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Hypertherm 

Plasma Systems

1-1

8-06

Section 1

SAFETY

In this section:

Recognize safety information ...................................................................................................................................1-2

Follow safety instructions..........................................................................................................................................1-2

Cutting can cause fire or explosion...........................................................................................................................1-2

Electric shock can kill................................................................................................................................................1-3

Static electricity can damage circuit boards..............................................................................................................1-3

Toxic fumes can cause injury or death......................................................................................................................1-4

A plasma arc can cause injury and burns .................................................................................................................1-5

Arc rays can burn eyes and skin...............................................................................................................................1-5

Grounding safety ......................................................................................................................................................1-5

Compressed gas equipment safety ..........................................................................................................................1-6

Gas cylinders can explode if damaged .....................................................................................................................1-6

Noise can damage hearing .......................................................................................................................................1-6

Pacemaker and hearing aid operation ......................................................................................................................1-6

A plasma arc can damage frozen pipes....................................................................................................................1-6

Additional safety information.....................................................................................................................................1-6

Warning labels ..........................................................................................................................................................1-7

Summary of Contents for HPR130

Page 1: ...Manual gas Instruction manual 804570 Revision 6 HyPerformance Plasma HPR130 ...

Page 2: ...______________________________________ ___________________________________________________________________ ___________________________________________________________________ Maintenance notes ________________________________________________________________________ ________________________________________________________________________ _____________________________________________________________...

Page 3: ...on 6 April 2008 Copyright 2008 Hypertherm Inc All Rights Reserved Hypertherm HyPerformance HyDefinition LongLife and Command THC are trademarks of Hypertherm Inc and may be registered in the United States and or other countries Hypertherm Inc Hanover NH USA www hypertherm com ...

Page 4: ...ai Trading Co Ltd Unit 1308 09 Careri Building 432 West Huai Hai Road Shanghai 200052 PR China 86 21 5258 3330 1 Tel 86 21 5258 3332 Fax Hypertherm Branch of Hypertherm UK UC PO Box 244 Wigan Lancashire England WN8 7WU 00 800 3324 9737 Tel 00 800 4973 7329 Fax 00 800 4973 7843 Technical Service France Representative office 15 Impasse des Rosiers 95610 Eragny France 00 800 3324 9737 Tel 00 800 4973...

Page 5: ...ser shall ensure that other equipment being used in the environment is compatible This may require additional protection measures h Time of day that cutting or other activities are to be carried out 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 surrounding area may extend beyond the boundaries of the pr...

Page 6: ...s where direct connection is not permitted the bonding should be achieved by suitable capacitances selected according to national regulations Note the cutting circuit may or may not be earthed for safety reasons Changing the earthing arrangements should only be authorized by a person who is competent to assess whether the changes will increase the risk of injury for example by allowing parallel cu...

Page 7: ...s OEMs may offer different or additional warranties but Distributors OEMs are not authorized to give any additional warranty protection to you or make any representation to you purporting to be binding upon Hypertherm Certification test marks Certified products are identified by one or more certification test marks from accredited testing laboratories The certification test marks are located on or...

Page 8: ...te to defend and to hold Hypertherm harmless in the event of any cause of action arising from the use of the Products National and Local codes National and Local codes governing plumbing and electrical installation shall take precedent over any instructions contained in this manual In no event shall Hypertherm be liable for injury to persons or property damage by reason of any code violation or po...

Page 9: ... peuvent être fatals 1a 3 L électricité statique peut endommager les cartes de circuits imprimés 1a 3 Les vapeurs toxiques peuvent provoquer des blessures ou la mort 1a 4 L arc plasma peut provoquer des blessures ou des brûlures 1a 5 Les rayons de l arc peuvent brûler les yeux et la peau 1a 5 Mise à la masse et à la terre 1a 5 Sécurité des bouteilles de gaz comprimé 1a 6 Les bouteilles de gaz comp...

Page 10: ...requirements 2 4 Power supply 2 5 Ignition console 078172 2 6 Gas consol 078170 2 8 Off valve 129816 2 9 Torch 128818 2 10 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 po...

Page 11: ...ork lead 3 30 Torch connections 3 31 Connect the torch to the torch lead assembly 3 31 Connect the torch to the quick disconnect 3 34 Torch mounting and alignment 3 35 Mounting the torch 3 35 Torch alignment 3 35 Torch lifter requirement 3 35 Power requirements 3 36 General 3 36 Line disconnect switch 3 36 Power cable 3 36 Connect the power 3 37 Torch coolant requirements 3 38 Standard installatio...

Page 12: ... quality 4 28 Tips for table and torch 4 28 Plasma set up tips 4 28 Maximize the life of consumable parts 4 28 Additional factors of cut quality 4 29 Additional improvements 4 30 Section 5 MAINTENANCE 5 1 IIntroduction 5 3 Routine maintenance 5 3 System description 5 4 Control and signal cables 5 4 Sequence of operation 5 5 Gas system purge process 5 6 Gas system valve usage 5 6 PCB block diagram ...

Page 13: ...e the torch 5 32 Test 4 supply line to the torch receptacle 5 32 Test 5 return line from the torch receptacle 5 32 Test 6 bucket test at the pump 5 33 Test 7 bypass the check valve 5 33 Pump and motor troubleshooting 5 34 Testing the flow switch 5 35 Gas leak test procedure 5 36 Power supply control board PCB3 5 37 Power supply power distribution board PCB2 5 38 Start circuit PCB1 5 39 Operation 5...

Page 14: ... Section 6 Accidental Release Measures a 3 Section 7 Handling and Storage a 3 Section 8 Exposure Controls Personal Protection a 4 Section 9 Physical and Chemical Properties a 4 Section 10 Stability and Reactivity a 4 Section 11 Toxicological Information a 4 Section 12 Ecological Information a 5 Section 13 Disposal Considerations a 5 Section 14 Transport Information a 5 Section 15 Regulatory Inform...

Page 15: ...ity can damage circuit boards 1 3 Toxic fumes can cause injury or death 1 4 A plasma arc can cause injury and burns 1 5 Arc rays can burn eyes and skin 1 5 Grounding safety 1 5 Compressed gas equipment safety 1 6 Gas cylinders can explode if damaged 1 6 Noise can damage hearing 1 6 Pacemaker and hearing aid operation 1 6 A plasma arc can damage frozen pipes 1 6 Additional safety information 1 6 Wa...

Page 16: ...e the area is safe before doing any cutting Keep a fire extinguisher nearby Remove all flammables within 35 feet 10 m of the cutting area Quench hot metal or allow it to cool before handling or before letting it touch combustible materials Never cut containers with potentially flammable materials inside they must be emptied and properly cleaned first Ventilate potentially flammable atmospheres bef...

Page 17: ...AN KILL Install and ground this equipment according to the instruction manual and in accordance with national and local codes Inspect the input power cord frequently for damage or cracking of the cover Replace a damaged power cord immediately Bare wiring can kill Inspect and replace any worn or damaged torch leads Do not pick up the workpiece including the waste cutoff while you cut Leave the work...

Page 18: ...where the equipment is used and to ensure that the air quality in the workplace meets all local and national standards and regulations TOXIC FUMES CAN CAUSE INJURY OR DEATH The air quality level in any relevant workplace depends on site specific variables such as Table design wet dry underwater Material composition surface finish and composition of coatings Volume of material removed Duration of c...

Page 19: ... clothing to cover all exposed areas Cuffless trousers to prevent entry of sparks and slag Remove any combustibles such as a butane lighter or matches from your pockets before cutting Cutting area Prepare the cutting area to reduce reflection and transmission of ultraviolet light Paint walls and other surfaces with dark colors to reduce reflection Use protective screens or barriers to protect othe...

Page 20: ...drape the torch lead or work cable around your body Keep as far away from the power supply as possible PACEMAKER AND HEARING AID OPERATION ADDITIONAL SAFETY INFORMATION 1 ANSI Standard Z49 1 Safety in Welding and Cutting American Welding Society 550 LeJeune Road P O Box 351020 Miami FL 33135 2 ANSI Standard Z49 2 Fire Prevention in the Use of Cutting and Welding Processes American National Standar...

Page 21: ...sma Systems 1 7 8 99 SAFETY WARNING LABEL This warning label is affixed to some power supplies It is important that the operator and maintenance technician understand the intent of these warning symbols as described ...

Page 22: ...ing path 2 3 Wear complete body protection 3 Electric shock from torch or wiring can kill Protect yourself from electric shock 3 1 Wear insulating gloves Do not wear wet or damaged gloves 3 2 Insulate yourself from work and ground 3 3 Disconnect input plug or power before working on machine 4 Breathing cutting fumes can be hazardous to your health 4 1 Keep your head out of the fumes 4 2 Use forced...

Page 23: ... imprimés 1a 3 Les vapeurs toxiques peuvent provoquer des blessures ou la mort 1a 4 L arc plasma peut provoquer des blessures ou des brûlures 1a 5 Les rayons de l arc peuvent brûler les yeux et la peau 1a 5 Mise à la masse et à la terre 1a 5 Sécurité des bouteilles de gaz comprimé 1a 6 Les bouteilles de gaz comprimé peuvent exploser en cas de dommages 1a 6 Le bruit peut provoquer des problèmes aud...

Page 24: ... sont pas suivies correctement Prévention des incendies Avant de commencer s assurer que la zone de coupage ne présente aucun danger Conserver un extincteur à proximité Éloigner toute matière inflammable à une distance d au moins 10 m du poste de coupage Tremper le métal chaud ou le laisser refroidir avant de le manipuler ou avant de le mettre en contact avec des matériaux combustibles Ne jamais c...

Page 25: ...ructions du présent manuel et conformément aux codes électriques locaux et nationaux Inspecter fréquemment le cordon d alimentation primaire pour s assurer qu il n est ni endommagé ni fendu Remplacer immédiatement un cordon endommagé Un câble dénudé peut tuer Inspecter et remplacer les câbles de la torche qui sont usés ou endommagés Ne pas saisir la pièce à couper ni les chutes lors du coupage Lai...

Page 26: ...ux normes et réglementation locales et nationales LES VAPEURS TOXIQUES PEUVENT PROVOQUER DES BLESSURES OU LA MORT Le niveau de qualité de l air dans tout lieu de travail dépend des variables propres au site comme Type de table humide sèche sous l eau Composition du matériau fini de la surface et composition des revêtements Volume de matériau enlevé Durée du coupage ou du gougeage Dimensions volume...

Page 27: ...iter que des étincelles ou des scories puissent s y loger Avant le coupage retirer de ses poches tout objet combustible comme les briquets au butane ou les allumettes Zone de coupage Préparer la zone de coupage afin de réduire la réverbération et la transmission de la lumière ultraviolette Peindre les murs et autres surfaces de couleur sombre pour réduire la réflexion de la lumière Utiliser des éc...

Page 28: ... jamais exposer des bouteilles à une chaleur excessive aux étincelles aux scories ou aux flammes nues Ne jamais utiliser des marteaux des clés ou d autres outils pour débloquer le robinet des bouteilles Les tuyaux gelés peuvent être endommagés ou éclater si l on essaie de les dégeler avec une torche plasma LE BRUIT PEUT PROVOQUER DES PROBLÈMES AUDITIFS UN ARC PLASMA PEUT ENDOMMAGER LES TUYAUX GELÉ...

Page 29: ...curité Cette étiquette est affichée sur la source de courant Il est important que l utilisateur et le technicien de maintenance comprennent la signification des symboles de sécurité Hypertherm Systèmes plasma 1a 7 SÉCURITÉ ...

Page 30: ...eut être fatal Se protéger contre les risques de chocs électriques 3 1 Porter des gants isolants Ne pas porter de gants mouillés ou abîmés 3 2 S isoler de la surface de travail et du sol 3 3 Débrancher la prise ou la source de courant avant de manipuler l équipement 4 L inhalation des vapeurs produites par le coupage peut être dangereuse pour la santé 4 1 Garder le visage à l écart des vapeurs 4 2...

Page 31: ...las de circuito 1b 3 Humos tóxicos pueden causar lesiones o muerte 1b 4 El arco de plasma puede causar lesiones y quemaduras 1b 5 Los rayos del arco pueden producir quemaduras en los ojos y en la piel 1b 5 Seguridad de toma a tierra 1b 5 Seguridad de los equipos de gas comprimido 1b 6 Los cilindros de gas pueden explotar si están dañados 1b 6 El ruido puede deteriorar la audición 1b 6 Operación de...

Page 32: ... daños en el equipo Prevención ante el fuego Asegúrese de que el área sea segura antes de proceder a cortar Tenga a mano un extinguidor de incendios Retire todos los materiales inflamables colocándolos a por lo menos 10 metros del área de corte Remoje los metales calientes o permita que se enfríen antes de que entren en contacto con materiales combustibles Nunca corte depósitos que contengan mater...

Page 33: ... Instale este equipo y conéctelo a tierra según el manual de instrucciones y de conformidad con los códigos locales y nacionales Inspeccione el cordón de alimentación primaria con frecuencia para asegurarse de que no esté dañado ni agrietado Si el cordón de alimentación primaria está dañado reemplácelo inmediatamente Un cable pelado puede provocar la muerte Inspeccione las mangueras de la antorcha...

Page 34: ...n el lugar de trabajo cumpla con todas las normas y reglamentos locales y nacionales HUMOS TÓXICOS PUEDEN CAUSAR LESIONES O MUERTE El nivel de la calidad del aire en cualquier lugar de trabajo relevante depende en variables específicas al sitio tales como Diseño de mesa mojada seca bajo agua La composición del material el acabado de la superficie y la composición de los recubrimientos Volumen que ...

Page 35: ... chispas y escorias Retire todo material combustible de los bolsillos como encendedores a butano e inclusive cerillas antes de comenzar a cortar Área de corte Prepare el área de corte para reducir la reflexión y la transmisión de la luz ultravioleta Pinte las paredes y demás superficies con colores oscuros para reducir la reflexión Utilice pantallas o barreras protectoras para proteger a los demás...

Page 36: ...r excesivo chispas escorias o llamas No emplee nunca martillos llaves u otro tipo de herramientas para abrir de golpe la válvula del cilindro Se puede hacer daño a los tubos congelados o se los puede reventar si uno trata de descongelarlos con una antorcha por plasma EL RUIDO PUEDE DETERIORAR LA AUDICIÓN UN ARCO PLASMA PUEDE DAÑAR TUBOS CONGELADOS Los campos magnéticos producidos por las elevadas ...

Page 37: ...herida a la fuente de energía Es importante que el operador y el técnico de mantenimiento comprendan el sentido de estos símbolos de advertencia según se describen El texto numerado corresponde a los cuadros numerados de la etiqueta SEGURIDAD Hypertherm Sistemas plasma 1b 7 ...

Page 38: ...choques provocados por la antorcha o el cableado pueden ser fatales Protéjase del electrochoque 3 1 Colóquese guantes aislantes No utilice guantes dañados o mojados 3 2 Aíslese de la pieza de trabajo y de la tierra 3 3 Antes de trabajar en una máquina desconecte el enchufe de entrada o la potencia primaria 4 La inhalación de los humos provenientes del área de corte puede ser nociva para la salud 4...

Page 39: ...s section System description 2 3 General 2 3 Power supply 2 3 Ignition console 2 3 Gas console 2 3 Off valve 2 3 Torch 2 3 Specifications 2 4 System gas requirements 2 4 Power supply 2 5 Ignition console 078172 2 6 Gas console 078170 2 8 Off valve 129816 2 9 Torch 128818 2 10 ...

Page 40: ...SPECIFICATIONS 2 2 HPR130 Manual Gas Instruction Manual 5 ...

Page 41: ...ower switch located on the gas console is the main power switch for the system Power may be present at all other components when it is in the ON l position The gas console manages the selection and flow rate of all incoming gases The gas console includes motor valves solenoid valves check valves and pressure transducers The gas console also houses a relay PC board and a control PC board Off valve ...

Page 42: ...to 0 5 microns in the largest dimension and 1 particle per cubic meter of air at a Size of 0 5 to 5 0 microns in the largest dimension Water there can not be more humidity in the air than in air at 40 C 40 F Oil the concentration of oil can be no more than 0 1 mg per cubic meter of air Gas quality and pressure requirements Quality Grade Pressure 10 Flow rate O2 Oxygen 99 5 pure G 827 kPa 8 3 bar 4...

Page 43: ...er factor cosϕ 0 88 130 ADC output Cooling Forced air Class F Insulation Class H Part number AC Voltage U1 Phase Frequency Hz Amperage I1 Regulatory approval Power kW 10 U1 x I1 x 1 73 078177 200 208 3 50 60 62 60 CSA 21 5 078178 220 3 50 60 57 CSA 21 5 078179 240 3 60 52 CSA 21 5 078193 380 3 50 60 33 CCC 21 5 078180 400 3 50 60 32 CE GOST R 21 5 078182 440 3 50 60 28 CSA 21 5 078181 480 3 60 26 ...

Page 44: ... or remotely on the cutting table s bridge RHF See Installation section for details Maximum cable length from the ignition console to the torch lifter station is 20 m 65 ft Allow room to remove the top for servicing The ignition console may be mounted horizontally or vertically 9 1 kg 20 lb 283 mm 11 125 219 mm 8 625 194 mm 7 625 152 mm 6 216 mm 8 5 ...

Page 45: ...SPECIFICATIONS HPR130 Manual Gas Instruction Manual 2 7 3 Horizontal mounting Vertical mounting LHF mounting local Mounted on table RHF mounting remote ...

Page 46: ...ply to the gas console is 75 m 250 ft Maximum cable length from the gas console to the off valve assembly is 20 m 65 ft Mount the gas console on top of the power supply or near the CNC on the cutting table Allow room to open the top for servicing 359 mm 14 125 292 mm 11 5 317 mm 12 5 178 mm 7 276 mm 10 88 14 kg 31 lb ...

Page 47: ...ion is 1 8 m 6 ft Mount the off valve assembly to the torch carriage on larger tables On smaller tables it can be mounted to a bracket just above the bridge The vent hole on the manifold must be kept clear at all times A A A A 70 mm 2 75 165 mm 6 5 30 mm 1 18 4 7 mm 0 187 157 mm 6 18 76 mm 3 19 mm 0 75 1 1 kg 2 5 lb Vent hole Do not block ...

Page 48: ...28818 The outside diameter of the torch mounting sleeve is 50 8 mm 2 0 in The maximum bend radius for the torch leads is 152 4 mm 6 0 in 1 8 m 6 2 11 kg 4 65 lb 193 mm 7 59 27 mm 1 07 116 mm 4 55 51 mm 2 00 48 mm 1 89 107 mm 4 22 51 mm 2 00 57 mm 2 25 336 mm 13 21 6 ...

Page 49: ...ement of the power supply 3 11 Install the ignition console 3 12 Placement of the gas console 3 14 Install the off valve 3 15 Power supply to ignition console leads 3 16 Pilot arc lead 3 16 Negative lead 3 16 Ignition console power cable 3 18 Ignition console coolant hoses 3 19 Power supply to gas console cables 3 20 Control cable 3 20 Power cable 3 20 Gas console to off valve connections 3 22 Cab...

Page 50: ...nt 3 35 Torch lifter requirement 3 35 Power requirements 3 36 General 3 36 Line disconnect switch 3 36 Power cable 3 36 Connect the power 3 37 Torch coolant requirements 3 38 Standard installation 3 38 Coolant for cold operating temperatures 3 39 Coolant for hot operating temperatures 3 40 Water purity requirements 3 40 Fill the power supply with coolant 3 41 Gas requirements 3 42 Setting the supp...

Page 51: ...conform to national or local electrical and plumbing codes This work should be performed only by qualified licensed personnel Direct any technical questions to the nearest Hypertherm Technical Service Department listed in the front of this manual or your authorized Hypertherm distributor Noise levels Acceptable noise levels as defined by national and local codes may be exceeded by this plasma syst...

Page 52: ...INSTALLATION 3 4 HPR130 Manual Gas Instruction Manual 5 Installation requirements A B C D 1 2 3 4 5 6 7 8 9 10 11 13 E 15 16 14 12 ...

Page 53: ...onsole power cable Ignition console coolant hoses Gas control cable Gas power cable Gas console to off valve hose and lead assembly CNC interface cable Optional CNC interface cable for systems with multiple power supplies Torch lead assembly Work lead Supply gas hoses Oxygen Nitrogen Air H35 or F5 Customer supplied power cable Main power cable B 12 13 14 15 16 11 E 10 9 8 7 6 5 4 C D 3 2 1 A 6 ...

Page 54: ...supply and other systems such as the CNC controller and the motor drivers as well as the supplemental ground rod connected to the work table In the plasma circuits the ground is carried from the plasma power supply chassis to the chassis of each separate console through the interconnecting cables B The DC power or cutting current ground This is the grounding system that completes the path of the c...

Page 55: ...e for mounting the ground bus can be steel Under no circumstances should aluminum or steel hardware be used 6 AC power PE and service grounds must be connected to all equipment according to local and national codes 7 The positive negative and pilot arc leads should be bundled together for as long a distance as possible The torch lead work lead and the pilot arc nozzle leads may only be run paralle...

Page 56: ... equivalent The cable used must have a braided shield not a foil shield The shield should be connected to the chassis of the power supply and left unconnected at the other end 14 All other signals analog digital serial encoder should run in twisted pairs inside a shielded cable Connectors on these cables should have a metal housing and the shield not the drain should be connected to the metal hous...

Page 57: ...idual ground cables from the components mounted on the gantry go to the bus except those from the RHF console and the torch holder A single heavy cable then goes from the gantry ground bus to the ground bus bolted to the table Applies to systems that use a remote high frequency RHF console Component ground cables Cable to ground bus on the cutting table ...

Page 58: ...er assembly and the RHF console each require a separate path to the cutting table ground bus bar Cutting table Plasma power supply Positive DC Command THC Bus bar Bus bar Command THC RHF console Metering console Gas Selection console CNC console Grounding diagram some systems will not include all the components shown Gantry ...

Page 59: ...are when lifting so that the underside of the power supply is not damaged Place the power supply 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 Cooling air is drawn in through the front panel and is exhausted through the rear of the unit by a cooling fan Do not place a...

Page 60: ...ignition console on the gantry bridge for the RHF configuration Mount the ignition console on the power supply for the LHF configuration Allow room to remove the top for servicing B 7 mm 028 4 places 32 mm 1 25 32 mm 1 25 184 mm 7 25 279 mm 11 00 248 mm 9 75 216 mm 8 50 Ignition console grounding ...

Page 61: ...INSTALLATION HPR130 Manual Gas Instruction Manual 3 13 LHF mounting Horizontal RHF mounting Vertical RHF mounting ...

Page 62: ...ide cover for servicing Preferred orientation is shown in the figure below The maximum length of cables between the power supply and gas console is 75 m 250 ft The maximum length of cables and hoses between the gas console and the off valve assembly is 20 m 65 ft C Preferred gas console orientation 38 1 mm 1 5 314 5 mm 12 38 228 6 mm 9 0 50 8 mm 2 0 Gas console grounding ...

Page 63: ...the off valve Mount the off valve assembly near the torch lifter station The maximum length of the gas hoses between the off valve assembly and the torch is 1 8 m 6 ft D A A A A 30 mm 1 18 4 7 mm 0 187 19 mm 075 157 mm 6 18 Off valve grounding Vent hole Do not block ...

Page 64: ... 123813 4 5 m 15 ft 123664 35 m 115 ft 123662 7 5 m 25 ft 123665 45 m 150 ft 123814 10 m 35 ft 123778 60 m 200 ft 123663 15 m 50 ft 123779 75 m 250 ft Part no Length Part no Length 123683 1 5 m 5 ft 123823 20 m 65 ft 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 45 m 150 ft 123822 10 m 35 ft 123824 60 m 200 ft 123667 15 m 50 ft 123825 75 m 250 f...

Page 65: ...INSTALLATION HPR130 Manual Gas Instruction Manual 3 17 3 Pilot arc lead Negative lead Pilot arc lead Negative lead 1 2 2 1 Work lead 1 2 ...

Page 66: ... 120Vac hot 1 2 120Vac return 2 3 Ground 3 4 Not connected 4 3 Part no Length Part no Length 123865 2 1 m 7 ft 123836 20 m 65 ft 123419 3 m 10 ft 123736 25 m 82 ft 123834 4 5 m 15 ft 123672 35 m 115 ft 123670 7 5 m 25 ft 123673 45 m 150 ft 123835 10 m 35 ft 123837 60 m 200 ft 123671 15 m 50 ft 123838 75 m 250 ft Cable number 123865 is for use with systems that have the ignition console mounted on ...

Page 67: ... Length 228030 0 7 m 2 5 ft 128984 20 m 65 ft 028652 3 m 10 ft 128078 25 m 82 ft 028440 4 5 m 15 ft 028896 35 m 115 ft 028441 7 5 m 25 ft 028445 45 m 150 ft 128173 10 m 35 ft 028637 60 m 200 ft 028442 15 m 50 ft 128985 75 m 250 ft Hose set number 228030 is for use with systems that have the ignition console mounted on the power supply ...

Page 68: ... supply end Gas console end Pin I O Description Pin I O Function 1 120Vac hot 1 2 120Vac return 2 3 ground 3 4 unused 4 5 unused 5 6 24Vac hot 6 7 24Vac return 7 Part no Length Part no Length 123784 3 m 10 ft 123737 25 m 82 ft 123839 4 5 m 15 ft 123738 35 m 115 ft 123691 7 5 m 25 ft 123739 45 m 150 ft 123840 10 m 35 ft 123842 60 m 200 ft 123711 15 m 50 ft 123843 75 m 250 ft 123841 20 m 65 ft Part ...

Page 69: ...INSTALLATION HPR130 Manual Gas Instruction Manual 3 21 1X5 J103 J300 Female Male 5 6 5 6 3X1 3X2 3X3 1 ...

Page 70: ...10 Ground GND Green Yellow 11 GND 12 GND 13 GND 14 Female end at off valve Male end at gas console Cable signal list gas console to off valve cable Gas console end Off valve end Pin Description Pin 1 120Vac Hot Shield preflow 1 2 120Vac Return Shield preflow 2 3 120Vac Hot Shield cutflow 3 4 120Vac Return Shield cutflow 4 5 120Vac Hot Plasma preflow 5 6 120Vac Return Plasma preflow 6 7 120Vac Hot ...

Page 71: ...INSTALLATION HPR130 Manual Gas Instruction Manual 3 23 3 7 Green Red Black Blue Green Red Black Blue ...

Page 72: ...the CNC s pierce delay has timed out Input Red 10 Output Motion 4 E Notifies the CNC that an arc transfer has occurred and to begin Input 2 3 Yellow 29 Output Motion 4 C machine motion once the CNC s pierce delay has timed out Input Red 11 None Not used Brown 30 None Not used Red 12 Input Corner CNC Notifies the plasma system that a corner is approaching and to Output 1 Orange 31 Input Corner redu...

Page 73: ...n 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 Outputs are optically isolated open collector transistors The maximum rating is 24 VDC at 10 mA Note 3 Machine motion is selectable and is used for conf...

Page 74: ... this configuration Warranty will be void High impedance 10mA 10K optional CNC PLC 5VDC 24VDC C HPR E HPR C E 5VDC 24VDC High impedance 10mA CNC PLC 10K optional CNC PLC CNC 24V 24VDC CNC 24V HPR C E Power ground External relay 24VDC low power coil 10mA or 2400ohm High current contact closure inputs AC or DC t Any voltage VOIDS WARRANTY HPR Install a Jumper 108056 J304 C E ...

Page 75: ... HPR Power ground 2 Optocoupler interface CNC PLC 24 VDC HPR Power ground Transistor output optocoupler 12V 24VDC CNC PLC 24 VDC HPR Power ground Power ground Active high drive 3 Amplified output interface Note The external relay s life may be improved by adding a metallized polyester capacitor 0 022µF 100V or higher in parallel with the relay contacts ...

Page 76: ...INSTALLATION 3 28 HPR130 Manual Gas Instruction Manual 6 TB2 location 1 2 3 1 3 TB2 1 3 1 2 3 1 3 TB2 1 3 WARNING ELECTRIC SHOCK CAN KILL Disconnect electrical power before performing any maintenance See the Safety section in this manual for more safety precautions Remote ON OFF switch provided by customer Note Use a switch relay or solid state relay that is compatible with 24 VAC 100 mA It must b...

Page 77: ...e 10 Grey Part no Length 128986 2 m 6 ft 128935 3 m 10 ft 128934 4 5 m 15 ft 128784 7 5 m 25 ft 128987 10 m 35 ft 128785 15 m 50 ft 128988 20 m 65 ft Caution Locate the exposed end of the plasma gas vent hose away from sparks caused by piercing to avoid ignition and possible damage to the torch leads ...

Page 78: ... Lower frame of work table typical Work table Power supply Part no Length Part no Length 123661 3 m 10 ft 123734 25 m 82 ft 123813 4 5 m 15 ft 123664 35 m 115 ft 123662 7 5 m 25 ft 123665 45 m 150 ft 123814 10 m 35 ft 123778 60 m 200 ft 123663 15 m 50 ft 123779 75 m 250 ft 123815 20 m 65 ft ...

Page 79: ...orch assembly in place with the spanner wrench 104269 and remove the mounting sleeve from the torch assembly 3 Push back the braided cover and slide the sleeve over the leads Align the torch with the hoses in the lead assembly The hoses must not be twisted They are taped together to help prevent twisting 4 Connect the coolant IN hose green to the torch Braided cover Sleeve Coolant IN hose 2WRENCHE...

Page 80: ... the pilot arc lead Note Be careful not to damage or remove the small slotted metal band at the end of the pilot arc cable 5a Pull the sleeve back until the connector is exposed 5b Screw the connector onto the pilot arc connection from the torch Tighten by hand until it is firmly seated 6 Connect the plasma gas vent hose ...

Page 81: ... gas hose 10 Slide the torch sleeve over connections and screw it onto the torch body 11 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 82: ... 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 See also Torch connections earlier in this section for torch lead connections to ignition console Apply a thin film of silicone lubricant to each o ring Torch body 220162 Torch quick disconnect receptacle 220163 ...

Page 83: ...ravel The unit should have the capability of maintaining a constant speed of up to 5080 mm min 200 ipm with positive braking A unit which drifts through the stop point is not acceptable Installation 1 Install the torch with torch leads attached in the torch mounting bracket 2 Position the torch below the mounting bracket so that the bracket is around the lower portion of the torch sleeve but not t...

Page 84: ...a licensed electrician SWITCH BOX Note Cable AWG recommendations taken from table 310 16 of the National Electric Code handbook USA Power requirements General All switches slow blow fuses and power cables are customer supplied and must be chosen as outlined by applicable national or local electrical codes Installation must be performed by a licensed electrician Use a separate primary line disconne...

Page 85: ...e installation of the system 5 Connect the power cord leads to the line disconnect switch following national or local electrical codes DANGER ELECTRICAL SHOCK CAN KILL The line disconnect switch must be in the OFF position before making the power cable connections In the U S use a lock out tag out procedure until installation is complete In other countries follow appropriate national or local safe...

Page 86: ...ing and cautions below Refer to the Material Safety Data Sheets Appendix for data on safety handling and storage of propylene glycol and benzotriazole Caution Never use automotive anti freeze in place of propylene glycol Antifreeze contains corrosion inhibitors that will damage the torch coolant system Always use purified water in the coolant mixture in order to prevent damage to the pump and corr...

Page 87: ... system due to freezing Hypertherm pre mix 028872 Maximum glycol percentage F C Coolant for cold operating temperatures below 0 C 32 F Use a custom coolant mix when operating in temperatures below 0 C 32 F 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 ...

Page 88: ...cifications in the table below Contact a water specialist for advice in choosing a water filtration system Coolant for hot operating temperatures above 38 C 100 F Use a custom coolant mix when operating in temperatures above 38 C 100 F Treated water with no propylene glycol can only be used as coolant when operating temperatures are never below 0 C 32 F For operations in very warm temperatures tre...

Page 89: ...pm 0 6 gpm release the knob The display will show the current again The pump will continue to run 3 Add coolant to the power supply until the tank is full and replace the filler cap 4 Add coolant to the power supply until the tank is full 1 Press and hold the current selection knob 8 and press power switch on the gas console The pump will run continuously while 8 is pressed 2 Caution Using the wro...

Page 90: ... level of the gas is too low or too high in the case of methane or if there are leaks in the supply hoses or connections Cut speeds can decrease Cut quality can deteriorate Cutting thickness capability can decrease Parts life can shorten Setting the supply regulators 1 Turn OFF the power to the system Set all gas regulator pressures to 8 3 bar 120 psi 2 Turn ON the power to the system 3 After the ...

Page 91: ...igh quality gas regulators listed below are available from Hypertherm and meet U S Compressed Gas Association CGA specifications In other countries select gas regulators that conform to national or local codes Part Number Description Qty 128544 Kit Oxygen 2 stage 1 128545 Kit Inert Gas 2 stage 1 128546 Kit Hydrogen H5 H35 and methane 2 stage 1 128547 Kit Air 2 stage 1 128548 Kit 1 stage for use wi...

Page 92: ...asma 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 Flashback arrestors are required unless not available for specific gases or required pressures to prevent fire from propagating to supply gas Note When cutting with oxygen as the plasma gas ai...

Page 93: ...24203 4 5 m 15 ft 024451 35 m 115 ft 024134 7 5 m 25 ft 024120 45 m 150 ft 024211 10 m 35 ft 024124 60 m 200 ft 024112 15 m 50 ft 024764 75 m 250 ft 024763 20 m 65 ft Part no Length Part no Length 024671 3 m 10 ft 024740 25 m 82 ft 024658 4 5 m 15 ft 024744 35 m 115 ft 024659 7 5 m 25 ft 024678 45 m 150 ft 024765 10 m 35 ft 024680 60 m 200 ft 024660 15 m 50 ft 024767 75 m 250 ft 024766 20 m 65 ft ...

Page 94: ...bles 4 7 Cut charts 4 8 Bevel cutting 4 8 Marking 4 8 Consumables for mirror image cutting 4 8 Estimated kerf width compensation 4 9 Changing consumable parts 4 22 Remove consumables 4 22 Inspect consumables 4 23 Inspect torch 4 24 Inspect electrode pit depth 4 25 Replace torch water tube 4 26 Common cutting faults 4 27 How to optimize cut quality 4 28 Tips for table and torch 4 28 Plasma set up t...

Page 95: ... to Changing consumable parts later in this section for details and for parts inspection tables Refer to the Cut charts to choose the correct consumables for your cutting needs 3 Replace consumable parts Refer to Changing consumable parts later in this section for details 4 Ensure that the torch is perpendicular to the workpiece WARNING Before operating this system you must read the Safety section...

Page 96: ...r supply The gas console controls all system functions Error codes are shown in the LED display over the current select knob AC Green Indicator Illuminates when the power switch is in the on position On Position I AC power is sent to the control transformer to turn on the power supply Off Position O AC power is cut off to the control transformer to turn off the power supply Main power switch Power...

Page 97: ... 7 to SET CUTFLOW 5 6 Set plasma cutflow 5 Set shield cutflow 6 7 Position switch 7 to RUN 8 Position switch 8 to SET AMPS Set amperage using knob above switch 8 Switch 8 can be in any position while operating System is ready to cut The 3 digit display is for reference The current shown during cutting may vary by 2 amps from the current shown when the amperage is set Manual gas console operation T...

Page 98: ...rl ring Electrode 220179 220179 220188 220182 220183 220189 220194 220176 220176 220313 220173 Stainless steel 220201 220308 220180 45A 220339 80A 220307 130A Shield Nozzle Swirl ring Electrode 220179 220179 220337 220197 220198 220338 220202 220304 H35 220176 N2 220304 220304 220173 220552 220553 220554 220555 220313 50A Retaining cap Retaining cap Inner Retaining cap ...

Page 99: ... Manual Gas Instruction Manual Aluminum 220201 220308 220180 45A 220307 H35 220181 Air 130A Shield Nozzle Swirl ring Electrode 220179 220197 220198 220202 220176 220173 220304 H35 220176 Air Retaining cap Inner Retaining cap ...

Page 100: ...arts are seated Clean the current ring using a cotton swab with water or 3 hydrogen peroxide Tool part number 104119 Apply a thin film of silicone lubricant on each o ring Install the electrode Install the swirl ring Install the nozzle and swirl ring Install the inner retaining cap Install the shield Install the retaining cap ...

Page 101: ...n desired results Bevel cutting See Appendix C in this manual for cut charts and consumables Marking Any of the consumable sets can also be used for marking Marking parameters are shown at the bottom of each cut chart The quality of the markings will vary depending on the cut process material type and material thickness combination Marking is not possible for every combination very thin materials ...

Page 102: ...346 1 448 SS 130A H35 N2 2 718 2 769 2 896 130A N2 N2 1 829 1 879 2 413 80A F5 N2 1 194 45A F5 N2 0 584 0 381 0 533 45A N2 N2 0 483 0 229 0 152 AL 130A H35 N2 2 718 2 769 2 896 130A Air Air 2 083 2 083 2 184 45A Air Air 1 067 1 092 1 245 Thickness in Process 0 060 0 135 1 4 3 8 1 2 3 4 1 MS 130A O2 Air 0 071 0 080 0 083 0 104 0 135 80A O2 Air 0 054 0 068 0 075 50A O2 O2 0 060 0 073 0 073 30A O2 O2...

Page 103: ...14 1 3 5355 2 3 180 0 1 0 8 115 4225 0 2 1 116 3615 0 3 1 2 117 2865 1 5 119 2210 35 5 2 120 1 5 1490 2 7 0 4 2 5 122 1325 75 3 123 1160 0 5 4 125 905 0 7 6 128 665 1 0 Metric Select Gases Set Preflow Set Cutflow Material Thickness Arc Voltage Torch to Work Distance Cutting Speed Initial Pierce Height Pierce Delay Time Plasma Shield Plasma Shield Plasma Shield in Volts in ipm in factor seconds O2 ...

Page 104: ... 112 160 060 114 0 05 125 0 10 075 115 110 105 118 80 0 1 135 120 0 06 60 0 12 0 2 3 16 121 50 0 3 1 4 125 0 08 35 0 16 0 5 5 16 130 25 English Select Gases Set Preflow Set Cutflow Amperage Torch to Work Distance Marking Speed Arc Voltage Amps mm in mm min ipm Volts N2 N2 10 10 10 10 15 2 5 0 100 6350 250 118 Marking Select Gases Set Preflow Set Cutflow Material Thickness Arc Voltage Torch to Work...

Page 105: ...ght Pierce Delay Time Plasma Shield Plasma Shield Plasma Shield mm Volts mm mm m mm factor seconds O2 Air 50 30 72 30 2 112 2 5 9810 3 8 150 0 1 2 5 115 7980 3 117 6145 0 2 4 120 2 0 4300 4 0 200 6 123 3045 0 3 10 127 1810 0 5 15 12 130 1410 5 0 250 0 7 15 133 1030 0 8 20 135 2 5 545 6 3 0 9 Select Gases Set Preflow Set Cutflow Material Thickness Arc Voltage Torch to Work Distance Cutting Speed In...

Page 106: ...0 6 6 0 5 15 135 3 8 1665 7 6 0 7 65 20 138 1050 1 0 25 141 4 0 550 190 1 8 32 160 4 5 375 Edge start 38 167 255 Select Gases Set Preflow Set Cutflow Material Thickness Arc Voltage Torch to Work Distance Cutting Speed Initial Pierce Height Pierce Delay Time Plasma Shield Plasma Shield Plasma Shield in Volts in ipm in factor seconds O2 Air 35 40 80 35 135 124 0 100 240 0 200 200 0 1 3 16 126 0 110 ...

Page 107: ...sma Shield mm Volts mm mm m mm factor seconds N2 N2 35 5 55 60 0 8 94 2 5 6380 3 8 150 0 0 1 5880 0 1 1 2 5380 0 2 1 5 95 4630 2 97 3935 2 5 101 3270 3 103 2550 0 3 4 1580 Select Gases Set Preflow Set Cutflow Material Thickness Arc Voltage Torch to Work Distance Cutting Speed Initial Pierce Height Pierce Delay Time Plasma Shield Plasma Shield Plasma Shield in Volts in ipm in factor seconds N2 N2 3...

Page 108: ...m mm m mm factor seconds F5 N2 35 25 55 60 0 8 99 2 5 6570 3 8 150 0 2 1 5740 1 2 4905 1 5 3890 2 101 3175 2 5 102 2510 3 103 2010 0 3 4 104 1435 15 6 110 2 0 845 190 0 5 Select Gases Set Preflow Set Cutflow Material Thickness Arc Voltage Torch to Work Distance Cutting Speed Initial Pierce Height Pierce Delay Time Plasma Shield Plasma Shield Plasma Shield in Volts in ipm in factor seconds F5 N2 35...

Page 109: ...mm factor seconds F5 N2 35 30 60 45 4 108 3 0 2180 4 5 150 0 2 6 112 2 5 1225 3 8 0 3 10 120 3 0 560 4 5 0 5 Select Gases Set Preflow Set Cutflow Material Thickness Arc Voltage Torch to Work Distance Cutting Speed Initial Pierce Height Pierce Delay Time Plasma Shield Plasma Shield Plasma Shield in Volts in ipm in factor seconds F5 N2 35 30 60 45 135 108 0 120 105 0 180 150 0 2 3 16 110 0 110 60 0 ...

Page 110: ...Plasma Shield Plasma Shield in Volts in ipm in factor seconds N2 N2 20 65 70 30 1 4 153 0 120 75 0 240 200 0 3 3 8 156 55 0 5 1 2 162 0 140 30 0 280 0 8 5 8 167 0 150 25 Edge start 3 4 176 0 170 15 Select Gases Set Preflow Set Cutflow Material Thickness Arc Voltage Torch to Work Distance Cutting Speed Initial Pierce Height Pierce Delay Time Plasma Shield Plasma Shield Plasma Shield mm Volts mm mm ...

Page 111: ...lasma Shield Plasma Shield Plasma Shield mm Volts mm mm m mm factor seconds H35 N2 20 40 70 60 10 154 4 5 980 7 7 170 0 3 45 12 158 820 0 5 30 15 162 580 0 8 20 165 360 1 3 20 25 172 260 Edge start Select Gases Set Preflow Set Cutflow Material Thickness Arc Voltage Torch to Work Distance Cutting Speed Initial Pierce Height Pierce Delay Time Plasma Shield Plasma Shield Plasma Shield in Volts in ipm...

Page 112: ...0 3 8 150 0 2 1 5 115 4160 2 113 3865 2 5 110 3675 3 107 2850 40 4 102 1 8 2660 2 7 0 3 6 117 3 0 1695 4 5 0 6 Select Gases Set Preflow Set Cutflow Material Thickness Arc Voltage Torch to Work Distance Cutting Speed Initial Pierce Height Pierce Delay Time Plasma Shield Plasma Shield Plasma Shield in Volts in ipm in factor seconds Air Air 35 25 55 60 040 130 0 100 220 0 150 150 0 2 051 115 170 064 ...

Page 113: ...or seconds Air Air 20 40 70 30 6 153 2 8 2370 5 6 200 0 2 10 154 3 0 1465 6 0 0 3 12 156 1225 0 5 15 158 3 3 1050 6 6 0 8 20 162 3 5 725 7 0 1 3 25 172 4 0 525 N A Select Gases Set Preflow Set Cutflow Material Thickness Arc Voltage Torch to Work Distance Cutting Speed Initial Pierce Height Pierce Delay Time Plasma Shield Plasma Shield Plasma Shield in Volts in ipm in factor seconds Air Air 20 40 7...

Page 114: ... Shield mm Volts mm mm m mm factor seconds H35 N2 20 40 70 60 10 158 5 0 1615 6 5 130 0 3 45 12 156 4 5 1455 7 7 170 0 5 30 15 1305 0 8 20 157 940 1 3 20 25 176 540 Edge start Select Gases Set Preflow Set Cutflow Material Thickness Arc Voltage Torch to Work Distance Cutting Speed Initial Pierce Height Pierce Delay Time Plasma Shield Plasma Shield Plasma Shield in Volts in ipm in factor seconds H35...

Page 115: ...ing into the water of the water table 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 The torch might be hot Turn OFF all power to the system Remove the retaining ca...

Page 116: ...ode Center surface Wear O rings 1 Damage Replace electrode 2 Lubricant Apply a thin film of silicone lubricant if dry Always replace the nozzle and electrode as a set Center hole 1 Must be round Replace nozzle if hole is no longer round 2 Signs of arcing Replace nozzle O rings 1 Damage Replace nozzle 2 Lubricant Apply a thin film of silicone lubricant if dry Erosion or missing material Replace noz...

Page 117: ...ge Replace torch Bullet connectors Damage Replace torch O rings 1 Damage Replace o ring 2 Lubricant Apply a thin film of silicone lubricant if dry External o rings 1 Damage Replace o ring 2 Lubricant Apply a thin film of silicone lubricant if dry Water tube 1 Pitted or missing material Replace tube See Replace torch water tube later in this section Inspect Check for Action Inspect torch Plasma gas...

Page 118: ... Part Check for Action 10 0 20 40 30 4 0 2 3 1 80 60 70 50 90 Inspect electrode pit depth Electrode Center surface Wear Replace electrode if pit is deeper than 1 mm 0 040 in Always replace the nozzle and electrode as a set Electrode pit depth gauge 004630 ...

Page 119: ...onsumables in this section Note The water tube may seem loose when correctly inserted but any side to side looseness will disappear after the electrode is installed WARNING The system is designed to go into an idle mode if the retaining cap is removed However DO NOT REMOVE CONSUMABLE PARTS WHILE IN THE IDLE MODE Always disconnect power to the power supply before removing torch consumable parts Use...

Page 120: ...s are worn see Changing consumable parts Cut angle is not square Causes can be 1 Wrong direction of machine travel High quality side is on the right with respect to the forward motion of the torch 2 Torch to work distance is not correct check Cut chart information 3 Cutting speed is not correct check Cut chart information 4 Arc current is not correct check Cut chart information 5 Damaged consumabl...

Page 121: ...top on the workpiece The torch should never fire into the air Starting the cut at the edge of the workpiece is acceptable as long as the arc is not fired in the air To start with a pierce use a pierce height that is 1 5 to 2 times the torch to work distance See Cut charts Each cut should end with the arc still attached to the workpiece to avoid arc blow outs ramp down errors When cutting drop part...

Page 122: ...gh Square cut Solution Increase arc voltage to raise the torch Decrease arc voltage to lower the torch Positive cut angle Negative cut angle Problem 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 th...

Page 123: ...more dross HyDefinition and HT4400 only On mild steel a higher concentration of O2 in the O2 N2 shield mixture may increase the cutting speed and produce less dross Trade off This may produce a rougher cut surface Piercing The pierce delay must be sufficiently long that the arc can pierce the material before the torch moves but not so long that the arc wanders while trying to find the edge of a la...

Page 124: ...ode troubleshooting 8 of 10 5 18 Error code troubleshooting 9 of 10 5 19 Error code troubleshooting 10 of 10 5 20 Power supply states 5 21 Plasma system operation with pump timeout 5 22 CNC operation with pump timeout 5 23 Initial checks 5 24 Power measurement 5 25 Power supply coolant system servicing 5 26 Draining the coolant system 5 26 Coolant system filter and strainer 5 27 Filter replacement...

Page 125: ...board PCB3 5 37 Power supply power distribution board PCB2 5 38 Start circuit PCB1 5 39 Operation 5 40 Start circuit functional schematic 5 40 Start circuit troubleshooting 5 40 Pilot arc current levels 5 41 Gas console control board PCB2 5 42 Gas console power distribution board PCB1 5 43 Gas console AC valve driver board PCB3 5 44 Chopper tests 5 45 Phase loss detection test 5 47 Torch lead test...

Page 126: ...rm 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 Refer to the Safety section for op...

Page 127: ...r Cable Provides 120 VAC to the Gas Console Signal Cable Provides process and status signals between the Power Supply and the Gas Console Power Cable Provides 120 VAC to the Ignition Console and control power for the off valve assembly Control Cable Provides 120 VAC control power to the solenoid valves ...

Page 128: ... flow on Chopper current off Line voltage ok 4 Preflow 2 second flow of gas 5 Pilot Arc Current flow between electrode and nozzle Chopper main contactor and pilot arc relay are on High frequency present Chopper current sensor pilot arc current 6 Transfer Pilot arc current sensed on the worklead 7 Ramp up Chopper current increases to set point and gas switches to cutflow Coolant flow on Gas pressur...

Page 129: ...first for 12 seconds The preflow and cutflow purges will follow the nitrogen purge Note error code 42 low nitrogen gas pressure will be displayed if nitrogen is not connected to the gas system If error code 42 is not resolved in 3 minutes it will be replaced by error code 139 purge time out error Exception 2 no purge process will occur if the operator changes from any process to a nitrogen marking...

Page 130: ...mber 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Preflow SV3 SV6 SV8 SV12 SV17 SV18 Cutflow SV3 SV6 SV8 SV12 SV14 SV16 SV19 N2 Air process Gas console AC valve driver board LEDs Valve location Gas console Off valve LED number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Preflow SV1 SV5 SV8 SV11 SV17 SV18 Cutflow SV1 SV5 SV8 SV11 SV14 SV16 SV19 N2 N2 process Gas console AC valve driver...

Page 131: ... number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Preflow SV1 SV5 SV7 SV9 SV17 SV18 Cutflow SV1 SV5 SV7 SV9 SV14 SV16 SV19 Marking process Gas console AC valve driver board LEDs Valve location Gas console Off valve LED number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Preflow SV6 SV8 SV11 SV17 SV18 Cutflow SV6 SV8 SV11 SV14 SV16 SV19 ...

Page 132: ...MAINTENANCE HPR130 Manual Gas Instruction Manual 5 9 PCB block diagram 3 ...

Page 133: ...MAINTENANCE 5 10 HPR130 Manual Gas Instruction Manual Error codes HyPerformance plasma system error codes Error codes are displayed in the 3 digit LED display on the gas console 3 ...

Page 134: ...t work lead for damage or loose connections 4 Perform current test see Maintenance section 024 Lost current Lost the current signal from the chopper after transfer 1 Verify that the consumable parts are in good condition 2 Verify proper cut flow gas settings 3 Verify pierce delay time 4 Verify arc did not lose contact with plate while cutting hole cutting scrap cutting etc 5 Perform chopper test s...

Page 135: ... before a steady state arc has been established 032 Hold timeout Hold signal was active for longer than 60 seconds 1 Check the interface cable for damage The hold wires may be short circuiting inside 2 The CNC is maintaining this input it could be waiting for an IHS complete input from another torch 3 If CNC interface cable is good and it is a 1 torch system change PCB3 033 Precharge time out Auto...

Page 136: ...es continuity tests replace PCB3 047 High line voltage Line voltage is close to or greater than the upper limit of 138 VAC 120 VAC 15 The normal upper limit for operation is 132 VAC 120 VAC 10 1 Verify input line voltage Voltage needs to be within 10 of nominal 120 VAC 2 Verify fuses on PCB2 3 Verify 120 VAC voltage on plug J2 4 pins 3 and 4 on PCB2 4 Verify voltage on receptacle J2 on PCB2 Should...

Page 137: ... on gas console with cut chart 3 Solenoid at off valve is not opening Verify power to valves disconnect plasma and shield hoses exiting off valve If pressures decrease a valve is not functioning or no power to the valve 055 MV1 inlet pressure Auto Gas Only Motor valve 1 inlet pressure is less than 3 45 bar 50 psi or greater than 9 65 bar 140 psi 1 Verify that gas pressure transducer P1 is between ...

Page 138: ... minutes replace chopper 6 If voltage is higher than 2 9 VDC and overtemp LED does not clear after 30 minutes replace PCB3 066 Chopper 2 overtemp Chopper has overheated 1 Verify that both chopper fans are operating properly Spinning fan blades should be difficult to see 2 Blow dust out of system especially from fans and heat sink of chopper 3 Verify that the voltage on rear side of J3 201 pins 2 a...

Page 139: ...onds to allow the timed out pump to turn on again 099 Chopper 1 overtemp at power up Chopper 1 is indicating an overtemp at power up 1 Verify that the temperature sensor for the chopper has not been jumped out or the wires to the temp switch shorted out in the harness 2 If no jumper is present the chopper is overheated and needs time to cool to 83 C 181 4 F 100 Chopper 2 overtemp at power up Chopp...

Page 140: ...rent sensors CS1 And CS3 are correct and not damaged 2 Replace PCB 3 if connections are correct and not damaged 109 Coolant flow at power up Coolant flow OK signal is active during power up and before pump motor is activated 1 Either coolant flow sensor was bypassed or the flow switch is faulty 111 Coolant overtemp at power up Coolant is indicating an overtemp at power up 1 Verify that the coolant...

Page 141: ...t cable number 6 power supply to gas console power cable is not damaged and is properly connected inside the power supply and to the rear of the gas console 4 Verify that D1 5 VDC and D2 3 3 VDC are illuminated on PCB2 inside the gas console These LEDs indicate power to PCB2 5 If power is present at PCB2 and PCB3 and both gas console cables are good then PCB2 or PCB3 has failed Use the CAN tester ...

Page 142: ...sole is working properly Replace if necessary 2 Verify that transducer P8 in the metering console is working properly Replace if necessary 3 Verify that the control boards in the metering and selection consoles are working properly Replace if necessary 141 Pressure transducer 2 or 7 error Auto Gas Only Faulty transducer or control board in the metering console or the selection console 1 Verify tha...

Page 143: ...on console 2 Verify that D17 5 VDC and D18 3 3 VDC are illuminated on PCB2 inside the selection console These LEDs indicate power to PCB2 Also verify that D26 CAN RX and D27 CAN TX are illuminated on PCB2 inside the selection console These LEDs indicate communication between the selection console and the power supply 3 If power is present at PCB2 and PCB3 and both selection console cables are good...

Page 144: ...atus position to view ID numbers 3 State code Name 00 Idle 02 Purge 03 Idle 2 04 Preflow 05 Pilot arc 06 Transfer 07 Ramp up 08 Steady state 09 Ramp down 10 Final ramp down 11 Auto off 12 Test cutflow 14 Shutdown 15 Reset 16 Maintenance 20 Test preflow 22 Manual pump control 23 Inlet leak check 24 System leak check ...

Page 145: ...MAINTENANCE 5 22 HPR130 Manual Gas Instruction Manual 5 Plasma system operation with pump timeout ...

Page 146: ...MAINTENANCE HPR130 Manual Gas Instruction Manual 5 23 CNC operation with pump timeout 5 ...

Page 147: ...entify parts and part numbers 4 If no damage is apparent connect power to the power supply and turn the main disconnect switch ON 5 Measure the voltage between the W V and U terminals of TB1 located on the right side of the power supply See figure on next page Also refer to the wiring diagram in Section 7 if required The voltage between any 2 of the 3 terminals should be equal to the supply voltag...

Page 148: ...nd If one line is 10 or higher than the other two put that leg on U DANGER There is line voltage at the contactor after the line disconnect switch is ON even if the the circuit breaker on the power supply is OFF Use extreme care when measuring primary power in these areas Voltages present at the terminal block and contactors can cause injury or death W V U 6 ...

Page 149: ...he power and remove the return coolant hose red tape from the pump and put it in a 20 liter 5 gallon container 3 Run the pump until the coolant stops flowing and immediately release the current selection knob 8 2 Press and hold the current selection knob 8 and turn ON the power switch The pump will run continuously while 8 is pressed ...

Page 150: ...4 5 Re install housing 6 Refill with new coolant Pump strainer cleaning 1 Turn OFF all power to the system 2 Drain coolant See Power supply coolant draining in this section 3 Remove nut 4 Remove and clean strainer with a mild soap and water solution 5 Re insert strainer 6 Re install nut 7 Refill with new coolant Nut Strainer Caution Coolant will flow from the filter when its housing is removed Dra...

Page 151: ...MAINTENANCE 5 28 HPR130 Manual Gas Instruction Manual 6 Coolant flow troubleshooting chart ...

Page 152: ...t must be drained from the system before the in line filter is cleaned step 1 below The coolant in the system will drain out as soon as the in line filter is removed 1 Clean the filter strainer 2 Replace the filter on the rear of the power supply 3 Verify that the system has the correct level of coolant when refilling the system after completing steps 1 and 2 Using the Hypertherm flow meter 128933...

Page 153: ...rn ON the power Press and hold the current selection knob 8 to turn on the pump manually and allow the coolant to flow for 60 seconds 2 Write down the coolant flow rate shown on the gas console s LED display The recorded flow rate will be used for comparison during some of the tests Coolant flow must be greater than 2 3 lpm 0 6 gpm for the system to operate 3 Release the current selection knob 8 a...

Page 154: ... is less than 0 8 gpm Go to test 2 If there is no flow go to pump and motor troubleshooting Test 2 supply line at ignition console Note remove the torch lead coolant hoses to access the supply 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 ...

Page 155: ...takes more than 65 seconds to fill the container look for an obstruction or kink in the coolant hose between the torch and the LHF RHF console If there is no obstruction or kink replace the torch leads If the container is full in 65 seconds or less go to test 5 Test 5 return line from the torch receptacle remove at the ignition console 1 Turn OFF the power Remove the return coolant line blue hose ...

Page 156: ...s to fill the container If it takes more than 65 seconds to fill the container replace the pump and check the motor shaft for damage If it takes less than 65 seconds to fill the container check the coolant supply line from the power supply to the RHF LHF console for kinks If no kinks are found replace the hoses between the power supply and RHF LHF console Test 7 bypass the check valve 1 Turn OFF t...

Page 157: ...ow shown on the LED display is less than 0 8 gpm replace the flow switch Note the check valve must be oriented correctly The arrow points up as shown Check valve orientation 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 fus...

Page 158: ...er 2 Measure the VDC between TP210 and TP206 TP206 is common on PCB3 TP210 provides a filtered 67 scaled voltage from the flow switch 0 45 VDC 0 67 VDC at the flow switch equals 2 3 lpm 0 6 gpm If the TP210 voltage reading is below 0 45 VDC and the flow is equal to or above 3 0 lpm 1 gpm replace the flow switch ...

Page 159: ...wer to the HPR130 2 After initial gas purge switch shield selector switch 2 to TEST 3 Select SET PREFLOW on switch 7 The off valve opens and exhausts gas between the gas console and torch The inlet valves in gas console will remain closed 4 The off valve will close after 20 seconds 5 Close gas supply valves 6 Monitor the pressure displays and the gas supply pressure gauges for 20 minutes The press...

Page 160: ...ma start Control PC board LED list LED Signal Notes D100 5 VDC D101 3 3 VDC D113 CAN TX Constant blinking D114 CAN RX Constant blinking Control PC Board LEDN301 List LEDN Output Input Notes LEDN1 HV transformer LEDN2 Pump motor enable LEDN3 Contactor LEDN4 Pilot arc relay LEDN5 Spare LEDN6 Surge select LEDN7 Not connected LEDN8 Not connected LEDN9 Not connected LEDN10 Phase loss Control PCB3 firmw...

Page 161: ...5 D1 D7 D5 D2 D35 Power distribution PC board LED list LED Output Color D1 Contactor Red D2 Pilot arc relay Red D3 120 VAC switched Green D5 HF ignition Red D7 Surge select Red D12 24 VAC switched Green D23 240 VAC switched Green D25 24 VDC Red D26 Pump motor Green D31 5 VDC Red D32 15 VDC Red D33 15 VDC Red D35 24 VAC Green 3 ...

Page 162: ...se injury or death 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 After initial pilot arc current is established the start circuit introduces i...

Page 163: ...place the board Note Resistance value may slowly increase to the correct value due to the capacitance in the circuit 4 Verify a resistance of 15 kΩ between C1 and H8 The work lead should not have any cuts or breaks verify a resistance of 1Ω or less The work lead connection to the cutting table should be clean and have good contact to the table Verify that LED D2 is illuminated If it is not illumin...

Page 164: ... arc current level See table below Pilot arc current Plasma gas 30 amps 45 amps 50 amps 80 amps 130 amps O2 25 30 30 30 30 N2 25 30 30 30 35 H35 25 30 30 30 35 F5 25 30 30 30 35 Air 25 30 30 30 35 Transfer current Plasma gas 30 amps 45 amps 50 amps 80 amps 130 amps O2 10 10 10 10 15 N2 10 10 10 10 15 H35 10 10 10 10 15 F5 10 10 10 10 15 Air 10 10 10 10 15 ...

Page 165: ...s console control board LEDN list LEDN Signal name Color LEDN1 Plasma preflow left digit Red LEDN2 Plasma preflow right digit Red LEDN3 Plasma cutflow left digit Red LEDN4 Plasma cutflow right digit Red LEDN5 Shield preflow left digit Red LEDN6 Shield preflow right digit Red LEDN7 Shield cutflow left digit Red LEDN8 Shield cutflow right digit Red LEDN9 Current left digit Red LEDN10 Current center ...

Page 166: ...MAINTENANCE HPR130 Manual Gas Instruction Manual 5 43 Gas console power distribution board PCB1 LED Signal Name Color D1 120 VAC switched Green D7 5 VDC Red D9 24 VDC Red 3 ...

Page 167: ...d D11 SV11 Red D2 SV2 Red D12 SV12 Red D3 SV3 Red D13 SV13 Red D4 SV4 Red D14 SV14 Red D5 SV5 Red D15 SV15 not used Red D6 SV6 Red D16 SV16 Red D7 SV7 Red D17 SV17 Red D8 SV8 Red D18 SV18 Red D9 SV9 Red D19 SV19 Red D10 SV10 Red D20 SV20 Red P2 P1 P3 P4 SV14 SV13 SV6 SV8 SV10 SV12 SV2 SV4 SV5 SV3 SV9 SV11 SV1 SV7 SV16 SV17 SV18 SV19 SV20 Off valve ...

Page 168: ...d continue with the tests below Troubleshooting low current error code 105 1 Verify that the current sensors CS1 and CS3 and cables are not damaged 2 Exchange CS1 and CS3 Replace the faulty sensor if the error code is not displayed again 3 Measure the resistance between wire 38 and wire 39 on PCB6 with a meter The value should be increasing as the capacitor charges Replace PCB6 if a constant value...

Page 169: ...ensor if the error the code is not displayed again 3 Look at the surge capacitor to ensure that it is not short circuited Replace PCB6 if the surge capacitor is shorted 4 Check for short circuits from the work terminal to the negative terminal on PCB6 Resistance should be about 100K ohm from the work terminal to the negative terminal Resistance will vary if you have a voltage divider for a height ...

Page 170: ... connector a Make a test cut If the phase loss error continues verify wiring between J2 8 on PCB2 and J3 302 on PCB3 by verifying the continuity between J2 8 pin1 to J3 302 pin14 J2 8 pin2 to J3 302 pin15 b If the wiring is ok replace PCB3 If any wiring is damaged repair or replace damaged wires c If the phase loss error goes away while the jumper is on J2 8 make another cut and measure the phase ...

Page 171: ...y jumper wire between H8 work and H9 nozzle on the start circuit PCB1 4 Locate the pilot arc relay CR1 and remove the dust cover Have a second person close the contact 5 Measure the ohm value between the nozzle and the plate The reading should be less than 3 ohms A measurement of greater than 3 ohms indicates a faulty connection between the torch and ignition console or between the ignition consol...

Page 172: ...e confirmation of your decision please contact Hypertherm s Technical Service department The power supply DANGER ELECTRIC SHOCK CAN KILL Turn off all electrical power before removing the power supply cover and set the line disconnect switch to OFF In the U S use a lock out and tag out procedure until the service or maintenance is complete In other countries follow appropriate local or national saf...

Page 173: ...to the threads usually results from not cleaning the torch and retaining cap threads properly so that dirt and particulates accumulate in the threads 10 Inspect the torch insulator for cracks Replace the torch if you find cracks 11 Inspect all o rings on the torch body and consumables Make sure that the correct amount of lubricant a thin film is applied to these o rings Too much lubricant may obst...

Page 174: ...dry the inside of the console with a cloth and try to identify the source of the moisture 20 Inspect the spark gap assembly Ensure that the wiring connections to the spark gap assembly are secure Check that the console doors close properly 21 Inspect the torch leads Ensure that they are fastened tightly to the outside of the ignition console System grounding 22 Verify that all components of the sy...

Page 175: ...eded Weekly Week Jan Feb March April May June July Aug Sept Oct Nov Dec 1 2 3 4 5 Semi Annually Year 1st Service 2nd Service Clean power supply with dry oil free compressed air or a vacuum cleaner Verify cooling fans are working properly Clean torch threads and current ring Verify proper coolant level Annually Year Replace service parts per the Service Part Replacement Schedule Replace service par...

Page 176: ...ct for particulates and blow out 앮P 앮NP 2 Inspect wiring harnesses 앮P 앮NP 3 Inspect main contactor 앮P 앮NP 4 Inspect pilot arc relay Coolant system 앮P 앮NP 5 Inspect filter element 앮P 앮NP 6 Perform coolant flow test A Coolant flow checked at _________ gallons per minute _________ l min Torch main body 앮P 앮NP 7 Inspect water tube 앮P 앮NP 8 Inspect current ring 앮P 앮NP 9 Clean threads on torch front end...

Page 177: ...ter element Coolant solution 70 30 Torch kit Quick disconnect kit 027664 028872 128879 128880 1 4 1 1 3 Years or 1800 arc hours Coolant filter element Coolant solution 70 30 Main contactor Torch main body Pilot arc relay Cooling fan 6 Cooling fan 10 027664 028872 003139 220162 003149 127039 027079 1 4 1 1 1 2 1 3 5 Years or 2100 arc hours Coolant filter element Coolant solution 70 30 Torch kit Qui...

Page 178: ...t System dependent 1 4 1 1 1 1 1 1 1 1 5 5 Years or 3300 arc hours Coolant filter element Coolant solution 70 30 Torch kit Quick disconnect kit 027664 028872 128879 128880 1 4 1 1 6 Years or 3600 arc hours Coolant filter element Coolant solution 70 30 Main contactor Torch main body Pilot arc relay Coolant pump kit Torch leads Cooling fan 6 Cooling fan 10 027664 028872 003139 220162 003149 128384 S...

Page 179: ... section Power supply 6 2 Ignition console 6 7 Gas console 1 of 2 6 8 Gas console 2 of 2 6 9 Off valve 6 9 HyPerformance torch 6 10 Torch assembly 6 10 Torch leads 6 10 Consumable parts kit 128878 6 11 Consumables for mirror image cutting 6 12 Recommended spare parts 6 13 ...

Page 180: ...rformance Plasma power supply 240 volt 078180 HyPerformance Plasma power supply 400 volt 078181 HyPerformance Plasma power supply 480 volt 078182 HyPerformance Plasma power supply 440 volt 078183 HyPerformance Plasma power supply 600 volt 2 228328 Panel top with lable 1 3 075241 Sheet metal screws 1 4 228330 Panel right or left side with lable 1 5 228329 Panel front with lable 1 6 129633 Green pow...

Page 181: ...upply Part Item Number Description Designator Qty 1 027634 Filter housing 1 027664 Filter element 1 2 127014 Cap coolant resevoir 1 3 129792 Chopper assembly CH1 1 4 127039 6 fan 230 CFM 115 VAC 50 60 HZ 2 5 027079 10 fan 450 550 CFM 120 VAC 50 60 HZ 1 2 1 3 5 4 ...

Page 182: ...t arc 120 VAC CR1 1 2 041837 PCB I O PCB6 1 3 003139 Contactor CON1 1 4 109036 EMI filter 60 amp 440 VAC 3PH 1 5 129791 Start circuit assembly PCB1 1 6a 109004 Current sensor hall 100 amp 4 volt CS3 1 6b 109004 Current sensor hall 100 amp 4 volt CS1 1 7 108263 Fuse 175 amp 250 volt F3 1 400 volt power supply only 3 4 1 2 7 5 6b 6a ...

Page 183: ...stribution PCB PCB2 1 4 109393 Temperature sensor T2 1 5 129793 Flow switch assembly FLS 1 6 027978 Heat exchanger assembly 1 027185 4 fan 2 7 129995 Solenoid valve assembly CLT SOL 1 006075 Check valve 1 4 FPT 1 8 228170 Kit pump with clamp 1 9 006046 Solenoid valve assembly 3 8 240 volt CLT SOL 1 10 128385 Kit motor with clamp 1 380 400 440 480 and 600 volt power supplies 200 208 and 240 volt po...

Page 184: ...r 200 208 volt 50 60 HZ T2 1 229117 Control transformer 220 volt 50 60 HZ 1 129966 Control transformer 240 volt 60 HZ 1 129787 Control transformer 380 400 volt 50 60 HZ 1 229013 Control transformer 440 volt 50 60 HZ 1 129967 Control transformer 480 volt 50 60 HZ 1 129989 Control transformer 600 volt 50 60 HZ 1 1 Power supply ...

Page 185: ... Manual Gas Instruction Manual 6 7 Ignition console Part Item Number Description Designator Qty 1 078172 Ignition Console 2 129831 Coil assembly T2 1 3 041817 HFHV Ignition PCB PCB IGN 1 4 129854 Transformer T1 1 1 2 3 4 ...

Page 186: ... Number Description Designator Qty 1 078170 Gas Console 2 041805 Power distribution PCB PCB1 1 3 041822 Valve driver PCB PCB3 1 4 005263 Pressure sensor PT1 PT4 4 5 006109 Solenoid valve SV1 SV14 14 006112 Replacement solenoid coil 6 005262 Illuminated power switch SW1 1 1 2 3 5 6 4 ...

Page 187: ...Regulator assembly with elbow fitting PR1 PR3 PR4 3 3 229129 Regulator assembly with elbow and tee fitting PR2 1 228147 Kit regulator upgrade replaces all 4 regulators Off valve Part Item Number Description Designator Qty 129816 Off valve assembly 1 1 006109 Solenoid valve V16 V20 5 006112 Replacement solenoid coil 5 2 123748 Off valve cable 1 1 2 1 2 3 ...

Page 188: ...acle 5 220232 Torch mounting sleeve assembly 6 104269 2 spanner wrench 128879 Torch kit bullet plugs o rings water tube and seal 128880 Quick disconnect kit o ring and connector See Appendix C of this manual for bevel cutting part numbers Torch leads Part Number Description 128986 2 m 6 ft 128935 3 m 10 ft 128934 4 5 m 15 ft 128784 7 5 m 25 ft 128987 10 m 35 ft 128785 15 m 50 ft 128988 20 m 65 ft ...

Page 189: ...l replacement 1 104269 Wrench spanner 1 220173 Retaining cap with IHS tab 1 220176 Inner retaining cap 2 220179 Swirl ring 1 220180 Swirl ring 1 220181 Electrode 3 220182 Nozzle 3 220183 Shield 2 220187 Electrode 3 220188 Nozzle 3 220189 Shield 2 220192 Electrode 2 220193 Nozzle 2 220194 Shield 1 220197 Nozzle 2 220198 Shield 1 220201 Nozzle 2 220202 Shield 1 220304 Inner retaining cap 1 220307 El...

Page 190: ...for mirror image cutting Mild steel 220193 220192 220306 30A 220187 80A 220181 130A Shield Nozzle Inner Retaining cap Swirl ring Electrode 220305 220305 220188 220182 220183 220189 220194 220304 220304 220314 220173 220552 220549 220554 220555 220314 50A Retaining cap ...

Page 191: ...mp 600 volt F1 F2 2 041909 Control PCB PCB3 1 041802 Power distribution PCB PCB2 1 129793 Flow switch assembly FLS 1 027185 Heat exchanger fan 4 1 006075 Check valve 1 4 FPT 1 129995 Solenoid valve assembly CLT SOL 1 129994 Pump assembly 70 gpm 200 psi 1 031113 Motor 1 3 HP 240 volt 50 60 HZ 1 400 480 and 600 volt power supplies Ignition console Part Number Description Designator Qty 041817 HFHV I...

Page 192: ...ge to page referencing is done in the following manner C SHEET 4 D3 C SHEET 4 D3 Destination and Source Coordinates refer to letters A D on the Y axis of each sheet and numbers 1 4 on the X axis of each sheet Lining up the coordinates will bring you to the source or destination blocks similar to a road map Wiring Diagram Symbols Wiring diagram symbols and their identification precede the system wi...

Page 193: ...interlock Fan Feedthru LC Filter AC DC supply Fuse Ground Clamp Ground Chassis Ground Earth IGBT Inductor LED Lamp Pin Socket Plug PNP Transistor Potentiometer Push Button Normally Closed MOV Push Button Normally Open Receptacle Relay Coil Relay Normally Closed Relay Normally Open Relay Solid State AC Relay Solid State DC Relay Solid State Dry SCR Shield Shunt Spark Gap Resistor ...

Page 194: ...ve Solenoid Voltage Source Zener Diode VAC Source Triac Switch Pressure Normally Closed Switch Pressure Normally Open Switch 1 Pole 1 Throw Switch 1 Pole 2 Throw Switch 1 Pole 1 Throw Center Off Switch Temperature Normally Closed Switch Temperature Normally Open Time Delay Closed NC Off Time Delay Open NO Off Time Delay Open NC On Terminal Block Torch HyDefinition WIRING DIAGRAMS Switch Flow ...

Page 195: ...HPR130 Manual Gas Instruction Manual 7 5 Discrete output functionality ...

Page 196: ...1 Unit 6 Nozzle Air Shield Plasma Preflow Shield Preflow Plasma Cutflow Shield Cutflow 3X3 4X1 Command I O Cable 1X4 Unit 5 Optional Unit THC Command Machine I O Cable Pendant Ext Cable Optional Unit Operator Unit N Pendant Lifter Torch Optional Unit Unit M Atm Vent Gas Valve Cable Positive Lead 72 Cooling Return Lead 3X2 1X2 PS Gas Control Cable Negative Supply Lead Plasma Interface w C THC Modul...

Page 197: ...3 21 22 H9 NEGATIVE POSITIVE H9 H8 BLK BLK PCB1 START CIRCUIT SA 129791 2 1 3 3 C1 I RED RED BLK J1 1 J1 3 B4 U RED RED BLK I O SURGE INJECTION 2 1 T2 YEL 24VAC RED 120VAC ORN 240VAC J11 WHT BLU CHOPPER SA 129792 4 2 1 3 T1 BLU WHT CS1 4 C1 G J1 4 J4 2 1 3 4 4 C4 H GRN BLK WHT RED 4 B1 J POSITIVE 3 D4 B 1C 1B 1A 4 C1 D BLK BLK F1 F2 38 22UF 10K 022UF 10K 22UF 100K 100 10K 350UF R2 10 R4 10 3 A4 AA...

Page 198: ...F 4 RED BLK RED 3 2 1 RED BLK RED AC PWR LT TB2 J8 J5 K1 K2 F3 F1 F4 F2 RED BLK RED 8 FAN 2 CLT F5 F6 F7 D3 120VAC D26 Pump motor signal D12 24VAC D32 15V D23 240VAC D31 5V D25 24V D33 15V 7 8 D1 CONTACTOR D2 PILOT ARC RELAY D5 HV XFMR D7 SURGE SELECT J2 3 J3 2 1 3 4 5 6 11 10 9 8 7 12 8 7 J2 5 5 6 4 2 3 1 J5 12 11 10 9 CONTACTOR PILOT ARC RELAY HV XFMR SURGE SELECT 120VAC RTN SS CON PAR HF 2 D4 T...

Page 199: ...E NOT READY C CORNER CURRENT CORNER CURRENT PIERCE PIERCE HOLD HOLD START START CNC 24V PWR GND CNC 16 15 13 14 1 7 10 12 11 9 8 4 6 5 3 2 J3 200 J200 14 12 13 11 10 9 8 2 7 6 5 4 3 J3 201 1 J201 24V COM COOLANT FLOW SENSOR A 3 3V COOLANT TEMP SENSOR XFMR TEMP SENSOR CHOPPER TEMP SENSOR A CHOPPER TEMP SENSOR B LINE VOLTAGE INPUT 15V 15V CHOPPER SENSOR A COM CHOPPER SENSOR B WORK LEAD SENSOR 2 D3 A...

Page 200: ...02 6 2 7 3 9 8 4 5 J101 1 2 3 D4 M BLU WHT BLU WHT RED BLK YEL 24V PWR GND 5V GND 15V 15V COM TMS TRST TDI COM 5V TDO TCK EMU0 EMU1 JTAG 1 4 5 9 COM 7 8 3 232TX 2 6 232RX J100 RS 232 CAN GND CAN 24V CANL CANH 121 CANA CANB 0 CABLE 123691 J3 101 RED 10 B4 AG BLK RED BLK SHIELD A B C 4 3 2 D 4 3 2 1 A B C 1 D SHEET SHEET 17 5 013348 K ...

Page 201: ... INPUT POWER FROM FACILITY PE L1 C4 B4 A4 CON1 TB1 PE L2 L3 V L1 W U V W L3 L2 B2 T1 B1 C2 C3 C4 C10 0 0 A2 B4 A1 B3 A3 1C 0 0 1B 0 A4 1A WIRED FOR 240V 60HZ INPUT POWER FROM FACILITY PE L1 WIRED FOR 200 208V 50 60HZ L2 B4 CON1 L3 C4 TB1 V U PE W L1 W V A4 L3 L1 PE L2 B4 1C C2 C10 T1 B10 C3 C4 0 B2 B30 A30 A2 A10 1B A4 1A FROM FACILITY INPUT POWER F1 F2 WHT BLU T2 F1 F2 WHT BLK T2 F1 F2 T2 BLK WHT...

Page 202: ... 380V 50HZ L1 L3 L2 PE FROM FACILITY INPUT POWER L1 L2 L3 PE L1 L2 L3 TB1 V U PE W A4 CON1 B4 C4 V W A1 T1 0 C3 C2 0 C1 B2 0 B1 C4 0 B4 0 B3 1C 1A A4 0 A3 A2 1B T2 BLK WHT WIRED FOR 440V 50 60HZ C4 B4 A4 CON1 TB1 PE L2 L3 V L1 W U V W L3 L2 B2 T1 B1 C2 C3 C4 C10 0 0 A2 B4 A1 B3 A3 1C 0 0 1B 0 A4 1A WIRED FOR 220V 50 60HZ INPUT POWER FROM FACILITY PE L1 F1 F2 WHT BRN T2 F1 F2 014284 014284 2 3 4 1 ...

Page 203: ...AND CONTROL MODULE J5 EMI GND ELECTRODE WORK SHIELD 19 18 37 36 35 17 16 15 34 33 32 14 13 12 31 30 29 11 10 28 9 27 26 8 7 6 25 24 23 5 4 3 22 21 2 20 1 37 19 18 36 35 17 34 16 15 14 33 32 31 13 12 J2B 9 30 29 11 10 28 8 27 26 7 25 6 3 23 24 5 4 22 20 21 2 1 37 19 18 36 35 17 34 16 15 14 33 32 31 13 12 9 30 29 11 10 28 8 27 26 7 25 6 3 23 24 5 4 22 20 21 2 1 PLASMA START OUT PLASMA START OUT GND ...

Page 204: ...V HOT 5V COM 120V RTN 5V 24V 24V COM 9 B4 AB 10 D4 AC RED RED BLK RED BLK RED BLU WHT BLU WHT RED BLK 11 D3 AE RED REMOTE ON OFF 7 5 6 WHT RED 1 2 1A 2A RED BLK RED WHT RED F1 D4 120VAC D12 24V D8 5V 8 7 9 D4 AB GAS CONSOLE SW1 10 D4 AC 3X1 CABLE 123674 DC POWER GAS CONSOLE AC VALVE DRIVER POWER SHEET SHEET SHEET SHEET SHEET A B C 4 3 2 D 4 3 2 1 A B C 1 D 17 9 013348 K ...

Page 205: ...8 4 5 6 7 8 9 10 11 12 13 14 15 16 SIG SIG SIG TXD RXD RS 232 CANH CANL CANH CAN GND 2 J8 1 CAN PWR CAN PWR CAN A CAN B JTAG TMS TRST TDI 5V COM 5V TDO TCK EMU0 EMU1 232 COM J2 8 3 6 8 7 5 4 J2 9 J9 2 1 9 CANL 6 9 8 7 3 5 4 2 1 J10 CAN GND CABLE 123692 BLK BLK RED RED SHIELD 6 9 8 7 3 5 4 2 1 CABLE 123691 3X2 5 A3 AG BLK BLK RED RED SHIELD CABLE 123703 SHEET SHEET A B C 4 3 2 D 4 3 2 1 A B C 1 D 1...

Page 206: ... RED BLK RED SV1 4 3 RED RED BLK SV2 7 8 6 5 RED RED BLK RED SV4 RED BLK SV3 16 15 11 12 13 14 RED RED BLK 10 9 RED RED BLK SV7 RED BLK RED RED SV8 SV6 RED BLK SV5 24 28 27 26 25 RED BLK RED RED BLK RED SV13 SV14 23 19 20 21 22 RED RED BLK 18 17 RED RED BLK SV11 RED BLK RED RED SV12 SV10 RED BLK SV9 RED BLK 1 RED BLK 5 RED BLK 3 RED BLK 1 RED BLK 9 RED 8 RED 6 RED 4 RED BLK 11 RED 2 RED 10 RED 12 ...

Page 207: ... J2 5kV SG2 109344 SG1 J1 009975 J3 1400pF 20kV 1400pF 20kV 1400pF 20kV 009975 C5 C4 009975 C3 J6 129150 T1 2X1 0 22uF 1kVDC 0 22uF 1kVDC J4 TORCH C1 009224 009224 C2 BLOCK CATHODE PILOT ARC J5 009793 CONNECTION NOZZLE T2 COIL SECONDARY OUT 2 D1 AJ 3 4 2 1 3 A4 AI BLK WHT GRN CABLE 123670 CABLE 123662 009045 FLTR SHEET ...

Page 208: ...F5 V2 V1 V3 V4 V5 V6 V7 V8 V9 V10 V11 V12 PR1 PR2 PR3 PR4 V13 V14 P1 P2 P3 P4 SHIELD CUTFLOW SHIELD PREFLOW PLASMA PREFLOW PLASMA CUTFLOW V16 V17 V18 V19 V20 SHIELD PLASMA ATM A 4 B 3 C D 4 3 2 1 A B 2 1 C D 17 13 013348 K ...

Page 209: ...7 20 6 A B C D 4 3 2 1 A B C D 4 3 2 1 HEAT EXCHANGER RESERVOIR PUMP SHUT OFF VALVE CHECK VALVE FILTER THERMISTOR FLOW SENSOR TORCH RHF MANIFOLD 17 14 013348 K ...

Page 210: ...open on all systems except for the very last system where they are in the closed position Termination resistors 120 ohm or termination jumpers must be installed set at the CNC for each of the RS 422 RX and TX signal pairs 17 15 013348 K Unit 1 041909 CONTROL BOARD S100 1 2 J303 3 4 3 2 1 4 Serial ID Dipswitch Machine Motion Jumper Block J106 2 1 J107 1 2 HPR PAC Dry Cutting System Unit 2 041909 CO...

Page 211: ...n 3 to position 2 Connect customer supplied Remote On Off cable in series with the power supply and the gas console power switch Connect one terminal of the Remote On Off cable to position 2 on TB2 and the other terminal to position 3 Refer to page 3 of the wiring diagram Depress the Gas Console Power switch to the closed position on position 2 For a multi system installation set up as described a...

Page 212: ...l ID S100 S100 Dipswitch 3 systems Serial ID S100 Dipswitch 4 systems Serial ID J106 J107 Optional Command THC Interface Notes 1 For a single system installation set Serial ID S100 Machine Motion J303 J106 J107 as shown 2 For a two system installation duplicate a second power supply and Command THC as illustrated for a single system set Serial ID as shown for the second system 3 For a three system...

Page 213: ...sures a 3 Section 6 Accidental Release Measures a 3 Section 7 Handling and Storage a 3 Section 8 Exposure Controls Personal Protection a 4 Section 9 Physical and Chemical Properties a 4 Section 10 Stability and Reactivity a 4 Section 11 Toxicological Information a 4 Section 12 Ecological Information a 5 Section 13 Disposal Considerations a 5 Section 14 Transport Information a 5 Section 15 Regulato...

Page 214: ... 03755 Product Information 603 643 3441 Hazardous EXPOSURE LIMITS Component CAS No by wt OSHA PEL ACGIH TLV R Phrases Benzotriazole Propylene Glycol 95 14 7 1 0 N E N E R22 36 37 38 57 55 6 50 0 N E N E R36 37 38 Emergency Overview Causes eye irritation May be harmful if swallowed May cause skin irritation Potential Health Effects Ingestion Inhalation eye contact skin contact Oral LD 50 rat as rep...

Page 215: ...ON 7 HANDLING AND STORAGE Flash Point Method None to boiling Flammable limits Not Established Extinguishing media Product is an aqueous solution Use Carbon Dioxide Dry Chemical Foam Full protective equipment including self contained breathing apparatus should be used During emergency conditions overexposure to decomposition products may cause a health hazard Symptoms may not be immediately apparen...

Page 216: ...one freezing point Not established 5 5 7 0 vapor pressure Not applicable 1 0 vapor density Not applicable Complete evaporation rate Not determined ODOR pH of Concentrate Specific gravity solubility in water Chemical Stability None None Known BY FIRE Carbon Dioxide Carbon Monoxide Nitrogen Oxides Will not occur X May occur Not applicable Incompatibility Conditions to avoid Hazardous products of dec...

Page 217: ...n connection with the use of this information Considered biodegradable Not biodegradable Waste disposal method RCRA Classification Recycle container Waste material must be disposed of in accordance with national local legislative requirements DOT Classification Hazardous Not Hazardous X NFPA Classification 1 BLUE Health hazard 0 RED Flammability 0 YELLOW reactivity WHITE Special hazard REGULATORY ...

Page 218: ... 70 60 50 40 30 20 10 0 10 20 30 40 0 10 20 30 40 50 60 Temperature C of Propylene Glycol 9 2 04 a 6 Hypertherm Plasma systems Freezing Point of Propylene Glycol Solution ...

Page 219: ...essage and take action b Check for serial messages from the external UART If valid message is received parse the message and take action c Check for CAN message If CAN message has arrived parse the message and take action d Check for error conditions every 10 milliseconds e Refresh data from gas console i e pressures every 250 milliseconds f Update the chopper control loop every 26 microseconds g ...

Page 220: ...ntil flow is above 2 2 lpm 0 6 gpm with no start allowed at this time 3 Idle2 If Start signal is active the gas console goes into Preflow state the contactor and the soft start controller turn on and system goes into Preflow state If the gas console or serial interface requests a state change take action After more than 10 seconds since the last Start signal turn off the contactor and soft start c...

Page 221: ... checking Check for coolant flow at power up 093 Check for over under line voltage 047 046 Check for coolant over temperature 071 Check for chopper over temperature 065 Check for transformer over temperature 067 8 Steady state If Pierce complete input is off then switch to cutflow gases If corner current input is on then switch to corner current setpoint If start signal input is off then go to Ram...

Page 222: ...ctor timer run for 10 seconds If no Start signal go to Idle2 state Error checking Check for coolant flow at power up 093 12 Shut down Gas console goes to Shut down state All outputs off CNC error output on Chopper setpoints 0 Wait for reset request 13 Reset Reset CAN controller Initialize timers Go to Idle state 14 Test cutflow Gas console runs cutflow gases Wait for request to go to Idle state or...

Page 223: ...ix C BEVEL CUTTING In this appendix Bevel torch dimensions c 2 Bevel cutting definitions c 3 Cut charts c 4 Torch connections c 7 Connect the torch lead assembly to the quick disconnect assembly c 7 Parts list c 9 Consumables c 9 Part selection c 10 ...

Page 224: ...APPENDIX C BEVEL CUTTING c 2 HPR130 Manual Gas Instruction Manual Bevel torch dimensions 280 5 mm 11 0 51 mm 2 0 42 122 mm 4 8 57 mm 2 25 154 mm 6 1 51 mm 2 0 ...

Page 225: ...earance The vertical distance from the lowest point of the torch to the surface of the workpiece Torch to work distance The linear distance from the center of the torch outlet to the workpiece surface along the torch center line A range of torch to work distances are listed in the cut chart The smallest number is for a straight cut bevel angle 0 The largest number is for a 45 bevel cut with a clea...

Page 226: ...0 12 3 3 8 6 2200 6 6 0 5 15 3 8 8 6 1665 7 6 0 7 20 1050 1 0 25 4 0 8 6 550 190 1 8 32 4 5 8 6 375 Edge start 38 255 Select Gases Set Preflow Set Cutflow Minimum Clearance Equivalent Material Thickness Torch to Work Distance Cutting Speed Initial Pierce Height Pierce Delay Time Plasma Shield Plasma Shield Plasma Shield in in in ipm in factor seconds O2 Air 15 23 80 30 0 080 0 135 0 100 0 340 240 ...

Page 227: ...ial Thickness Torch to Work Distance Cutting Speed Initial Pierce Height Pierce Delay Time Plasma Shield Plasma Shield Plasma Shield mm mm mm mm m mm factor seconds H35 N2 20 40 70 80 2 0 10 4 5 10 0 980 7 7 170 0 3 12 820 0 5 15 580 0 8 20 360 1 3 25 260 Edge start Select Gases Set Preflow Set Cutflow Minimum Clearance Equivalent Material Thickness Torch to Work Distance Cutting Speed Initial Pie...

Page 228: ...ma Shield Plasma Shield Plasma Shield mm mm mm mm m mm factor seconds N2 N2 20 65 70 80 2 0 6 3 0 10 0 1960 6 0 200 0 3 10 1300 0 5 12 3 5 10 0 900 7 0 0 8 15 3 8 10 0 670 Edge start 20 4 3 10 0 305 Select Gases Set Preflow Set Cutflow Minimum Clearance Equivalent Material Thickness Torch to Work Distance Cutting Speed Initial Pierce Height Pierce Delay Time Plasma Shield Plasma Shield Plasma Shie...

Page 229: ...orch assembly and remove the mounting sleeve from the torch quick disconnect assembly 3 Slide the mounting sleeve over the leads and align the torch quick disconnect fittings with the hoses in the lead assembly The connections are color coded The hoses must not be twisted and are taped together to help prevent twisting Do not remove tape from leads 4 Connect the coolant inlet hose green 5 Connect ...

Page 230: ...ch quick disconnect 11 Slide the spiral wrap into the torch sleeve about 50 mm 2 in There will be a gap between the spiral wrap and the braided cover The spiral wrap and braiding do not get clamped in place Note The connectors in steps 6 9 are push to connect fittings To make a connection slide the hose fitting into the appropriate connector until it stops To disconnect a fitting pull back on the ...

Page 231: ...0649 220179 220646 220645 220603 220700 Stainless steel 130A Consumables Parts list Shield Nozzle Inner retaining cap Swirl ring Electrode Water tube Retaining cap Shield Nozzle Swirl ring Electrode Water tube Retaining cap 220398 220606 220179 220656 220609 220608 220571 Inner retaining cap ...

Page 232: ...20162 Used in all applications Bevel quick disconnect 220573 short torch mounting sleeve included in 220573 Torch sleeve standard 220232 Torch sleeve extended 220516 Standard quick disconnect 220163 Leads with push to connect fittings and 1 83 m 6 ft gas leads OR Leads with push to connect fittings and 2 5 m 8 17 ft gas leads Leads with standard fittings and 1 83 m 6 ft gas leads OR Leads with sta...

Page 233: ...Part number Overall length Gas lead length 228075 1 83 m 6 ft 1 83 m 6 ft 228076 3 05 m 10 ft 1 83 m 6 ft 228079 4 5 m 15 ft 1 83 m 6 ft 228081 7 5 m 25 ft 1 83 m 6 ft 228083 10 m 35 ft 1 83 m 6 ft 228086 15 m 50 ft 1 83 m 6 ft 228088 20 m 65 ft 1 83 m 6 ft 228077 3 05 m 10 ft 2 5 m 8 17 ft 228061 4 5 m 15 ft 2 5 m 8 17 ft 228062 7 5 m 25 ft 2 5 m 8 17 ft 228084 10 m 35 ft 2 5 m 8 17 ft 228063 15 ...

Page 234: ... 3 24 Corrected the part number for the 10 m 35 ft CNC interface cable It was 123314 and is was changed to 123214 3 25 and 3 27 Added 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 to note 1 3 25 and note 3 27 3 31 Removed reference to plastic insulator in step 4 It is no longer used 3 32 Added new pil...

Page 235: ...75241 Added part numbers for sheet metal front top and side panels 6 4 and 6 13 Moved start circuit assembly from item 6 to item 5 Listed the 2 current sensors separately 6a and 6b to identify their designators 108263 item 7 fuse was a 150 amp fuse and is now 175 amps 6 13 also 6 5 Added temperature sensor item number 4 109393 Changed stand alone pump and motors to kits that include the clamp Adde...

Page 236: ... numbers new lengths Added vent hose caution box 3 29 and 3 30 Added Connecting the torch to the torch leads 3 31 Changed heading to Connecting the torch to the quick disconnect Changed Torch leads to Torch quick disconnect receptacle Removed torch lead part numbers and added the part number for the receptacle 3 32 Updated art and instructions for mounting the HPR torch 3 33 Updated text for cable...

Page 237: ...1909 6 5 Item number 7 solenoid valve assembly is part of the check valve assembly item number 6 It can be ordered separately but does not need a separate item number 129994 is now item number 7 and 031113 is now item number 8 6 8 Item number 1 control PCB under Gas console changed from 041814 to 041912 6 9 Changed item number 5 sleeve from 024751 to 046175 The new sleeve has a larger ID Added 2 s...

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