steel, Thick Piercing, Bevel Cutting
    120
    
    Stainless Steel Bevel Cutting
    121
  - Install and Inspect Consumables
    122
  - Torch Maintenance
    125
    
    Maintenance Kit
    125
    
    Quick-Disconnect Maintenance
    125
    
    Routine Maintenance
    125
  - Torch Connections
    126
  - Replace Torch Water Tube
    126
  - Common Cutting Faults
    127
  - How to Optimize Cut Quality
    128
    
    Maximize the Life of Consumable Parts
    128
    
    Plasma Set-Up Tips
    128
    
    Tips for Table and Torch
    128
    
    Additional Factors of Cut Quality
    129
    
    Additional Improvements
    131
  - Cut Charts
    132
  - Thin Stainless Steel with Hdi Technology
    132
    
    Overview
    132
  - Thick Stainless Steel Piercing Technique
    133
    
    Overview
    133
  - Fine Feature Cutting
    135
    
    Overview
    135
    
    Recommendations
    135
  - Bevel Cutting
    136
    
    Bevel Compensation Tables
    136
    
    Consumables
    136
  - Bevel Cutting Definitions
    137
    
    Cutting Thick Material
    138
    
    Overview
    139
    
    Underwater Cut Charts
    139
    
    Estimated Kerf-Width Compensation
    141
Section 5 Maintenance

215
Section 6 Parts List

271
- Parts List
  
  271
  - Power Supply
    272
  - Chiller
    276
  - Chiller Interface Console
    277
  - Ignition Console
    278
  - Torch Lead Junction Box (Optional)
    279
    
    Ignition Console to Junction Box Leads
    280
  - Metering Console
    283
  - Hyperformance Torch
    284
    
    Torch Assembly
    284
    
    Ohmic Contact Wire
    285
    
    Torch Leads
    285
  - Consumable Parts Kits
    286
  - Consumable Parts Kits
    288
  - Consumables for Mirror-Image Cutting
    289
    
    Straight Cutting
    289
    
    Bevel Cutting
    291
  - Recommended Spare Parts
    293
    
    Warning Label - 110647
    296
- Wiring Diagrams
  
  297
  - Discrete Output Functionality
    300
- Appendix A Hypertherm Torch Coolant Safety Data
  
  325
  - Identification of the Substance/Mixture and of the Company Undertaking
    326
  - Composition/Information on Ingredients
    327
  - Handling and Storage
    328
  - Stability and Reactivity
    329
  - Disposal Considerations
    330
  - Other Information
    331
  - Freezing Point of Propylene Glycol Solution
    332
    
    Checksum
    333
- Appendix B Interface Hardware
  
  334
  - Hardware
    335
  - Multi-Drop Wiring
    336
  - Multi-Drop Addressing
    337
  - Command Table (1 of 14)
    338
    
    Error Responses
    352
    
    Error Codes
    353
  - Status Codes
    357
  - CNC Requirements
    358
  - Serial Interface Guidelines
    359
- Appendix C Robotic Applications
  
  361
  - Components for Robotic Applications
    362
    
    Rotational Mounting Sleeve (Optional) – 220864
    363
    
    Rotational Mounting Sleeve Clamp Dimensions
    364
- HPR800XD Auto Gas Revision Changes (806500)
  
  365

Hypertherm HyPerformance Plasma HPR800XD Instruction Manual (33 pages)

Brand: Hypertherm | Category: Welding System | Size: 6 MB

Table of Contents
7
Preventive Maintenance Program
9
Overview
9
Cleaning and Inspection Schedule
10
- Daily
  11
- Weekly
  13
- Monthly
  14
  - Clean Inside the Power Supply
    14
  - Clean the Chiller Air Filter
    14
  - Clean Inside the Chiller
    15
  - Examine the Coolant System
    15
  - Examine the Main Contactor
    16
  - Examine the Pilot Arc Relay
    16
  - Do the Coolant Flow Test
    16
  - Examine the Gas Line Connections
    17
  - Examine the Hoses
    17
  - Examine the Cables
    17
  - Examine the Ground Connections
    17
  - Examine the Table-To-Workpiece Connection
    17
Component Replacement Schedule
18
- Cutting Area and Operation Effects
  21
  - External Cutting Area
    21
  - Incoming Air Supply Quality
    22
  - Metal Dust Inside the Power Supply Cabinet
    22
  - Consumable Use
    23
  - Cut-Cycle Time
    24
Find Arc Hour Data on a Hypertherm CNC
25
Part Numbers for HPR800XD Auto Gas Cables and Leads
26
- Primary Power Supply to Secondary Power Supply Cables
  26
  - Interface Cable
    26
  - Communication Cable
    26
- Power Supply to Ignition Console Leads
  26
  - Pilot Arc Lead
    26
  - Negative Lead
    26
  - Ignition Console Power Cable
    27
- Coolant Hoses
  27
  - Chiller-Interface Console to Ignition Console
    27
  - Chiller to Chiller-Interface Console
    27
- Power Supply to Chiller Cables
  27
  - Control Cable
    27
  - Power Cable
    27
- Power Supply to Selection Console Cables
  28
  - Control Cable
    28
  - Power Cable
    28
- Cable and Gas Hose Assembly (Selection Console to Metering Console)
  28
- Power Supply to CNC Interface Cable
  28
- Torch Lead
  29
- Work Lead
  29
- Ohmic Contact Wire
  29
- Supply Gas Hoses
  30
  - Air Hose
    30
  - Argon-Hydrogen (H35) or Nitrogen-Hydrogen (F5) Hose
    30
  - Nitrogen or Argon Hose
    30
  - Oxygen Hose
    30
System Information
31
- Model Number
  31
- Serial Number
  31
- System Voltage
  31
- Coolant Requirements
  31
Notes
32
Maintenance Log for HPR800XD Auto Gas Plasma Systems
33

Hypertherm HyPerformance Plasma HPR800XD Manual (17 pages)

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Brand: Hypertherm | Category: Cutter | Size: 0 MB

Hypertherm HyPerformance Plasma HPR800XD Field Service Bulletin (8 pages)

Snubber Board Replacement

Brand: Hypertherm | Category: Welding System | Size: 1 MB

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Table of Contents

Table of Contents

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Section 4 Operation

Section 5 Maintenance

Section 6 Parts List

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