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Hypertherm HyPerformance HPR130XD, Instruction Manual

The Hypertherm HyPerformance HPR130XD is a state-of-the-art cutting system that delivers exceptional speed, precision, and reliability. To assist users in maximizing its potential, we offer a comprehensive Instruction Manual for download, absolutely free. Visit our website to get this manual and unlock the full potential of this remarkable product.

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INPUT POWER

FROM FACILITY

L1

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SEE PAGES 6 AND 7 FOR

OTHER CONFIGURATIONS

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ELEC SCH:HPR130XD POWER SUPPLY W/AUTO

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Summary of Contents for HyPerformance HPR130XD

Page 1: ...HyPerformance Plasma HPR130XD Auto gas Instruction manual 806330 Revision 3 ...

Page 2: ..._____________________________________ ____________________________________________________________________ ____________________________________________________________________ Maintenance notes ________________________________________________________________________ ________________________________________________________________________ ____________________________________________________________...

Page 3: ...Revision 3 June 2015 Hypertherm Inc Hanover NH USA www hypertherm com 2015 Hypertherm Inc All Rights Reserved Hypertherm HyPerformance HyDefinition LongLife and CommandTHC are trademarks of Hypertherm Inc and may be registered in the United States and or other countries ...

Page 4: ...489 Tel 65 6841 2490 Fax 65 6841 2489 Technical Service Hypertherm Shanghai Trading Co Ltd Unit 301 South Building 495 ShangZhong Road Shanghai 200231 PR China 86 21 60740003 Tel 86 21 60740393 Fax Hypertherm Europe B V Vaartveld 9 4704 SE Roosendaal Nederland 31 165 596907 Tel 31 165 596901 Fax 31 165 596908 Tel Marketing 31 165 596900 Tel Technical Service 00 800 4973 7843 Tel Technical Service ...

Page 5: ...uipment 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 premises Methods of reducing emi...

Page 6: ...es 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 in crease the risk of injury for example by allowing parallel ...

Page 7: ...operly packed to Hypertherm s place of business in Hanover New Hampshire or to an authorized Hypertherm repair facility all costs insurance and freight pre paid by the customer Hypertherm shall not be liable for any repairs replacement or adjustments of Products covered by this warranty except those made pursuant to this paragraph and with Hypertherm s prior written consent The warranty set forth ...

Page 8: ...erage sufficient and appropriate to defend and to hold Hypertherm harmless in the event of any cause of action arising from the use of the products transfer of rights You may transfer any remaining rights you may have hereunder only in connection with the sale of all or substantially all of your assets or capital stock to a successor in interest who agrees to be bound by all of the terms and condi...

Page 9: ...C 5 Gas cylinders can explode if damaged SC 5 Toxic fumes can cause injury or death SC 5 A plasma arc can cause injury and burns SC 6 Arc rays can burn eyes and skin SC 6 Pacemaker and hearing aid operation SC 6 Noise can damage hearing SC 7 Dry dust collection information SC 7 Laser radiation SC 8 Additional safety information SC 8 Section 2 Specifications 2 1 System description 2 3 General 2 3 P...

Page 10: ... 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 selection console cables 3 20 Control cable 3 20 Power cable 3 20 Selection console to metering console connections 3 22 Cable and gas hose assembly 3 22 Power supply to CNC interface cable 3 24 Optional multi system CNC interface...

Page 11: ...9 Fill the power supply with coolant 3 50 Gas requirements 3 51 Setting the supply regulators 3 51 Gas regulators 3 52 Supply gas plumbing 3 53 Connect the supply gases 3 54 Supply gas hoses 3 55 Section 4 Operation 4 1 Daily start up 4 3 Check torch 4 3 Power indicators 4 4 General 4 4 Power supply 4 4 Selection console 4 4 Metering console 4 4 CNC controller requirements 4 5 Base required elemen...

Page 12: ...ty 4 21 Additional improvements 4 23 Cut charts 4 24 Overview 4 24 Bevel cutting definitions 4 27 Estimated kerf width compensation 4 30 Section 5 maintenance 5 1 Introduction 5 3 Routine maintenance 5 3 System description 5 4 Power and signal cables 5 4 Sequence of operation 5 5 Gas system purge cycle 5 6 Gas system valve usage 5 6 Marking process 5 8 PCB block diagram 5 9 Error codes 5 10 Error ...

Page 13: ... 5 33 Power supply coolant system servicing 5 34 Draining the coolant system 5 34 Coolant system filter and strainer 5 35 Filter replacement 5 35 Pump strainer cleaning 5 35 Coolant flow troubleshooting chart 5 36 Coolant flow tests 5 37 Before testing 5 37 Using the Hypertherm flow meter 128933 5 37 Manual pump operation 5 38 Test 1 return line 5 39 Test 2 supply line at ignition console 5 39 Tes...

Page 14: ...ion console 6 10 Metering console 6 12 HyPerformance torch 6 13 Torch assembly 6 13 Torch leads 6 14 Ohmic contact wire 6 14 Consumable parts kits 6 15 Consumables for mirror image cutting 6 16 Straight cutting 6 16 Bevel cutting 6 18 Recommended spare parts 6 19 Warning Label 110647 6 20 Section 7 Wiring Diagrams 7 1 Introduction 7 1 Wiring Diagram Symbols 7 1 Discrete output functionality 7 4 Ap...

Page 15: ...at b 5 Framing b 5 Commands b 5 Command table 1 of 14 b 6 Error responses b 20 Calculating checksums b 20 Error codes b 21 Status codes b 25 Gas type codes b 25 CNC requirements b 26 Auto gas console b 26 Serial interface guidelines b 27 Checksum b 27 Message retries b 27 Cable shielding b 27 Appendix C robotic applications c 1 Components for robotic applications c 2 Torch leads c 2 Ohmic contact ...

Page 16: ...Table of Contents viii HPR130XD Auto Gas 806330 ...

Page 17: ...ety SC 3 Electrical hazards SC 3 Electric shock can kill SC 3 Cutting can cause fire or explosion SC 4 Machine motion can cause injury SC 4 Compressed gas equipment safety SC 5 Gas cylinders can explode if damaged SC 5 Toxic fumes can cause injury or death SC 5 A plasma arc can cause injury and burns SC 6 Arc rays can burn eyes and skin SC 6 Pacemaker and hearing aid operation SC 6 Noise can damag...

Page 18: ...afe operation the equipment must be repaired by qualified personnel prior to its next use or withdrawn from service Responsibility for safety The person or entity responsible for the safety of the workplace must Make sure that operators and their supervisors are trained in the safe use of their equipment the safe use of the process and emergency procedures Make sure that all hazards and safety pre...

Page 19: ... torch and the workpiece The workpiece and anything touching the workpiece are part of the electrical circuit In machine torch applications never touch the torch body workpiece or water in a water table when the plasma system is operating Electric shock prevention All plasma systems use high voltage in the cutting process 200 to 400 VDC are common Take the following precautions when operating this...

Page 20: ... the plasma arc or a spark from any source can ignite this trapped hydrogen gas causing an explosion that may result in death personal injury loss of property or equipment damage Consult with the table manufacturer and other experts prior to cutting aluminum to implement a risk assessment and mitigation plan that eliminates the risk of detonation by preventing hydrogen accumulation Also make sure ...

Page 21: ... of welding and cutting systems in operation Other workplace processes that may produce fumes If the workplace must conform to national or local regulations only monitoring or testing done at the site can determine whether the workplace is above or below allowable levels To reduce the risk of exposure to fumes Remove all coatings and solvents from the metal before cutting Use local exhaust ventila...

Page 22: ...ne 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 others from flash and glare Warn others not to watch the arc Use placards or signs Arc current Minimum protective shade number ANSI Z...

Page 23: ...ial explosion hazard The U S National Fire Protection Association s NFPA standard 68 Explosion Protection by Deflagration Venting provides requirements for the design location installation maintenance and use of devices and systems to vent combustion gases and pressures after any deflagration event Consult with the manufacturer or installer of any dry dust collection system for applicable requirem...

Page 24: ... remove or deface the laser safety label 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 Standards Institute 1430 Broadway New York NY 10018 3 ANSI Standard Z87 1 Safe Practices for Occupation a...

Page 25: ...gnition console 2 3 Selection console 2 3 Metering console 2 3 Torch 2 3 Specifications 2 4 System gas requirements 2 4 Power supply 2 5 Ignition console 078172 2 6 Torch lead junction box Optional 078619 2 8 Selection console 078533 2 9 Metering console 078535 2 10 Torch 228520 2 11 IEC symbols 2 12 Symbols and Marks 2 13 ...

Page 26: ...Specifications 2 2 HPR130XD Auto Gas 806330 ...

Page 27: ...n and mixing of the plasma gases It contains motor valves solenoid valves and pressure transducers It also contains a PC control board an AC relay board and a power distribution board The selection console has an LED lamp that illuminates when power is supplied to the system Metering console The metering console may be located up to 1 8 m 6 ft away from the torch and controls the flow rate of the ...

Page 28: ...sion Water the pressure dewpoint of the humidity must be less than or equal to 3 C 37 4 F Oil the concentration of oil can be no more than 0 1 mg per cubic meter of air Gas quality and pressure requirements Gas type Quality Pressure 10 Flow rate O2 oxygen 99 5 pure Clean dry oil free 793 kPa 8 bar 115 psi 4250 l h 150 scfh N2 nitrogen 99 99 pure Clean dry oil free 793 kPa 8 bar 115 psi 7080 l h 25...

Page 29: ...utput Cooling Forced air Class F Insulation Class H Power supply part numbers AC Voltage U1 Phase Frequency Hz Amperage I1 Regulatory approval Power kVA 10 U1 x I1 x 1 73 Without Hypernet With Hypernet 078538 078546 200 208 3 50 60 62 60 CSA 21 5 078539 078547 220 3 50 60 57 CSA 21 5 078540 078548 240 3 60 52 CSA 21 5 078541 078549 380 3 50 60 33 CCC 21 5 078542 078550 400 3 50 60 32 CE GOST R 21 ...

Page 30: ...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 inch 219 mm 8 625 inch 194 mm 7 625 inch 152 mm 6 inch 216 mm 8 5 inch ...

Page 31: ...Specifications HPR130XD Auto Gas 806330 2 7 Horizontal mounting Vertical mounting LHF mounting local Mounted on table RHF mounting remote ...

Page 32: ...gnition console and torch to facilitate easier replacement of torch leads in certain applications Maximum combined lead length from the ignition console to the torch must be less than or equal to 20 m 65 feet for HPR130XD HPR260XD 15 m 50 feet for HPR400XD HPR800XD 109 mm 4 33 inch 330 mm 13 0 inch 77 5 mm 3 05 inch 178 mm 7 00 inch 254 mm 10 0 inch 165 mm 6 5 inch 7 9 mm 0 31 inch 4 6 kg 10 2 lb ...

Page 33: ...able length from the selection console to the metering console is 20 m 65 ft Mount the selection console on top of the power supply or near the CNC on the cutting table Allow room to open the top for servicing 355 6 mm 14 00 inch 285 75 mm 11 25 inch 311 15 mm 12 25 inch 314 5 mm 12 38 inch 254 0 mm 10 0 inch 13 6 kg 30 lb 0 38 1 mm 1 5 inch 0 76 2 mm 3 0 inch ...

Page 34: ... torch carriage on larger tables On smaller tables it can be mounted to a bracket just above the bridge The vent hole on the console must be kept clear at all times 153 9 mm 6 1 inch 33 3 mm 1 3 inch 122 2 mm 4 8 inch 0 54 9 mm 2 2 inch 76 2 mm 3 0 inch 6 4 kg 14 lb 282 5 mm 11 1 inch 0 248 9 mm 9 8 inch Vent hole Do not block 263 53 mm 10 375 inch 155 58 mm 6 125 inch 285 75 mm 11 25 inch ...

Page 35: ...er of the torch mounting sleeve is 50 8 mm 2 0 inches The minimum bend radius for the torch leads is 152 4 mm 6 0 inches 1 8 m 6 ft 1 9 kg 4 2 lb 193 mm 7 59 inch 49 mm 1 91 inch 104 mm 4 10 inch 57 mm 2 25 inch 51 mm 2 inch 95 mm 3 74 inch 51 mm 2 00 inch 345 mm 13 60 inch 43 ...

Page 36: ...utting Plate metal cutting Expanded metal cutting Gouging AC input power connection The terminal for the external protective earth conductor l Power is ON O Power is OFF f1 f2 1 An inverter based power source either 1 phase or 3 phase Volt amperage curve droop ing characteristic AC Power is ON LED System fault LED Inlet gas pressure fault LCD Missing or loose consumables LCD Power supply is out of...

Page 37: ...ng located on or near the data plate have been tested for compliance with the European Low Voltage Directive and the European Electromagnetic Compatibility EMC Directive EMC filters needed to comply with the European EMC Directive are incorporated within versions of the product with a CE marking Eurasian Customs Union CU mark CE versions of products that include an EAC mark of conformity meet the ...

Page 38: ...Specifications 2 14 HPR130XD Auto Gas 806330 ...

Page 39: ... practices 3 6 Grounding diagram 3 9 Placement of the power supply 3 11 Install the ignition console 3 12 Install the metering console 3 14 Placement of the selection console 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 selection console cables 3 20 Control cable 3 20 Po...

Page 40: ...nting the torch 3 42 Torch alignment 3 42 Torch lifter requirement 3 43 Hypernet 3 43 Power requirements 3 44 General 3 44 Line disconnect switch 3 45 Main power cable 3 45 Connect the power 3 46 Torch coolant requirements 3 47 Premixed coolant for standard operating temperatures 3 47 Custom Coolant mix for cold operating temperatures 3 48 Custom Coolant mix for hot operating temperatures 3 49 Wat...

Page 41: ...d 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 system Always wear proper ear protection when cutting or gouging Any noise measurements taken are dependant o...

Page 42: ...Installation 3 4 HPR130XD Auto Gas 806330 Installation requirements A B C D 1 2 3 4 5 6 7 8 9 10 11 13 E 15 14 12 13 15 16 ...

Page 43: ...able 4 Ignition console coolant hoses 5 Gas control cable 6 Gas power cable 7 Selection console to metering console hose and lead assembly 8 CNC interface cable 9 Optional CNC interface cable for systems with multiple power supplies 10 Torch lead assembly 11 Work lead Supply gas hoses 12 Oxygen 13 Nitrogen or argon 14 Air 15 Argon hydrogen H35 or nitrogen hydrogen F5 Customer supplied power cable ...

Page 44: ...a shock hazard to any personnel from any of the equipment or the cutting table It includes the service ground coming into the plasma system and other systems such as the CNC and the motor drives as well as the supplemental ground rod connected to the cutting table In the plasma circuits the ground is carried from the plasma system chassis to the chassis of each separate console through the interco...

Page 45: ...abinet or enclosure must have a separate ground cable to the common star ground on the table This includes the ignition console whether it is bolted to the plasma system or to the cutting table 10 The metal braided shield on the torch lead must be connected firmly to the ignition console and to the torch It must be electrically insulated from any metal and from any contact with the floor or buildi...

Page 46: ...equency RHF console 5 CNC enclosure 6 Torch holder 7 Plasma system chassis The following picture shows an example of a gantry ground bus It is bolted to the gantry close to the motor All of the individual ground cables from the components mounted on the gantry connect to the bus A single heavy cable then connects the gantry ground bus to the table ground bus 1 2 1 Cable to the cutting table ground...

Page 47: ...ting table 2 Gantry 3 Plasma system 4 Table ground bus bar 5 Gantry ground bus bar 6 Torch height control lifter ArcGlide Sensor THC Sensor PHC or other 7 RHF console not on all systems Connect to table ground bus bar 8 9 System specific component such as metering console gas console or selection console 10 CNC chassis 11 Torch height control module ArcGlide Command THC 12 System specific componen...

Page 48: ...Installation 3 10 HPR130XD Auto Gas 806330 ...

Page 49: ...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 any filter device over the air intake locations which reduces cooling efficiency and VOIDS ...

Page 50: ...antry 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 Ignition console grounding 7 mm 0 28 inch 4 places 32 mm 1 25 inch 32 mm 1 25 inch 184 mm 7 25 inch 279 mm 11 00 inch 248 mm 9 75 inch 216 mm 8 50 inch B ...

Page 51: ...Installation HPR130XD Auto Gas 806330 3 13 LHF mounting Horizontal RHF mounting Vertical RHF mounting ...

Page 52: ...h lifter station The maximum length of the gas hoses between the metering console and the torch is 1 8 m 6 ft Metering console grounding 153 9 mm 6 1 inch 33 3 mm 1 3 inch 122 2 mm 4 8 inch 0 54 9 mm 2 2 inch 76 2 mm 3 0 inch 282 5 mm 11 1 inch 0 248 9 mm 9 8 inch Vent hole Do not block 7 mm 0 28 inch 4 places C ...

Page 53: ...tion is shown in the figure below The maximum length of cables between the power supply and selection console is 75 m 250 ft The maximum length of cables and hoses between the selection console and the metering console assembly is 20 m 65 ft Preferred selection console orientation Selection console grounding 314 5 m 12 38 inch 254 0 mm 10 0 inch 0 38 1 mm 1 5 inch 0 76 2 mm 3 0 inch 7 mm 0 28 inch...

Page 54: ...pply 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 ft Part no Length Part no Length 123702 1 5 m 5 ft 123815 20 m 65 ft 123661 3 m 10 ft 123734 25 m 82 ft 123813 4 5 m 15 ft 123664 35 m 115 ft 12366...

Page 55: ...Installation HPR130XD Auto Gas 806330 3 17 Pilot arc lead Negative lead Pilot arc lead Negative lead 1 2 2 1 Work lead 1 2 ...

Page 56: ...sole end Pin No Description Pin No 1 120 Vac hot 1 2 120 Vac return 2 3 Ground 3 4 Not used 4 Part no Length Part no Length 123865 2 1 m 7 ft 123836 20 m 65 ft 123419 3 m 10 ft 123425 22 5 m 75 ft 123834 4 5 m 15 ft 123736 25 m 82 ft 123420 6 m 20 ft 123426 30 m 100 ft 123670 7 5 m 25 ft 123672 35 m 115 ft 123422 9 m 30 ft 123938 37 5 m 125 ft 123835 10 m 35 ft 123673 45 m 150 ft 123423 12 m 40 ft...

Page 57: ...he ignition console mounted on the power supply Part no Length Part no Length 228030 0 7 m 2 5 ft 128984 20 m 65 ft 028652 3 m 10 ft 128078 25 m 85 ft 028440 4 5 m 15 ft 028896 35 m 115 ft 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 4 Caution Never use PTFE tape on any joint preparation ...

Page 58: ...3 6 m 20 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 Cable signal list power supply to gas console Power supply end Gas console end Pin No Input Output Description Pin No Input Output Function 1 Not used 1 Not used 6 Not used 6 Not used 2 Input Output CAN L 2 Input Output CAN serial communication 7 Input Outp...

Page 59: ...Installation HPR130XD Auto Gas 806330 3 21 1X1 J103 J300 Female Male 5 6 5 6 3X1 3X2 3X3 3X4 ...

Page 60: ...in No Input Output Description Pin No Input Output Function 1 Input 120 VAC power 1 Output AC in return 2 Input 120 VAC power 2 Output AC in hot 3 Input Chassis ground 3 Output Chassis ground 4 Not used 4 Not used 5 Not used 5 Not used 6 Not used 6 Not used 7 Not used 7 Not used Comunication cable signal list 9 pin DSUB connectors Metering console end Selection console end Pin No Input Output Desc...

Page 61: ...Installation HPR130XD Auto Gas 806330 3 23 7 Caution Never use PTFE tape on any joint preparation ...

Page 62: ...has timed out Input Input 2 3 Red Yellow 10 29 Output Output Motion 4 E Motion 4 C Notifies the CNC that an arc transfer has occurred and to begin machine motion once the CNC s pierce delay has timed out Input Input 2 3 Red Brown 11 30 None None Not used Not used Red Orange 12 31 Input Input Corner Corner The CNC Notifies the plasma system that a corner is approaching and to reduce cut current Cut...

Page 63: ... isolated open collector transistors The maximum rating is 24 VDC at 10 mA Note 3 Machine motion is selectable and is used for configurations with multiple plasma systems Note 4 CNC 24 VDC provides 24 VDC at 200 mA maximum A jumper is required on J301 to use 24 V power Caution The CNC cable must be constructed using cable with 360 degree shielding and metal housing connectors at each end The shiel...

Page 64: ...impedance 10 mA 10K optional CNC PLC 5 VDC 24 VDC C HPR E HPR C E 5 VDC 24 VDC High impedance 10 mA CNC PLC 10K optional CNC PLC CNC 24 V 24 VDC CNC 24 V HPR C E Power ground High current contact closure inputs AC or DC t Any voltage VO IDS WARRANTY HPR Install a Jumper 108056 J304 C E External relay 24 VDC low power coil 10 mA or 2400 ohms All relay coils require a freewheeling diode across the r...

Page 65: ...r ground 2 Optocoupler interface CNC PLC 24 VDC HPR Power ground Transistor output optocoupler 12 V 24 VDC 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 100 V or higher in parallel with the relay contacts ...

Page 66: ...3 as shown TB2 location Note Use a switch relay or solid state relay that is compatible with 24 VAC 100 mA It must be a maintained contact switch not a momentary contact switch Remote ON OFF switch provided by customer DANGER Electric Shock Can Kill Disconnect electrical power before performing any maintenance See the Safety Section in this Manual for more safety precautions TB2 2 1 3 1 1 3 3 TB2 ...

Page 67: ...ft 228295 7 5 m 25 ft 228296 10 m 35 ft 228297 15 m 50 ft 228547 20 m 65 ft 10 Caution The length of the hoses from the torch to the metering console are critical to cut quality and consumable life Do not alter the length of the hoses 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 68: ...ist for part numbers Caution Total lead length from the ignition console to the torch must be less than or equal to 20 m 65 feet for HPR130XD HPR260XD 15 m 50 feet for HPR400XD HPR800XD 1 Metering console 2 Ignition console 3 Junction box lead 4 Junction box 5 Junction box to torch lead 1 2 3 4 5 ...

Page 69: ...utting location See Specification for Junction box mounting dimensions Note Allow space to install and remove the cover of the box for servicing 3 Ground the junction box to the bus bar on the cutting table or equivalent See Recommended grounding and shielding in the Installation section in your system s instruction manual for more information ...

Page 70: ...en the connections Junction box to the ignition console 1 Connect one end of the junction box lead to the junction box Note The lead can go in either end of the junction box 1 Coolant supply hose green 3 Pilot arc lead yellow 2 Coolant return hose red From the ignition console 1 2 3 ...

Page 71: ...Installation HPR130XD Auto Gas 806330 3 33 2 Connect the other end of the junction box lead to the ignition console 1 Coolant supply hose green 3 Pilot arc lead yellow 2 Coolant return hose red 1 2 3 ...

Page 72: ...d from the torch to the junction box 1 Connect the lead from the torch to the junction box 1 Coolant supply hose green 3 Pilot arc lead yellow 2 Coolant return hose red 2 Install the junction box cover From the ignition console From the torch 1 2 3 ...

Page 73: ...tallation HPR130XD Auto Gas 806330 3 35 3 Connect the torch hoses to the metering console 1 Metering console 2 Junction box 3 Plasma gas vent hose white 4 Plasma gas hose black 5 Shield hose blue 1 3 2 4 5 ...

Page 74: ...me 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 11 ...

Page 75: ... 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 return hose red Braided cover Sleeve Coolant return hose E Caution Never use PTFE tape on any joint...

Page 76: ...e through the opening in the braided cover and the torch sleeve Braided cover Sleeve 6b Insert the connector into the torch receptacle and turn it by hand until it is tight Ohmic contact wire part numbers Not part of the HPR130XD system Shown for reference only Part no Length 123983 3 m 10 ft 123984 6 m 20 ft 123985 7 5 m 25 ft 123986 9 m 30 ft 123987 12 m 40 ft 123988 15 m 50 ft 123989 23 m 75 ft...

Page 77: ...in steps 7 10 are push to connect fittings To make a connection push the hose fitting into the appropriate connector until it stops 13 mm 0 5 in To disconnect a fitting push the connector collar toward the torch and pull the hose away from the torch connector collar 8 Connect the coolant supply hose green 9 Connect the plasma gas hose black ...

Page 78: ... screw it onto the torch assembly 12 Slide the braided cover up to the torch sleeve Make sure that the plasma shield and vent hoses are routed through the hole in the braided cover Loosen the hose clamp on the braided cover slide the braided cover and clamp over the sleeve and tighten the clamp ...

Page 79: ...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 220706 Torch quick disconnect receptacle 220705 ...

Page 80: ...ached 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 touching the torch quick disconnect 3 Tighten the securing screws Note The bracket should be as low on the torch sleeve as possible to minimize vibration at the tip of the torch Lower torch sleeve Torch mounting bracket customer supplied Up...

Page 81: ...fts through the stop point is not acceptable Hypernet Hypernet is only used to connect certain Hypertherm components to each other An HPRXD system can be connected to the ArcGlide torch height control and an EDGE Pro or MicroEDGE Pro CNC using an ethernet hub and cable The Hypernet PCB provides communication between components and is the source for the arc voltage needed for the torch height contr...

Page 82: ... performed by a licensed electrician Use a separate primary line disconnect switch for the power supply Recommendations on fuse and circuit breaker sizing are listed below however actual sizes required will vary based on individual site electrical line conditions including but not limited to source impedance line impedance and line voltage fluctuation product inrush characteristics and regulatory ...

Page 83: ...tion Have one OFF and one ON position clearly marked with O OFF and l ON Have an external operating handle capable of being locked in the OFF position Contain a power operated mechanism that serves as an emergency stop Have slow blow fuses installed for the proper breaking capacity see table above Main power cable Wire sizes vary based on the distance of the receptacle from the main box The wire s...

Page 84: ...stallation of the system 5 Connect the power cord leads to the line disconnect switch following national and local electrical codes North American wire colors U Black V White W Red PE Earth ground Green Yellow European wire colors U Black V Blue W Brown PE Earth ground Green Yellow Line disconnect switch Power cable TB1 W V PE U DANGER Electric Shock Can Kill The line disconnect switch must be in ...

Page 85: ...owed Upon contact flush skin or eyes with water If swallowed seek immediate medical attention 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 corrosion in the torch coolant system Definitions Ambient tem...

Page 86: ...m due to freezing Use the chart below to determine what percentage of propylene glycol to use in the mixture Mix 100 glycol 028873 with the premixed Hypertherm coolant 028872 to increase the percentage of glycol The 100 glycol solution can also be mixed with purified water see next page for water purity requirements to achieve the required protection from freezing Note The maximum percentage of gl...

Page 87: ...ets the minimum and maximum specifications in the table below when using a custom coolant mix Water that does not meet the minimum purity specifications below can cause excessive deposits on the nozzle that will alter the water flow and produce an unstable arc Water that does not meet the maximum purity specifications below can also cause problems Deionized water that is too pure will cause leachi...

Page 88: ...the CNC screen for manual pump control The pump needs to run to fill the leads 4 Add coolant to the power supply until the tank is full and replace the filler cap 1 Add coolant to the power supply until the tank is full 2 Turn ON the power supply using the remote ON OFF switch or the CNC Caution Using the wrong coolant can cause damage to the system Refer to torch coolant requirements in this sect...

Page 89: ...115 psi 2 Turn ON the power to the system using the remote ON OFF switch or the CNC 3 Set to Test Preflow 4 While gas is flowing adjust the supply regulator for the shield gas pressure to 8 bar 115 psi 5 Turn OFF Test Preflow 6 Set system to Test Cutflow 7 While gas is flowing adjust the supply regulator for the plasma gas to 8 bar 115 psi 8 Turn OFF Test Cutflow Caution Gas supply pressures not w...

Page 90: ...ality gas regulators listed below are available from Hypertherm and meet U S Compressed Gas Association CGA specifications In other countries select gas regulators that conform to national and local codes 2 stage regulator Single stage regulator 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 s...

Page 91: ...nsole to achieve the proper mixtures in the preflow and cutflow modes Caution When connecting the selection console to the supply gases make sure that all hoses hose connections and fittings are acceptable for use with oxygen and argon hydrogen Installation must be made in accordance with national and local codes WARNING CUTTING WITH OXYGEN CAN CAUSE FIRE OR EXPLOSION Cutting with oxygen as the pl...

Page 92: ...ants containing esters that are used in some air compressors will damage polycarbonates used in the air regulator bowl Fitting Size N2 Ar 5 8 18 RH internal inert gas B Air 9 16 18 JIC 6 H35 F5 H5 9 16 18 LH fuel gas B O2 9 16 18 RH oxygen B Caution Replacing the fittings on the selection console may cause the internal valves to malfunction because particulates can migrate into the valves ...

Page 93: ...1 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 Oxygen hose 12 13 14 Argon hydrogen H35 or nitrogen hydrogen F5 Part no Length P...

Page 94: ...Installation 3 56 HPR130XD Auto Gas 806330 ...

Page 95: ...examples 4 6 Main control screen 4 6 Diagnostics screen 4 7 Test screen 4 8 Cut chart screen 4 9 Consumable selection 4 10 Standard cutting 0 4 10 Bevel cutting 0 to 45 4 10 Marking 4 10 Consumables for mirror image cutting 4 10 SilverPlus electrodes 4 10 Mild steel 4 11 Stainless steel 4 11 Aluminum 4 12 Mild steel bevel cutting 4 13 Stainless steel bevel cutting 4 13 Install and Inspect consumab...

Page 96: ... Common cutting faults 4 19 How to optimize cut quality 4 20 Tips for table and torch 4 20 Plasma set up tips 4 20 Maximize the life of consumable parts 4 20 Additional factors of cut quality 4 21 Additional improvements 4 23 Cut charts 4 24 Overview 4 24 Bevel cutting definitions 4 27 Estimated kerf width compensation 4 30 ...

Page 97: ...ause the torch to malfunction Refer to Install and inspect consumables 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 Install and inspect consumables later in this section for details 4 Ensure that the torch is perpendicular to the workpiece Shield cap Torch Curre...

Page 98: ...General Power for the system is controlled by the CNC The power supply selection console and metering console each have an LED lamp that illuminates when power is supplied to the component Green indicator Power supply Selection console Metering console Green indicator ...

Page 99: ...ntrol Required real time elements The following elements should be able to be displayed in real time while cutting This is necessary for trouble shooting and diagnostic purposes 5 Display line voltage 6 Display chopper current 7 Display work lead current 8 Display system status code 9 Display chopper temperature 10 Display transformer temperature 11 Display coolant temperature 12 Display coolant f...

Page 100: ...HPR130XD Auto Gas 806330 Revision 2 CNC screen examples The screens shown are for reference The screens you work with may be different but should include the functions listed on the previous page Main control screen ...

Page 101: ...Operation HPR130XD Auto Gas 806330 Revision 2 4 7 Diagnostics screen ...

Page 102: ...Operation 4 8 HPR130XD Auto Gas 806330 Revision 2 Test screen ...

Page 103: ...Operation HPR130XD Auto Gas 806330 Revision 2 4 9 Cut chart screen ...

Page 104: ...ark can be increased by reducing the marking speed or the depth can be decreased by increasing the marking speed Argon marking currents can be increased by up to 30 to increase the depth of the mark When marking with an argon process at 25 amperes or greater the process will start with air before changing to argon and a thicker darker mark will be seen at the start of the mark When using the argon...

Page 105: ...0179 220179 220188 220182 220183 220189 220194 220756 220756 220754 220747 Shield Nozzle Swirl ring Electrode Nozzle retaining cap Shield cap 220552 220553 220554 220555 220754 50 A 220340 Water tube 220201 220308 220180 45 A 220339 80 A 220307 130 A 220179 220179 220337 220197 220198 220338 220202 220755 H35 220756 N2 220755 220755 220747 Shield Nozzle Swirl ring Electrode Nozzle retaining cap Sh...

Page 106: ...as 806330 Revision 2 Aluminum 220201 220308 220180 220307 H35 220181 Air 220179 220197 220198 220202 220756 220747 220755 H35 220756 Air Shield Nozzle Swirl ring Electrode Nozzle retaining cap Shield cap 220340 45 A 130 A Water tube ...

Page 107: ...p 220606 220179 220656 220571 Nozzle retaining cap Mild steel bevel cutting Stainless steel bevel cutting 220637 220739 220738 Shield Nozzle Swirl ring Electrode Water tube Shield cap 130 A 220649 220179 220646 220700 220742 220740 220637 Nozzle retaining cap 80 A 220802 220179 220806 220700 220742 220845 220637 ...

Page 108: ...the shield cap Install consumables Check the consumable parts daily for wear before cutting Before removing consumables bring the torch to the edge of the cutting table with the torch lifter raised to its highest point to prevent the consumables from dropping into the water of the water table Note Do not overtighten parts Only tighten until mating parts are seated WARNING The system is designed to...

Page 109: ...s no longer round Replace shield Apply a thin film of silicone lubricant if the o rings are dry Nozzle retaining cap General Damage to insulating ring Poor cut quality after replacing other consumables Replace nozzle retaining cap Replace nozzle retaining cap Nozzle Always replace the nozzle and electrode as a set General Erosion or missing material Blocked gas holes Center hole Must be round Sign...

Page 110: ...e Always replace the nozzle and electrode as a set Center surface Emitter wear a pit forms as the emitter wears O rings Damage Lubricant In general replace the electrode when the pit depth is 1 mm 0 04 in or greater For the 400 A mild steel electrode and all SilverPlus electrodes replace the electrode when the pit depth is 1 5 mm 0 06 in or greater See Electrode pit depth gage below Replace electr...

Page 111: ...e 4 If consumables will be reused use a clean cloth to wipe them off and use compressed air to blow them off before they are installed again This is especially critical for the nozzle retaining cap Quick disconnect maintenance The following steps should be completed every 5 10 times consumables are changed 1 Remove the torch from the quick disconnect assembly 2 Use compressed air to blow off all i...

Page 112: ...s See Install and inspect consumables in this section Replace torch water tube Plasma gas Plasma vent Coolant in Pilot arc Shield gas Coolant return Torch connections Ohmic contact pin Torch quick disconnect receptacle Torch Coolant in Coolant return Note The coolant in and the coolant return lines in the quick disconnect are in opposite positions from the torch coolant lines This helps reduce the...

Page 113: ...e worn see Install and inspect consumables 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 consuma...

Page 114: ... LongLife process also requires that cuts start and stop 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 ...

Page 115: ...angle problem is being caused by the plasma system or the drive system make a test cut and measure the angle of each side Next rotate the torch 90 in its holder and repeat the process If the angles are the same in both tests the problem is in the drive system If a cut angle problem persists after mechanical causes have been eliminated see Tips for table and torch previous page check the torch to w...

Page 116: ...uts will likely produce the least dross As the workpiece heats up more dross may form on subsequent cuts Dross is more likely to form on mild steel than on stainless steel or aluminum Worn or damaged consumables may produce intermittent dross Straightness of the cut surface A typical plasma cut surface is slightly concave The cut surface may become more concave or convex Correct torch height is re...

Page 117: ... same as the thickness of the material being pierced 50 mm 2 in material requires a 50 mm lead in To avoid damage to the shield from the build up of molten material created by the pierce do not allow the torch to descend to cut height until it has cleared the puddle of molten material Different material chemistries can have an adverse effect on the pierce capability of the system In particular hig...

Page 118: ... of the cut A shiny surface finish Good cut edge angularity You can use these 60 A stainless steel settings with your existing HPRXD system along with the following three new consumables 220814 nozzle retaining cap 220815 shield 220847 nozzle The cut charts and consumables for the 60 A stainless steel process can be used with both automatic and manual gas consoles Recommendations Hypertherm develo...

Page 119: ...signed to work best when the torch is perpendicular to the workpiece Operators can expect to achieve the same consumable life they currently get using comparable amperage processes with the standard quality cut charts Note The pierce complete or pierce control signal must be turned off when the shield gas preflow pressure is lower than the shield gas cutflow pressure for example the 80 A processes...

Page 120: ...g bevel heads with an HPRXD plasma cutting system are now able to use dynamic cut charts or compensation tables with compatible CNC and nesting software to achieve more accurate bevel cutting results with mild steel These specialized cut charts enable operators to retrieve bevel cut settings that are specially tailored for making V cuts A cuts and Y Top cuts The bevel compensation tables require a...

Page 121: ...s divided by the cosine of the bevel angle Equivalent thicknesses are listed in the cut chart Clearance 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...

Page 122: ...increased dross levels WARNING Explosion hazard underwater cutting with fuel gases or aluminum Do not cut under water with fuel gases containing hydrogen Do not cut aluminum alloys underwater or on a water table unless you can prevent the accumulation of hydrogen gas Doing so can result in an explosive condition that can detonate during plasma cutting operations All underwater processes 80 400 A u...

Page 123: ...ut not so high that the excess force causes a deflection of the workpiece and inaccurate IHS operation In this example the cut height value can be adjusted from the cut chart while the stall force value can be adjusted from the THC setup parameters Refer to the instruction manuals for your Hypertherm CNC and THC systems for more details on setting the stall force threshold or on disabling ohmic co...

Page 124: ...N A 30A O2 O2 1 35 1 45 1 54 1 56 N A N A N A N A N A N A N A N A Stainless steel 130A H35 N2 N A N A N A N A 2 69 2 72 2 77 3 03 2 90 3 25 N A N A 130A N2 N2 N A N A N A 1 83 1 89 1 88 2 42 2 51 3 00 N A N A N A 130A H35 and N2 N2 N A N A N A 1 78 2 25 2 73 2 76 3 03 2 90 N A N A N A 80A F5 N2 N A N A 1 02 1 20 1 05 0 96 N A N A N A N A N A N A 45A F5 N2 0 59 0 38 0 52 0 54 N A N A N A N A N A N ...

Page 125: ...24 0 125 0 129 N A N A 130A N2 N2 N A N A 0 072 0 074 0 083 0 095 0 100 0 118 N A N A N A 130A H35 and N2 N2 N A N A 0 070 0 089 0 107 0 109 0 123 0 114 N A N A N A 80A F5 N2 N A 0 032 0 047 0 050 0 052 N A N A N A N A N A N A 45A F5 N2 0 023 0 015 0 021 N A N A N A N A N A N A N A N A 45A N2 N2 0 019 0 009 0 006 N A N A N A N A N A N A N A N A Aluminum 130A H35 N2 N A N A N A 0 106 0 107 0 109 0 ...

Page 126: ...ozzle Retaining Cap Nozzle Swirl Ring Electrode Water Tube mm Amps Plasma gas Shield gas Part Number 3 30 O 2 O 2 220747 220194 220754 220193 220180 220192 220340 4 5 6 5 50 O 2 O 2 220747 220555 220754 220554 220553 220552 220340 6 7 80 O 2 Air 220747 220189 220756 220188 220179 220187 220340 8 9 10 10 130 O 2 Air 220747 220183 220756 220182 220179 220181 220340 12 ...

Page 127: ... gas Plasma gas Shield gas Plasma gas Shield gas Volts mm mm m mm Factor Seconds 3 30 O 2 O 2 78 75 94 7 119 1 5 1160 2 7 180 0 5 4 124 905 0 7 5 125 744 0 9 6 128 665 1 0 5 50 O 2 O 2 70 30 81 14 123 1 5 1200 3 0 200 0 4 6 128 2 0 950 4 0 0 5 7 80 O 2 Air 48 23 78 25 119 1 5 2286 4 1 267 0 4 8 2240 9 121 1987 0 5 10 122 1733 10 130 O 2 Air 32 32 84 27 129 2 3 2437 6 1 267 0 3 12 25 132 2 5 1935 6...

Page 128: ...zle Retaining Cap Nozzle Swirl Ring Electrode Water Tube in Amps Plasma gas Shield gas Part Number 0 135 30 O 2 O 2 220747 220194 220754 220193 220180 220192 220340 3 16 1 4 50 O 2 O 2 220747 220555 220754 220554 220553 220552 220340 5 16 80 O 2 Air 220747 220189 220756 220188 220179 220187 220340 3 8 3 8 130 O 2 Air 220747 220183 220756 220182 220179 220181 220340 1 2 ...

Page 129: ...ime in Amps Plasma gas Shield gas Plasma gas Shield gas Plasma gas Shield gas Volts in ipm in Factor Seconds 0 135 30 O 2 O 2 78 75 94 7 123 0 06 40 0 11 180 0 5 3 16 128 30 0 7 1 4 50 O 2 O 2 70 30 81 14 125 0 08 35 0 16 200 0 5 5 16 80 O 2 Air 48 23 78 25 119 0 06 90 0 16 267 0 4 3 8 121 70 0 5 3 8 130 O 2 Air 32 32 84 27 128 0 09 98 0 24 267 0 3 1 2 25 132 0 10 70 0 26 260 0 5 Note The pierce c...

Page 130: ... 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 gas Shield gas Plasma gas Shield gas Plasma gas Shield gas inches Volts inches ipm inches Factor Seconds O2 O2 78 17 94 17 0 018 114 0 05 215 0 09 180 0 1 0 024 200 0 030 115 17...

Page 131: ... 5 5 16 130 25 English Marking Select Gases Set Preflow Set Cutflow Material Thickness Arc Voltage Torch to Work Distance Cutting Speed Initial Pierce Height Pierce Delay Time Plasma gas Shield gas Plasma gas Shield gas Plasma gas Shield gas mm Volts mm mm m mm Factor Seconds O2 O2 70 30 81 14 0 8 110 1 0 6500 2 0 200 0 0 1 111 5000 1 2 112 4150 1 5 114 1 3 3200 2 6 2 115 2700 2 5 117 2200 0 1 3 1...

Page 132: ... Shield gas Plasma gas Shield gas Plasma gas Shield gas mm Volts mm mm m mm factor seconds O2 Air 48 23 78 23 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 5 121 3670 0 3 6 123 3045 8 125 2430 0 4 10 127 1810 0 5 10 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 Distanc...

Page 133: ...ierce Delay Time Plasma gas Shield gas Plasma gas Shield gas Plasma gas Shield gas mm mm Range mm mm m mm factor seconds O2 Air 48 39 78 39 2 0 2 2 5 8 6 9810 3 8 150 0 1 2 5 7980 3 6145 0 2 4 2 0 8 6 4300 4 0 200 5 3670 0 3 6 3045 8 2430 0 4 10 1810 0 5 17 12 1410 5 0 250 0 7 15 1030 0 8 20 2 5 8 6 545 6 3 0 9 Select Gases Set Preflow Set Cutflow Minimum Clearance Equivalent Material Thickness To...

Page 134: ...d gas mm Volts mm mm m mm factor seconds O2 Air 48 23 78 23 4 116 2 0 3877 4 0 200 0 2 5 118 3407 0 3 6 122 2746 8 125 2162 10 129 1639 10 12 132 1271 5 0 250 0 5 15 136 922 0 7 220189 220747 220756 220179 220188 220340 220187 Select Gases Set Preflow Set Cutflow Material Thickness Arc Voltage Torch to Work Distance Cutting Speed Initial Pierce Height Pierce Delay Time Plasma gas Shield gas Plasma...

Page 135: ...econds O2 Air 32 32 84 28 3 124 2 5 6505 5 0 200 0 1 4 126 2 8 5550 5 6 0 2 5 4795 0 3 6 127 4035 22 8 129 3 0 3360 6 0 10 130 2680 12 132 3 3 2200 6 6 0 5 15 135 3 8 1665 7 6 0 7 52 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 T...

Page 136: ...sma gas Shield gas Plasma gas Shield gas Plasma gas Shield gas inches inches Range inches ipm inches factor seconds O2 Air 15 23 84 21 0 08 0 135 0 10 0 34 240 0 20 200 0 1 3 16 0 11 0 34 190 0 22 0 2 1 4 150 0 3 15 5 16 0 12 0 34 132 0 24 3 8 110 1 2 0 13 0 34 80 0 26 0 5 5 8 0 15 0 34 60 0 30 0 7 3 4 45 1 0 1 0 16 0 34 20 190 1 8 33 1 1 4 0 18 0 34 15 0 40 220 4 0 1 1 2 10 Edge start Mild steel ...

Page 137: ...ield gas mm Volts mm mm m mm factor seconds O2 Air 32 32 84 28 5 127 2 8 4212 5 6 200 0 3 22 8 129 3 0 2998 6 0 10 131 2412 12 133 3 3 1980 6 6 0 5 15 138 3 8 1497 7 6 0 7 220183 220747 220756 220179 220182 220340 220181 Select Gases Set Preflow Set Cutflow Material Thickness Arc Voltage Torch to Work Distance Cutting Speed Initial Pierce Height Pierce Delay Time Plasma gas Shield gas Plasma gas S...

Page 138: ... 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 gas Shield gas Plasma gas Shield gas Plasma gas Shield gas inches Volts inches ipm inches Factor Seconds N2 N2 35 5 62 49 0 036 94 0 10 240 0 15 150 0 0 0 048 210 0 1 0...

Page 139: ... 11 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 gas Shield gas Plasma gas Shield gas Plasma gas Shield gas inches Volts inches ipm inches Factor Seconds F5 N2 35 18 62 49 0 036 99 0 10 240 0 15 150 0 2 0 048 190 0 060 150 0 075 100 130 0 105 102 90 0 135 104 65 0 3 11 3...

Page 140: ...t Preflow Set Cutflow Material Thickness Arc Voltage Torch to Work Distance Cutting Speed Initial Pierce Height Pierce Delay Time Plasma gas Shield gas Plasma gas Shield gas Plasma gas Shield gas mm Volts mm mm m mm Factor Seconds F5 N2 70 40 90 35 3 114 2 0 2770 4 0 200 0 3 4 117 2250 5 118 1955 45 6 120 1635 0 5 Select Gases Set Preflow Set Cutflow Material Thickness Arc Voltage Torch to Work Di...

Page 141: ...tage Torch to Work Distance Cutting Speed Initial Pierce Height Pierce Delay Time Plasma gas Shield gas Plasma gas Shield gas Plasma gas Shield gas mm Volts mm mm m mm factor seconds F5 N2 33 23 65 60 4 108 3 0 2180 4 5 150 0 2 5 110 2 7 1700 4 1 0 3 6 112 2 5 1225 3 8 8 116 3 0 895 4 5 0 4 10 120 560 0 5 Select Gases Set Preflow Set Cutflow Material Thickness Arc Voltage Torch to Work Distance Cu...

Page 142: ...ases Set Preflow Set Cutflow Material Thickness Arc Voltage Torch to Work Distance Cutting Speed Initial Pierce Height Pierce Delay Time Plasma gas Shield gas Plasma gas Shield gas Plasma gas Shield gas inches Volts inches ipm inches factor seconds N2 N2 19 51 75 23 1 4 153 0 12 75 0 24 200 0 3 5 16 155 64 0 4 3 8 156 55 0 5 1 2 162 0 14 30 0 28 0 8 5 8 167 0 15 25 Edge start 3 4 176 0 17 15 Selec...

Page 143: ... English Select Gases Set Preflow Set Cutflow Material Thickness Arc Voltage Torch to Work Distance Cutting Speed Initial Pierce Height Pierce Delay Time Plasma gas Shield gas Plasma gas Shield gas Plasma gas Shield mm Volts mm mm m mm factor seconds H35 N2 19 32 75 49 8 150 4 5 1140 7 7 170 0 3 10 154 980 37 12 158 820 0 5 24 15 162 580 0 8 20 165 360 1 3 16 25 172 260 Edge start Select Gases Set...

Page 144: ...195 27 12 160 3 5 875 7 0 0 5 15 168 3 8 670 7 6 0 8 20 176 4 3 305 7 7 180 1 3 Select Gases Set Preflow Set Cutflow Material Thickness Arc Voltage Torch to Work Distance Cutting Speed Initial Pierce Height Pierce Delay Time Plasma gas Shield gas Plasma gas Shield gas Plasma gas Shield gas Mix Gas 1 Mix Gas 2 inches Volts inches ipm inches Factor Seconds H35 N2 19 51 75 38 32 18 1 4 150 0 12 70 0 ...

Page 145: ...kness Torch to Work Distance Cutting Speed Initial Pierce Height Pierce Delay Time Plasma gas Shield gas Plasma gas Shield gas Plasma gas Shield gas mm mm Range mm mm m mm factor seconds N2 N2 19 51 75 63 2 0 6 3 0 10 0 1960 6 0 200 0 3 8 1630 0 4 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 Materia...

Page 146: ...inimum Clearance Equivalent Material Thickness Torch to Work Distance Cutting Speed Initial Pierce Height Pierce Delay Time Plasma gas Shield gas Plasma gas Shield gas Plasma gas Shield gas mm mm Range mm mm m mm factor seconds H35 N2 19 32 75 63 2 0 8 4 5 10 0 1140 7 7 170 0 3 10 980 12 820 0 5 15 580 0 8 20 360 1 3 25 260 Edge start Select Gases Set Preflow Set Cutflow Minimum Clearance Equivale...

Page 147: ...30 A Select Gases Set Preflow Set Cutflow Minimum Clearance Equivalent Material Thickness Torch to Work Distance Cutting Speed Initial Pierce Height Pierce Delay Time Plasma gas Shield gas Plasma gas Shield gas Plasma gas Shield gas Mix Gas 1 Mix Gas 2 inches inches Range inches ipm inchesFactor Seconds H35 N2 19 51 75 80 32 18 0 080 1 4 0 12 0 40 70 0 24 200 0 3 5 16 60 3 8 50 1 2 0 14 0 40 30 0 ...

Page 148: ...17 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 gas Shield gas Plasma gas Shield gas Plasma gas Shield gas inches Volts inches ipm inches Factor Seconds Air Air 35 19 62 49 0 040 130 0 10 220 0 15 150 0 2 0 051 115 170 0 064 113 160 0 102 110 140 33 0 125 102 0 07 110 0 11 0 ...

Page 149: ...5 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 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 gas Shield gas Plasma gas Shield gas Plasma gas Shield gas inches Volts inches ipm inches Factor Seconds Air Air 19 31 75 23 1 4 153 0 11 90 0 22 200 0 2 5 16 154 0 12 7...

Page 150: ...eflow Set Cutflow Material Thickness Arc Voltage Torch to Work Distance Cutting Speed Initial Pierce Height Pierce Delay Time Plasma gas Shield gas Plasma gas Shield gas Plasma gas Shield gas inches Volts inches ipm inches Factor Seconds H35 N2 19 32 75 49 5 16 158 0 20 70 0 26 130 0 3 3 8 65 37 1 2 156 0 18 55 0 31 170 0 5 24 5 8 50 0 8 3 4 157 40 1 3 16 1 176 20 Edge start Marking Flow rates lpm...

Page 151: ... Preflow Set Cutflow Material Thickness Arc Voltage Torch to Work Distance Cutting Speed Initial Pierce Height Pierce Delay Time Plasma gas Shield gas Plasma gas Shield gas Plasma gas Shield gas Mix Gas 1 Mix Gas 2 inches Volts inches ipm inches Factor Seconds H35 N2 19 51 75 27 32 18 1 4 156 0 14 85 0 28 200 0 3 5 16 157 75 3 8 158 65 1 2 159 0 12 55 0 24 0 5 5 8 160 45 0 8 3 4 163 35 1 3 Marking...

Page 152: ...Operation 4 58 HPR130XD Auto Gas 806330 Revision 2 ...

Page 153: ...leshooting error codes 062 to 067 265 to 267 5 17 Error code troubleshooting error codes 071 to 075 273 to 275 5 18 Error code troubleshooting error codes 076 to 101 276 to 301 5 19 Error code troubleshooting error codes 102 to 111 302 to 308 5 20 Error code troubleshooting error codes 116 to 133 316 5 21 Error code troubleshooting error codes 134 to 140 334 and 338 5 22 Error code troubleshooting...

Page 154: ...ve 5 41 Pump and motor troubleshooting 5 42 Testing the flow sensor 5 43 Gas leak tests 5 44 Leak test 1 inlet leak test 5 44 Leak test 2 system leak test 5 45 Leak test 3 proportional valve test in the metering console 5 45 Power supply control board PCB3 5 46 Power supply power distribution board PCB2 5 47 Start circuit PCB1 5 48 Operation 5 48 Start circuit functional schematic 5 48 Start circu...

Page 155: ...rning formats Routine maintenance See Preventive Maintenance located at the end of this section for maintenance information Contact the Technical Services department listed at the front of this manual with any questions regarding maintenance procedures WARNING Shock Hazard Use extreme care when working near the chopper modules Each large electrolytic capacitor blue cased cylinder stores large amou...

Page 156: ...n console CAN bus signal cable Provides process and status signals between the power supply and the selection console CAN bus signal cable Provides process and status signals between the power supply and the metering console Power cable Provides 120 VAC to the ignition console Power cable Provides 120 VAC to the metering console ...

Page 157: ...ow on Chopper current off Line voltage ok 4 Preflow 2 second flow of gas 5 Pilot arc Current flows 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 its setpoint and gas changes to cutflow Coolant flow on Gas pressur...

Page 158: ... 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 cycle will occur if the operator changes from any cut process to a nitrogen marking process Gas system valve usage The following tables show which v...

Page 159: ...SV5 SV9 SV14 H35 N2 N2 process Metering console control board Selection console control board LED number 38 39 28 37 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Preflow B3 B1 SV5 SV9 Cutflow B4 B1 SV5 SV9 SV12 SV13 N2 Air process Metering console control board Selection console control board LED number 38 39 28 37 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Preflow B3 B2 SV3 SV9 SV10 Cutflow B3 B2 SV3 SV9 S...

Page 160: ...low B3 B1 SV9 Cutflow B3 B1 SV9 Valves active when changing from a process that does not use a fuel gas Valves active when changing from a process that does use a fuel gas Ar N2 Metering console control board Selection console control board LED number 38 39 28 37 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Preflow B4 B1 SV9 SV15 Cutflow B4 B1 SV9 SV15 Ar Air 25 to 35 A Metering console control board Se...

Page 161: ...munication DC power in Total current Plasma interface cable Plasma interface PCB optional Machine interface cable Arc voltage Chopper Duty cycle Chopper current sensor Chopper temp sensor AC power Start circuit PA enable AC power Control signals to outputs Power distribution board Gas control board DC power in AC power in Power distribution board AC power in Valve driver board Control signals to v...

Page 162: ...06330 Error codes Error codes are displayed on the CNC screen The diagnostic screen shown below is for reference The screens you work with may be different but should include the functions described in the Operation section of this manual ...

Page 163: ...ly 1 Verify that the secondary power supply is turned ON 2 Verify that the current for the selected process is within the range of the power supply capability up to 400A for 400XD and up to 800A for 800XD 012 Test in progress One of the gas test modes is running Wait for the test to finish 013 Test passed The test was successful No action required 014 Cut gas channel 1 fail The gas pressure in cha...

Page 164: ...ost the current signal from Chopper 2 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 026 Primary 226 Secondary Lost transfer Lost the transfer signal after transfer completed 1 Verify that the consumable parts are in goo...

Page 165: ...e start input the CNC is dropping the start signal 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 to...

Page 166: ...ve 046 Low line voltage Line voltage is close to or less than the lower limit of 102 VAC 120 VAC 15 The normal lower limit for operation is 108 VAC 120 VAC 10 1 Verify input line voltage at PCB2 in the power supply also PCB1 in the cooler for HPR400XD systems Voltage needs to be within 10 of nominal 120 VAC 2 Verify fuses on PCB2 in the power supply 3 Verify 120 VAC voltage on plug J2 4 pins 3 and...

Page 167: ...urred with the CAN communications between the power supply and the gas console 1 Verify that cable number 5 power supply to gas console control cable is not damaged and is properly connected to PCB3 and to the rear of the gas console 2 Verify that 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 conso...

Page 168: ...r 140 psi in the selection console Verify that gas pressure transducer P3 is between 3 45 bar 50 psi and 9 65 bar 140 psi Increase or decrease the inlet gas pressure to correct the problem 058 Cut gas 2 pressure Auto Gas Only Cut gas 2 outlet pressure is less than 3 45 bar 50 psi for non mixing or less than 1 38 bar 20 psi when mixing or greater than 9 65 bar 140 psi for non mixing and mixing Veri...

Page 169: ...s good and overtemp error does not clear after 30 minutes of the power supply idling with the fans running replace the chopper 066 Primary 266 Secondary Chopper 2 overtemp HPR260XD HPR400XD Only Chopper 2 has overheated 1 Verify that all 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 Verif...

Page 170: ...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 202 pins 8 and 9 on PCB3 is less than or equal to 2 9 VDC 4 If the voltage is low verify correct wiring between chopper temperature sensor and J3 202 pins 7 and 8 5 If wiring is good and overtemp error does not clear after 30 m...

Page 171: ... contactor and input to chopper for loose connections 4 Inspect phase loss fuses on Power Distribution board Replace board if fuses are blown 5 Perform phase loss test see Maintenance section 099 Primary 299 Secondary 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 bypassed or that the wires to the tem...

Page 172: ...2 HPR260XD HPR400XD Only A current less than 10 amperes has been detected by current sensor 2 See the chopper test later in this section 107 Primary 307 Secondary High current on CS3 HPR400XD Only A current greater than 35 amperes has been detected by current sensor 3 See the chopper test later in this section 108 Primary 308 Secondary Transfer at power up The system has detected current on the wo...

Page 173: ...ur corners 123 MV1 error Auto Gas Only Motor valve 1 did not move into position within 60 seconds Verify that LED D17 or D18 illuminates on the AC valve driver PCB in the selection console If either illuminates replace the motor valve If they do not illuminate replace PCB3 124 MV2 error Auto Gas Only Motor valve 2 did not move into position within 60 seconds Verify that LED D19 or D20 illuminates ...

Page 174: ... damaged 2 Measure voltage across current sensor a Red to black 15 VDC Green to black 15 VDC white to black 0 VDC at idle and varies with current output 4 VDC 100 A b If possible take a voltage reading on current sensor while trying to cut Ratio is 4 VDC 100 A c If the current sensor voltage is approximately 6 4 VDC or greater at idle replace the current sensor 3 Remove connector JB 1 from the cho...

Page 175: ... 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 144 Internal flash error Manual Gas Only Communication problem to the flash chip on the gas console control board Replace the control board 145 Internal flash error Auto Gas Only Communication problem to the flash chip on t...

Page 176: ...he chopper does not go into overcurrent replace PCB3 155 Primary 355 Secondary Chopper 4 overcurrent HPR400XD Only Chopper 4 current feedback has exceeded 160 amperes 1 Verify that the wiring between CS4 and PCB3 is correct and not damaged 2 Measure voltage across current sensor a Red to black 15 VDC Green to black 15 VDC white to black 0 VDC at idle and varies with current output 4 VDC 100 A b If...

Page 177: ...is not tripped and there is no power to PCB7 verify that the fuse on PCB2 in the power supply is good 2 If D32 on PCB7 illuminates the solenoid valve and motor are drawing too much current D32 will only illuminate for a short time and extinguishes after the outputs from the pump motor drive turn off in response to the fault condition Verify the wiring to the solenoid valve and the motor Verify tha...

Page 178: ...at the coolant is mixed in the proper proportions 180 Selection console CAN time out Auto Gas Only The power supply did not receive a CAN message from the selection console within 1 second 1 Verify that the power supply to selection console CONTROL and POWER cables are not damaged and are properly connected to PCB3 and the rear of the selection console 2 Verify that D17 5 VDC and D18 3 3 VDC are i...

Page 179: ...o the chassis at all four corners 182 Secondary power supply time out HPR800XD Only The secondary power supply fails before transmitting the error to the primary power supply 1 The primary power supply to secondary power supply CAN communication cable was disconnected after power up 2 The cable has electrical interference noise or the cable shielding has been compromised 298 Secondary power supply...

Page 180: ... for reference State code Name State code Name 00 Power up idle 11 Cycle complete Auto off 02 Purge 12 Test cutflow 03 Ready for start Idle 2 14 Shutdown 04 Preflow 15 Reset 05 Pilot arc 16 Maintenance 06 Transfer 20 Test preflow 07 Ramp up 22 Manual pump control 08 Steady state 23 Inlet leak check 09 Ramp down 24 System leak check 10 Final ramp down ...

Page 181: ...ump Fire the torch and begin cutting If the pump has timed out turn on the NOT READY FOR START signal and turn on the pump Purge cycle begins NOT READY FOR START signal is active System is in IDLE state waiting for a START signal NOT READY FOR START signal is inactive PLASMA START signal active STAR signal Is the flow sensor satisfied Purge timer done Yes Yes Yes START signal removed No No ...

Page 182: ...e out User presses START on CNC Assert the PLASMA START and HOLD signals to all plasma systems Remove the START and HOLD signals Complete the cut cycle Apply the START signal and remove the HOLD signal Yes No Is the NOT READY FOR START signal active on any plasma system ...

Page 183: ...and part numbers 4 If no damage is apparent connect power to the power supply and turn ON the main disconnect switch 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 voltage If there is...

Page 184: ... one line is 10 greater or more than the other 2 put that leg on U Main power in DANGER Shock Hazard There is line voltage at the contactor and the power distribution board PCB2 when the line disconnect switch is on Use extreme care when measuring primary power in these areas Voltages present at the terminal block and contactors can cause injury or death ...

Page 185: ...e it The filter housing has an o ring around the top Apply a thin film of silicone lubricant on the o ring to extend it s life The o ring should look shiny but there should not be any excess or built up grease 4 Use a screwdriver to remove the filter element from the filter housing Then install the new filter element Note Do not allow the filter element to turn when loosening the screw Filter bowl...

Page 186: ...aining the coolant system 1 Turn OFF the power and remove the return coolant hose red tape from the pump and put it in a 20 liter 5 gallon container 3 Turn OFF the pump when the coolant stops flowing 2 Turn ON the pump manually using the manual pump control button on your CNC screen ...

Page 187: ...e 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 Drain co...

Page 188: ... the hose set between the power supply and the high frequency console There is a kink or clog between the high frequency console and the power supply If there is not a kink replace the leads There is a kink in the leads between the high frequency console and the torch If there is not a kink replace the leads Go to test 6 Replace the pump and inspect the shaft for damage No flow Flow rate from buck...

Page 189: ...hould have the same functions shown here Before testing Note Coolant must be drained from the system before the filter strainer is cleaned step 1 below The coolant in the system will drain out as soon as the filter strainer 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 ...

Page 190: ...within 8 seconds of turning on the power supply or the power will have to be turned off and then on again 2 Turn ON the power Turn ON the pump manually and allow the coolant to flow for 60 seconds 3 Write down the coolant flow rate on the CNC screen 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 operat...

Page 191: ...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 acess 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 how l...

Page 192: ...e If it 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 bl...

Page 193: ...te down how long it takes 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 ...

Page 194: ...n 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 fuse is OK and make sure ther...

Page 195: ...ween 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 041993 TP 206 TP 210 ...

Page 196: ...ose Tests the inlet valve solenoids in the selection console for leaks Test description The valves in the metering console B1 B4 open to release all gas pressure to the atmosphere then the valves close and pressure is monitored by P3 and P4 in the selection console The pressure will increase if an inlet valve is leaking Code number 14 cut gas channel number 1 failed or 15 cut gas channel number 2 ...

Page 197: ...e torch and the Burkert valve that controls the plasma gas channel B3 attempts to maintain the set plasma gas pressure monitored by P7 and P8 by adjusting the valve dynamically The signal percentage to the valve is measured example 65 on and the value is checked against the expected range 55 75 The test is successful if the signal percentage is within the expected range Code number 14 shield gas c...

Page 198: ...326 Pilot arc enable D327 Hold D328 Pierce D329 Corner current D330 Plasma start Control PCB LED list LED Output Input Notes D331 HV transformer D332 Pump motor enable D333 Contactor D334 Pilot arc relay D335 Spare D336 Surge select D337 Phase loss Control PCB LED list LED Signal name Notes D100 5 VDC D101 3 3 VDC D113 CAN TX Constant blinking D114 CAN RX Constant blinking D117 RS 422 TX D118 RS 4...

Page 199: ...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 ...

Page 200: ...w through the pilot arc lead quickly with little impedance 2 After initial pilot arc current is established the start circuit introduces impedance to the pilot arc lead to aid in transferring the arc to the workpiece See schematic below Plasma power supply Choke Diode Start circuit Cutting arc Pilot arc Power resistor Control logic ALEL Caps Chopper IGBT DANGER Shock Hazard Always use caution when...

Page 201: ... Resistance value may slowly increase to the correct value due to the capacitance in the circuit 4 Verify a resistance of about 15 kΩ between snubber 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 illuminated the ...

Page 202: ... selected and the process See table below Pilot arc current Plasma gas 30 A 45 A 50 A 80 A 130 A 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 A 45 A 50 A 80 A 130 A 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 203: ...er must be removed Control PCB2 firmware list Item Part number U9 081110 EVEN U10 081110 ODD Gas console control board LED list LED Signal name Color D17 3 3 VDC Green D18 5 VDC Green D26 CAN RX Green D27 CAN TX Green D28 Not used Red D37 Not used Red D38 Not used Red D39 Not used Red D40 15 VDC Green D45 24 VDC Green ...

Page 204: ...Maintenance 5 52 HPR130XD Auto Gas 806330 Selection console power distribution board PCB1 Gas console control board LED list LED Signal name Color D2 SV16 Red D4 5 VDC Green ...

Page 205: ...ver board PCB3 SV4 LED Signal name Color LED Signal name Color D1 SV1 Red 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 Red D6 SV6 Red D16 Metering console vent solenoid Red D7 SV7 Red D17 MV1 close Red D8 SV8 Red D18 MV1 open Red D9 SV9 Red D19 MV2 close Red D10 SV10 Red D20 MV2 open Red ...

Page 206: ...P7 P6 SV16 P5 not visible Control PCB2 firmware list Item Part number U9 081110 EVEN U10 081110 ODD Gas console control board LED list LED Signal name Color D17 3 3 VDC Green D18 5 VDC Green D26 CAN RX Green D27 CAN TX Green D28 Burkert valve 2 Red D37 Burkert valve 1 Red D38 Burkert valve 4 Red D39 Burkert valve 3 Red D40 15 VDC Green D45 24 VDC Green ...

Page 207: ...Maintenance HPR130XD Auto Gas 806330 5 55 Metering console power distribution board PCB1 Gas console control board LED list LED Signal name Color D2 SV16 Red D4 5 VDC Green ...

Page 208: ...umber 103 or 105 is displayed 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 Use a meter to measure the resistance between wire 38 and wire 39 on PCB6 The value should increase as the capacitor charges Replace...

Page 209: ...or if the error 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 control...

Page 210: ...or 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 any damaged wires c If the phase loss error goes away while the jumper is on J2 8 make another cut and measure the phase to p...

Page 211: ...e 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 console and the power supply 6 Verify that the pilot arc wire on the torch lead is not damaged If it is damaged replace the lead If it is not damaged replace the torch head H8 WORK H9 NOZZLE H8 WORK H9 NOZZLE D1 D2 WARNING Shock Haza...

Page 212: ... to maintain your plasma system contact your OEM or regional Hypertherm Technical Service team You can find contact information for each regional office at www hypertherm com global on the Contact us page after choosing your language This document refers to your system s instruction manual If you do not have your instruction manual you can find it in the Hypertherm downloads library 1 Go to www hy...

Page 213: ...8 Ignition console to junction box leads 6 9 Selection console 6 10 Metering console 6 12 HyPerformance torch 6 13 Torch assembly 6 13 Torch leads 6 14 Ohmic contact wire 6 14 Consumable parts kits 6 15 Consumables for mirror image cutting 6 16 Straight cutting 6 16 Bevel cutting 6 18 Recommended spare parts 6 19 Warning Label 110647 6 20 ...

Page 214: ...power lamp assembly 1 7 228611 Kit Hypernet upgrade not shown 1 1 3 6 2 4 5 Power supplies Without Hypernet With Hypernet Voltage AC 078538 078546 200 208 078539 078547 220 078540 078548 240 078541 078549 380 078542 078550 400 078603 078604 415 078543 078551 440 078544 078552 480 078545 078553 600 Note Hypernet is only used to connect certain Hypertherm components to each other An HPRXD system can...

Page 215: ...former 19 5 KW 3 ph 50 HZ T2 1 014284 220 volt main transformer 19 5 KW 3 ph 50 60HZ 1 014282 240 volt main transformer 19 5 KW 3 ph 60 HZ 1 014303 380 volt main transformer 19 5 KW 3 ph 50 HZ 1 014283 400 volt main transformer 19 5 KW 3 ph 50 HZ 1 014283 415 volt main transformer 19 5 KW 3 ph 50 HZ 1 014284 440 volt main transformer 19 5 KW 3 ph 50 60 HZ 1 014282 480 volt main transformer 19 5 KW...

Page 216: ... arc 120 VAC CR1 1 2 041837 PCB I O PCB6 1 3 003249 Contactor CON1 1 4 109036 EMI filter 60 A 440 VAC 3PH 1 5 229238 Start circuit assembly PCB1 1 6a 109004 Current sensor Hall 100 A 4 volt CS3 1 6b 109004 Current sensor Hall 100 A 4 volt CS1 1 7 014280 Inductor 4MH 1 400 415 volt power supplies only 3 4 1 2 6b 6a 7 5 ...

Page 217: ...4 027978 Heat exchanger assembly 1 027185 4 in fan 2 5 006075 Check valve 1 4 in FPT 1 6 228170 Kit Pump with clamp 1 7 006046 Solenoid valve assembly 3 8 in 240 volt CLT SOL 1 8 228538 Kit Motor with clamp 1 9 127039 Fan for pump motor 230 cfm 115 VAC 50 60 Hz 1 10 031122 Pump to motor shaft coupler not shown 1 380 400 440 480 and 600 volt power supplies 200 208 and 240 volt power supplies 415 vo...

Page 218: ...9786 Control transformer 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 229094 Control transformer 380 volt 50 HZ 1 129787 Control transformer 400 volt 50 60 HZ 1 229451 Control transformer 415 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 transforme...

Page 219: ...PR130XD Auto Gas 806330 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 220: ...t 6 8 HPR130XD Auto Gas 806330 Torch lead junction box Optional Item Part Number Description Qty 078619 HPRXD junction box 1 1 015007 Coolant fitting 4 2 104763 Pilot arc fitting 1 3 104762 Coolant block 1 2 3 1 ...

Page 221: ...must be less than or equal to 20 m 65 feet for HPR130XD HPR260XD 15 m 50 feet for HPR400XD HPR800XD Part no Description Part no Description 428420 3 m 10 ft 428425 10 m 35 ft 428421 4 5 m 15 ft 428426 12 2 m 40 ft 428339 5 5 m 18 ft 428427 13 7 m 45 ft 428422 6 m 20 ft 428428 15 m 50 ft 428423 7 5 m 25 ft 428429 16 8 m 55 ft 428424 9 1 m 30 ft ...

Page 222: ...lamp 1 3 011109 Filter assembly 1 011110 Filter element 1 4 228069 Kit Control PCB PCB2 1 5 005263 Pressure sensor P1 P4 4 123780 Pressure sensor wire harness P1 P4 1 6 228984 Solenoid valve SV3 and SV10 2 7 006109 Solenoid valve SV1 and SV2 SV4 SV9 SV11 SV15 13 006112 Replacement solenoid coil 8 041897 Power distribution PCB PCB1 1 008756 Fuse 5A 250V slow blow F1 1 ...

Page 223: ...6 11 Selection console Part Item Number Description Designator Qty 1 041822 Valve driver PCB PCB3 1 008756 Fuse 5 A 250V slow blow F1 1 2 129999 Motor valve assembly MV1 MV2 2 229217 Selection console wire harness 1 228347 Hose kit 1 1 2 ...

Page 224: ...lves 2 6 006109 Solenoid valve SV16 1 006112 Replacement solenoid coil 7 005263 Pressure transducer 3 of 4 shown P5 P8 4 123802 Pressure transducer wire harness 1 8 006128 Proportional valve B1 B4 4 228023 Kit HPR gas metering manifold upgrade 1 229032 Metering console wire harness 1 Gas consoles with a serial number of 500134 or later take this part number Gas consoles with a serial number of 500...

Page 225: ...torch 3 220571 Water tube 4 220705 Quick disconnect receptacle 5 220789 Torch mounting sleeve assembly Standard 181 mm 7 in 220788 Torch mounting sleeve assembly Short 114 mm 4 5 in 220790 Torch mounting sleeve assembly Long 248 mm 9 75 in 6 104269 2 in spanner wrench 128879 Torch kit o rings water tube and seal 128880 Quick disconnect kit o ring and connector 1 3 2 4 6 5 ...

Page 226: ...989 23 m 75 ft 123990 30 m 100 ft 123991 45 m 150 ft Part no Description 228291 2 m 6 ft 228292 3 m 10 ft 228293 4 5 m 15 ft 228294 6 m 20 ft 228295 7 5 m 25 ft 228296 10 m 35 ft 228297 15 m 50 ft 228547 20 m 65 ft Ohmic contact wire Note The ohmic contact wire is not part of the HPR260XD system Shown for reference only Not part of the HPR400XD system Shown for reference only ...

Page 227: ...trode 50 A 2 220553 Swirl ring 50 A 1 220554 Nozzle 50 A 2 220555 Shield 50 A 1 220665 SilverPlus electrode 130 A 1 220747 Shield cap 130 A 1 220754 Nozzle retaining cap 30 A 1 220756 Nozzle retaining cap 130 A 1 Stainless steel and Aluminum consumable starter kit 228421 Part Number Description Qty 026009 O ring 0 208 in X 0 070 in 5 027055 Lubricant Silicone 1 4 oz tube 1 044028 O ring 1 364 in X...

Page 228: ...Straight cutting Mild steel 220193 220192 220306 30 A 220187 80 A 220181 130 A 220305 220305 220188 220182 220183 220189 220194 220755 220755 220810 220747 Shield Nozzle Swirl ring Electrode 220552 220549 220554 220555 220810 50 A Nozzle retaining cap Shield cap Water tube 220340 ...

Page 229: ...01 220308 220306 45 A 220339 60 A 220306 220847 220815 220202 420337 220756 220747 Shield Nozzle Swirl ring Electrode Nozzle retaining cap Shield cap 220340 Water tube 220339 80 A 220305 220337 220338 220756 220307 130 A 220305 220197 220198 220756 H35 220755 N2 ...

Page 230: ...de 220606 220305 220656 420336 Shield cap Nozzle retaining cap 220738 130 A 220637 Water tube 220571 Shield Nozzle Nozzle retaining cap Swirl ring Electrode Shield cap Water tube 80 A 220802 220305 220806 220742 220996 130 A 220700 220649 220305 220646 220742 220794 Bevel cutting Mild steel ...

Page 231: ...00 volt F1 F2 2 228548 Control PCB PCB3 1 041802 Power distribution PCB PCB2 1 229206 Flow switch assembly FLS 1 027185 Heat exchanger fan 4 in 1 006075 Check valve 1 4 in FPT 1 229229 Solenoid valve assembly CLT SOL 1 228170 Kit Pump 70 gpm 200 psi 1 228538 Kit Motor 1 3 HP 240 volt 50 60 HZ 1 400 415 480 and 600 volt power supplies Ignition console Part Number Description Designator Qty 041817 H...

Page 232: ...th 2 3 Wear complete body protection 3 Hazardous voltage Risk of electric shock or burn 3 1 Wear insulating gloves Replace gloves when wet or damaged 3 2 Protect from shock by insulating yourself from work and ground 3 3 Disconnect power before servicing Do not touch live parts 4 Plasma fumes can be hazardous 4 1 Do not inhale fumes 4 2 Use forced ventilation or local exhaust to remove the fumes 4...

Page 233: ...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 wirin...

Page 234: ...ock 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 235: ...r Coil Valve 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 Switch Flow ...

Page 236: ...7 4 HPR130XD Auto Gas 806330 Discrete output functionality ...

Page 237: ...C CNC Interface Cable Pendant Ext Cable Optional Unit Operator Unit N Pendant Lifter Torch Optional Unit Unit M Atm Vent Off Valve Cable Work Lead 72 3X2 1X2 Gas Control Cable Negative Lead 1X5 Motor Drive Cable CNC Interface Cable Lifter I O Interface Cable 128782 H35 F5 1X6 CNC Interface Cable Cooling Supply Lead Cooling Return Lead Workpiece Plasma Shield Plasma Preflow Shield Preflow Plasma Cu...

Page 238: ...K I O SURGE INJECTION 041837 2 1 T2 YEL 24VAC RED 120VAC ORN 240VAC J11 WHT BLU CHOPPER SA 129792 4 2 1 3 T1 BLU WHT CS1 J1 4 J4 2 1 3 4 GRN BLK WHT RED POSITIVE 1C 1B 1A BLK BLK F1 F2 38 22UF 10K 022UF 10K 22UF 100K 100 10K 350UF 10 10 K1 A1 A2 K2 RED BLK 2 1 RED J4 1 J1 3 K1 H9 39 H8 J2 J3 J1 SHIELD CABLE 123666 YEL BLK YEL CR1 ENABLE 10K 10K 1 A B C D 4 3 2 1 A B C D 4 3 2 TB1 1 2 3 4 L1 R1 C1 ...

Page 239: ... 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 RED RED BLK RED RED BLK RED BLK RED WHT BLU WHT BLU WHT BLU PHASE LOSS INPUT BLU WHT RED RED BLK 9 10 FAN 1 REMOTE ON OFF 7 WHT 6 5 RED 1 2 3 4 RED RED BLK RED BLK RED 1X3 WHT...

Page 240: ...NC 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 A 3 3V COOLANT TEMP SENSOR XFMR TEMP SENSOR CHOPPER TEMP SENSOR A CHOPPER TEMP SENSOR B LINE VOLTAGE INPUT 15V 15V COM BLU WHT BLU WHT BLU WHT BLU WHT PA E SS E 1 2 J107 2 1 J106 121 121 RED RED BLK SHIELD SHIELD FLS 1 2 J1 3 J8 1 1 2 J4 J3 J8 4 FLOW GND GND RLY 120VAC RTN 120VAC HOT J3 107 J...

Page 241: ...2 6 2 7 3 9 8 4 5 J101 1 2 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 CAN GND CAN 24V CANL CANH 121 CANA CANB 0 CABLE 123691 J3 101 RED BLK RED BLK SHIELD A B C 4 3 2 D 4 3 2 1 A B C 1 D SHEET 3 D4 R SHEET 11 A3 X ELEC SCH HPR130XD POWER SUPPLY W AUTO D 013376 SHEET 5 OF 22 ...

Page 242: ...FOR 240V 60HZ INPUT POWER FROM FACILITY PE L1 WIRED FOR 200 208V 50 60HZ L2 B4 CON1 L3 C4 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 F1 F2 014282 014283 014282 014283 C4 B4 A4 CON1 EMI FILTER L2 L3 PE L1 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 ...

Page 243: ...ILITY INPUT POWER L1 L2 L3 PE L1 L2 L3 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 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 A B C 4 3 2 D 4 3 2 1 A B C 1 D 2 3 4 TB1 1 2 4...

Page 244: ...I 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 24VDC CABLE 123760 J12 2...

Page 245: ... 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 J5 9 30 29 11 10 28 8 27 26 7 25 6 3 23 24 5 4 22 20 21 2 1 7 8 5 6 4 3 2 1 PLASMA START OUT PLASMA START OUT CABLE 123760 J13 5 J3 303B TO POWER SUPPLY YEL BLK YEL 2 1 J301 1 2 24V CNC 24V 422 GND t0 MOTION 2 E MOTION 2 C MOTION 3 E MOTION 3 C MOTION 4 E MOTION 4 C MOT...

Page 246: ...V SV16 5V GND 6 4 3 5 2 1 J2 RED BLK RED 4 6 5 7 2 3 1 3X2 GRN YEL PCB1 041897 BLU WHT WHT BLU RED RED BLK AC2 AC1 AC IN TO METERING CONSOLE WHT BLU 15V 15V COM RED BLK BLK WHT BLK WHT RED SHD SHD BLK 1 120VAC 2 J1 6 J6 RED BLK RED RED AC2 SV16 2 3 1 RED BLK J1 5 J5 4 AC IN A B C 4 3 2 D 4 3 2 1 A B C 1 D SHEET 11 D4 AA F1 SHEET 13 A4 Z SHEET 3 A1 U SHEET 12 D3 Y LED ELEC SCH HPR130XD POWER SUPPLY...

Page 247: ...M 15V J9 1 2 3 4 7 6 5 BLK BLU BRN 8 9 10 11 13 12 16 14 15 BRN BLU BLK BRN BLU BLK BRN BLU BLK PT1 TP3 TP5 PT2 TP16 PT3 TP13 PT4 COM POWER INDICATORS D45 24V D40 15V D18 5V D17 3 3V BLU WHT BLU WHT BLU WHT 24V PWR GND 5V GND 15V COM 15V J2 9 3X4 3X3 BLK RED BLK RED SHLD SHLD RED BLK BLK RED 7 6 8 8 6 7 RED YEL BLK RED YEL BLK J2 2 POT 2 POT 1 TO METERING CONSOLE HPR AUTO GAS SELECTION CONSOLE CON...

Page 248: ...10 13 12 11 8 9 7 3 6 5 4 1 2 J3 5 3 4 2 J2 J3 2 1 9 10 8 7 6 31 32 33 34 35 36 J3 3 SV1 B RED BLK RED SV2 B SV2 A SV4 A SV4 B SV3 B SV3 A SV8 B SV8 A SV6 A SV6 B SV7 A SV7 B SV5 B SV5 A SV12 B SV14 B SV14 A SV13 B SV13 A SV12 A SV10 A SV10 B SV11 A SV11 B SV9 B SV9 A SV1 A RED RED BLK RED RED BLK RED RED BLK RED RED BLK RED RED BLK RED RED BLK RED RED BLK RED BLK RED RED BLK RED RED BLK RED RED B...

Page 249: ...ND 5V SV16 5V GND 6 4 3 5 2 1 J1 2 J2 PCB1 041897 BLU WHT BLU WHT BLU WHT WHT BLU RED RED BLK AC2 AC1 AC IN POWER IN RAMPDOWN VALVE CONTROL INPUT 15V 15V COM WHT BLU RED BLK SHD BLK WHT 1 120VAC 2 J1 6 J6 RED BLK RED AC2 SV16 2 3 1 J1 5 J5 4 AC IN RAMPDOWN VALVE OUTPUT POWER INDICATOR RED BLK RED SV16 A B C 4 3 2 D 4 3 2 1 A B C 1 D F1 SHEET 14 D4 CC SHEET 14 D1 DD SHEET 10 A3 Z LED ELEC SCH HPR13...

Page 250: ...1 2 3 4 7 6 5 BLK BLU BRN 8 9 10 11 13 12 16 14 15 BRN BLU BLK BRN BLU BLK BRN BLU BLK PT1 TP3 TP5 PT2 TP16 PT3 TP13 PT4 COM POWER INDICATORS D45 24V D40 15V D18 5V D17 3 3V BLU WHT BLU WHT BLU WHT 24V PWR GND 5V GND 15V COM 15V J2 9 BLU WHT BLU WHT 4X2 4X3 SHLD RED BLK BLK RED RAMPDOWN VALVE CONTROL OUTPUT PRESSURE INPUTS METERING VALVE POT FEEDBACK INPUTS POWER IN HPR AUTO GAS METERING CONSOLE C...

Page 251: ...20 SPARE 2 SPARE 1 SV9 SV10 SV8 SV7 SV11 SV12 SV14 SV13 SV1 SV2 SV3 SV4 SV6 SV5 2 4 6 3 7 9 8 11 12 13 10 14 1 5 24V PWM4 PWM3 PWM2 PWM1 BURKERT 4 BURKERT 3 BURKERT 2 BURKERT 1 BLK METERING CONSOLE ENABLE J2 12 J12 HPR AUTO GAS METERING CONSOLE CONTROL 041828 PCB2 A B C 4 3 2 D 4 3 2 1 A B C 1 D D38 D39 D28 D37 ELEC SCH HPR130XD POWER SUPPLY W AUTO D 013376 SHEET 15 OF 22 ...

Page 252: ... 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 3 4 2 1 BLK WHT GRN CABLE 123670 CABLE 123666 009045 FLTR A B C 4 3 2 D 4 3 2 1 A B C 1 D SHEET 2 D1 N D SHEET 3 A4 W ELEC SCH HPR130XD POWER SUPPLY W AUTO D 013376 SHEET 16 OF 22 ...

Page 253: ...s 2 Selection O2 V1 V2 V3 V4 V5 V6 V7 V8 V9 V10 V11 V12 V13 V14 P1 P2 P3 P4 MV1 MV2 B1 B2 B4 P5 P6 P7 P8 V16 B3 Vent Metering Torch Vent HPR130 Auto Console V15 5 Micron Filter Gas Schematic Console Shield Plasma ELEC SCH HPR130XD POWER SUPPLY W AUTO D 013376 SHEET 17 OF 22 ...

Page 254: ... 22 PUMP SHUT OFF VALVE CHECK VALVE FILTER THERMISTOR FLOW SENSOR TORCH RHF MANIFOLD HEAT EXCHANGER RESERVOIR A B C D 4 3 2 1 A B C D 4 3 2 1 ELEC SCH HPR130XD POWER SUPPLY W AUTO D 013376 SHEET 18 OF 22 ...

Page 255: ...em 4 3 2 1 1 A 4 3 2 A B C D B C D 120 RX Termination Termination 120 TX ELEC SCH HPR130XD POWER SUPPLY W AUTO D 013376 SHEET 19 OF 22 Notes 1 For single system installations set Serial ID S100 and Machine Motion J303 as shown in Unit 1 jumpers J106 and J107 must be closed 2 On multi system installations refer to the illustration Jumpers J106 and J107 are left open on all systems except for the ve...

Page 256: ...or min 24Vac 0 5 Amp 7 RED BLK RED WHT RED Gas Console 078170 Gas Power Cable Customer Supplied Remote On Off J106 2 1 2 1 J107 Optional Remote On Off TB2 WHT RED RED BLK RED 6 2 1 1X1 BMD J2 BTR J7 RS 232 J9 RS 422 BHST AHST J3 AMD J5 J6 RS 422 J10 RS 232 ATR J8 J1 SV RIBBON CABLE Serial isolation board in a Hypertherm Automation controller 1 2 3 4 5 6 7 8 ON 1 2 3 4 S101 ON HPR PAC Dry Cutting S...

Page 257: ...em installation set up as described above set Serial ID as shown for the third system 4 For a four system installation set up as described above set Serial ID as shown for the fourth system 5 All machine interface cables Pwr supply CNC used for serial communication between Pwr supply CNC will have a common connection node with the CNC 6 The CNC will need a dedicated I O port for each Command THC 7...

Page 258: ...hrough 4 5 6 7 8 ON J300B J5 141131 ETHERNET INTERFACE BOARD 0 7 1 5 4 6 2 3 SW1 UNIT ADDRESS 1 2 3 4 J1 Serial ID Dipswitch Machine Motion Jumper Block 2 1 1 2 5 6 7 8 ON J5 0 7 1 5 4 6 2 3 SW1 UNIT ADDRESS 1 2 3 4 J1 Serial ID Dipswitch Machine Motion Jumper Block 2 1 1 2 5 6 7 8 ON J5 0 7 1 5 4 6 2 3 SW1 UNIT ADDRESS 1 2 3 4 J1 Serial ID Dipswitch Machine Motion Jumper Block 2 1 1 2 5 6 7 8 ON ...

Page 259: ... 4 First aid measures a 3 5 Fire fighting measures a 3 6 Accidental release measures a 3 7 Handling and storage a 4 8 Exposure controls personal protection a 4 9 Physical and chemical properties a 4 10 Stability and reactivity a 5 11 Toxicological information a 5 12 Ecological information a 5 13 Disposal considerations a 6 14 Transport information a 6 15 Regulatory information a 6 16 Other informa...

Page 260: ...ailable Details of the supplier of the safety data sheet Company Identification Hypertherm Telephone 1 603 643 5638 USA 31 0 165 596 907 Europe E Mail competent person technical service Hypertherm com Address P O Box 5010 Hanover NH 03755 USA USA Vaartveld 9 4704 SE Roosendaal Nederlands Europe Emergency telephone number 800 255 3924 USA 1 813 248 0585 International 2 Hazards identification EC Cla...

Page 261: ...ss present as an aerosol Remove patient from exposure Skin Contact Wash skin with water Eye Contact If substance has gotten into the eyes immediately wash out with plenty of water for several minutes Ingestion Laxative Do not induce vomiting If swallowed seek medical advice immediately and show this container or label Further Medical Treatment Unlikely to be required but if necessary treat symptom...

Page 262: ...ls Ensure adequate ventilation to remove vapors fumes dust etc Other None Occupational Exposure Limits SUBSTANCE CAS No LTEL 8 hr TWA ppm LTEL 8 hr TWA mg m3 STEL ppm STEL mg m3 Note Propylene Glycol 57 55 6 NE 10 NE NE AIHA WEEL in the USA Benzotriazole 95 14 7 NE NE NE NE None 9 Physical and chemical properties Information on basic physical and chemical properties Appearance Liquid Vapor Pressur...

Page 263: ...tion Skin Contact Mild irritant to rabbit skin Eye Contact Mild irritant to the eye Hazard label s None Serious eye damage irritation Mild irritant to the eye Respiratory or skin sensitization Mild irritant to rabbit skin Mutagenicity Not known Carcinogenicity IARC NTP OSHA ACGIH do not list this product or any components thereof as known or suspected carcinogen Reproductive toxicity Not known STO...

Page 264: ...15 Regulatory information USA TSCA Toxic Substance Control Act Listed SARA 302 Extremely Hazardous Substances Not applicable SARA 313 Toxic Chemicals Not applicable SARA 311 312 Hazard Categories None CERCLA Comprehensive Environmental Response Compensation and Liability Act Not applicable CWA Clean Water Act CWA 307 Priority Pollutants None CAA Clean Air Act 1990 CAA 112 Hazardous Air Pollutants ...

Page 265: ... Additional Information USA NFPA National Fire Protection Association NFPA Rating Flammability 1 Health 0 Instability Reactivity 0 Information contained in this publication or as otherwise supplied to Users is believed to be accurate and is given in good faith but it is for the Users to satisfy themselves of the suitability of the product for their own particular purpose Hypertherm gives no warran...

Page 266: ...SAFETY DATA SHEET Revision 6 Dec 2010 Torch Coolant 30 PG Mixture 2 01CLP Freezing Point of Propylene Glycol Solution 0 0 0 0 0 0 0 0 7 6 5 4 3 2 1 10 20 30 40 0 10 20 30 40 50 60 57 51 46 40 34 29 23 18 12 7 1 4 Temperature of Propylene Glycol F C ...

Page 267: ... drop wiring b 4 Multi drop addressing b 5 Serial commands b 5 Format b 5 Framing b 5 Commands b 5 Command table 1 of 14 b 6 Error responses b 20 Calculating checksums b 20 Error codes b 21 Status codes b 25 Gas type codes b 25 CNC requirements b 26 Auto gas console b 26 Serial interface guidelines b 27 Checksum b 27 Message retries b 27 Cable shielding b 27 ...

Page 268: ...remaining motion signals can be used to wire multiple systems in a daisy chain configuration Machine Motion 2 Output Indicates the arc has transferred to the plate This signal is selected using jumper on power supply control board Only 1 motion signal is needed per system The remaining motion signals can be used to wire multiple systems in a daisy chain configuration Machine Motion 3 Output Indica...

Page 269: ...t gas mode Ramp down Error Output Indicates the arc did not ramp down properly Consumable life is shortened TX Serial Transmitting from the system Connect to CNC RX TX Serial Transmitting from the system Connect to CNC RX RX Serial Receiving by the system Connect to CNC TX RX Serial Receiving by the system Connect to CNC TX Signal list continued Signal name Type Description Hardware Inputs active ...

Page 270: ...start Hold ignition Pierce complete Corner current Machine motion 1 Machine motion 2 Machine motion 3 Machine motion 4 System error Rampdown error RS422 serial Remote power ON OFF HPR system 1 Remote power ON OFF HPR system 2 CNC Remote power ON OFF HPR system 3 Remote power ON OFF HPR system 4 DB37 ...

Page 271: ...the SLEEP command 086 which will put all systems on the line into sleep mode The WAKE command 085 with specific system ID will wake the system that the CNC wants to communicate with Any command can now be sent to that power supply while all other systems will ignore the communications When the CNC is finished communicating with that power supply the SLEEP command must be sent then the WAKE command...

Page 272: ...VERSION Manual gas system Auto gas system Get the version of the power supply firmware Data None Return value Power supply firmware then Gas console firmware space delimited Sample 00191 001A 0 A 25 power supply rev A gas rev A 002 GET_STATE Manual gas system Auto gas system Get the current state of the plasma system Data None Return value Status code see table V Sample 00292 002000052 status code...

Page 273: ...PREFLOW_TEST_START Manual gas system Auto gas system Turn on the preflow gases Not allowed when cutting Data None Return value 1 accepted 0 not accepted Sample 0649A 0641CB 065 GAS_PREFLOW_TEST_STOP Manual gas system Auto gas system Turn off the preflow gases Not allowed when cutting Data None Return value 1 accepted 0 not accepted Sample 0659B 0651CC 066 GAS_CUTFLOW_TEST_START Manual gas system A...

Page 274: ...ower supply will switch to the current percentage specified Data of cutting current 50 100 50 50 Return value achieved Sample 0707503 070007563 set 75 071 MANUAL_PUMP_CONTROL Manual gas system Auto gas system Used to override software control of the coolant pump If the system has a fatal error the pump cannot be overridden Data 1 override software to force pump on 0 system software controls the pu...

Page 275: ...00 PF10000000B7 078 SET_ALL_GAS_FLOWS Auto gas system Set all gas flow rates N2 mix setpoint and Gas 2 mix setpoint are only applicable when using a mixed plasma gas such as H35 N2 Otherwise these 2 values should be set to 0 A value of 0 for N2 mix setpoint will cause the system to close SV12 the solenoid valve for N2 mixing A value of 0 for Gas 2 Mix Setpoint will cause the system to close SV13 a...

Page 276: ...e 0044 44 psi Note Cut gas 1 Cut gas 2 N2 mix inlet and Gas 2 mix inlet are not measured in the manual gas console configuration Sample 079A0 079PC0044 PP0042 SC0034 SP0035 CS0040 ST0003 ER0000 CG0000 CG0000 MV0000 MV0000DE 084 DOWNLOAD_SOFTWARE Not currently implemented on the HD4070 or the HPR systems TBD Download new firmware to the plasma system Data TBD Return value 1 packet accepted 0 not ac...

Page 277: ...t gases change power supply will enter the purge state Gas type changes are not allowed when the system is cutting state 4 state 10 N2 mix setpoint and Gas 2 mix setpoint are only applicable when using a mixed plasma gas such as H35 N2 otherwise these 2 values should be set to 0 A value of 0 for N2 Mix setpoint will cause the system to close SV12 the solenoid valve for N2 mixing A value of 0 for G...

Page 278: ...s N2 0961D0 097 READ_CORNER_CURRENT Manual gas system Auto gas system Read the corner current percentage Data None Return value Percentage Sample 097A0 09700756C 75 098 GET_INLET_GASES Manual gas system Auto gas system Read the inlet gas types Data None Return value Plasma gas type code See table VI Shield gas type code See table VI space delimited Sample 098A1 0980001 000648 Plasma gas O2 and shi...

Page 279: ...opper A setpoint 5 130 A Chopper B setpoint 5 130 A PWM chopper A 100 1070 PWM chopper B 100 1070 Data None Return value Above info is space delimited Sample 10091 100CAT0482 CBT0021 LVO0118 CFL0009 CTP0481 TTP0481 CAC0001 CBC0014 WLC0005 CAS0000 CBS0534 PWMA0000 PWMB00000B 101 SET_IO_STATUS Manual gas system Auto gas system This command will allow the user to turn on or off each output of the pro...

Page 280: ...nual Gas Console Shield cutflow SV16 Calibrate bypass SV13 Plasma cutflow 1 SV14 Ramp down valve SV20 Shield preflow SV17 Plasma preflow SV18 Plasma cutflow 2 SV19 H35 plasma cutflow 2 SV12 Spare valve SV15 O2 shield cutflow SV4 Air shield cutflow SV5 N2 shield cutflow SV6 Air preflow SV7 N2 preflow SV8 Air plasma cutflow 2 SV9 Air plasma cutflow 1 SV1 O2 plasma cutflow 1 SV2 H35 plasma cutflow 1 ...

Page 281: ... 6 Dipswitch 7 Dipswitch 8 Chopper A overcurrent Chopper B overcurrent Sample 11496 114000000000000000000F6 117 READ_GAS_INPUTS_FROM_PS Manual gas system Auto gas system This command will allow the CNC to query the gas console I O by sending the command to the serial port on the power supply control board Data None Return value 1 on 0 off Manual Gas Console Error select Status select Test preflow ...

Page 282: ... the pressure The Burkert flow test checks for an expected PWM value for a set pressure and does a gas ramp down test NOTE This test is preformed using 130 A O2 Air consumables and setting the 30 A O2 O2 process Each test takes about 40 seconds to complete This command will only be accepted when the power supply is in the state IDLE2 03 After leak checking is complete the system must be set to mod...

Page 283: ...table VI Shield gas type code See table VI space delimited Sample 12295 1220001 00063C 124 INDEX_MOTORVALVES Auto gas system Move the motor valve by a fixed number of ADC counts Data Motor Valve number 1 or 2 Open Clos 0 Close 1 Open Multiplier move by x10 counts 3 move 30 counts Return value 1 accepted Sample Open Motor valve 1 by 30 counts 1241 1 36C 1241C8 125 GET_TIMER_COUNTER Manual gas syste...

Page 284: ...provides data for the 3rd and 4th choppers used in the HPR400 system Chopper C temp raw A D Chopper D temp raw A D Chopper C current A Chopper D current A Data None Return value Above info space delimited Sample 13397 133CCT0482 CDT0021 CCC0000 CDC000050 134 READ ERROR LOG ALL HPR SYSTEMS This command will return the last 4 error codes the system encountered The log will only record errors error c...

Page 285: ... The HPR power supply will reduce its response speed Data None Return value 1 if successful Sample Send 1369A response 1361CB 158 GET_SECONDARY_VERSION HPR800XD ONLY Get the software version of the secondary power supply Data None Return value The Secondary Power Supply software version ex D 0 0 0 is returned if no secondary power supply is connected and the power is on sample 1589E 158D 040 Comma...

Page 286: ... Bad command Return ID 501 Description If the module does not recognize the command ID it will return ID 501 Sample 999AB unknown ID 50196 bad command Calculating checksums Checksum is calculated on the command ID and command data only HELLO Command 00090 0 0x30 ASCII value for number 0 0 0x30 0 0x30 Checksum 0x30 0x30 0x30 90 READ INPUTS power supply response 107000058 1 0x31 0 0x30 7 0x37 0 0x30...

Page 287: ...signal 026 Primary 226 Secondary LOST TRANSFER After transfer lost the transfer signal 027 Primary 227 Secondary LOST PHASE When main contactor is engaged no phase OK input 028 Primary 228 Secondary LOST CURRENT CH3 After transfer lost the chopper current signal 030 GAS SYSTEM ERROR A failure has occurred in the gas system 031 Primary 231 Secondary START LOST Start signal was removed before steady...

Page 288: ...OVERTEMP Torch coolant has overheated 072 AUTOMATIC GAS CONTROL BOARD OVERTEMP Control board has exceeded 90 C 194 F 073 Primary 273 Secondary CHOPPER3 OVERTEMP Chopper 3 overheated 074 Primary 274 Secondary CHOPPER4 OVERTEMP Chopper 4 overheated 075 Primary 275 Secondary CURRENT TOO LOW ON LEM 3 A current less than 10 amperes has been detected by current sensor 3 076 Primary 276 Secondary CURRENT...

Page 289: ... Primary 338 Secondary CHOPPER 2 OVERCURRENT Chopper 2 current feedback has exceeded 160 amperes 139 PURGE TIMEOUT ERROR The purge cycle did not complete within 3 minutes 140 AUTO GAS PRESSURE TRANSDUCER 1 ERROR Faulty transducer or auto gas control PCB 141 AUTO GAS PRESSURE TRANSDUCER 2 ERROR Faulty transducer or auto gas control PCB 142 AUTO GAS PRESSURE TRANSDUCER 3 ERROR Faulty transducer or a...

Page 290: ...0 HPR COOLER CAN FAULT Communications between the control board and the pump motor drive board was interrupted for greater than 1 second 161 MAXIMUM COOLANT FLOW EXCEEDED Coolant flow has exceeded 6 8 lpm 1 8 gpm for a cooler 8 52 lpm 2 25 gpm for a chiller 180 SELECTION CONSOLE CAN TIMEOUT Power supply has not received a CAN message from the selection console within 1 second 181 METERING CONSOLE ...

Page 291: ...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 25 Burkert flow check ID Gas type 0 No gas 1 Oxygen 2 Methane CH4 not supported 3 H35 argon hydrogen 4 H5 not supported 5 Air 6 Nitrogen 7 Argon 8 F5 N95 ...

Page 292: ...djust the shield gas type inlet gas selection see command ID No 95 8 Display and adjust the gas mixing setpoint pressure setpoint see command ID No 95 9 Display the system error code error code numbers see command ID No 3 10 Display the system status code status code numbers see command ID No 2 11 Manual pump control manually turn on off the pump see command ID No 71 12 Display the firmware versio...

Page 293: ...ions for up to 1 second Another alternative to handling the high frequency ignition is to poll for the power supply state using the GET_STATE command If the state is 5 Pilot arc then stop serial communications until the state is no longer 5 Pilot arc Cable shielding We have chosen to use metal shell DB style machine serial interface cables on some on the newer systems One of the reasons this type ...

Page 294: ...Appendix B CNC Interface Protocol b 28 HPR130XD Auto Gas 806330 Revision 1 ...

Page 295: ... robotic applications c 2 Torch leads c 2 Ohmic contact extension c 2 Rotational mounting sleeve optional 220864 c 3 Leather overwrap 024866 c 3 Robotic teaching torch laser pointer 228394 c 3 Torch and rotational mounting sleeve dimensions c 3 Rotational mounting sleeve clamp dimensions c 4 ...

Page 296: ... table below Overall length 1 8 M 6 feet gas lead 2 4 M 8 feet gas lead 2 m 6 ft 228514 228516 2 5 m 8 ft 228515 228517 3 m 10 ft 228475 228482 3 5 m 12 ft 228476 228483 4 5 m 15 ft 228477 228484 6 m 20 ft 228478 228485 7 5 m 25 ft 228479 228486 10 m 35 ft 228480 228487 15 m 50 ft 228481 228488 Components for robotic applications Torch leads The torch leads listed below have been designed to withs...

Page 297: ...leather overwrap is 3 m 10 ft long and is designed to be installed over the leads from where they attach to the torch This adds protection in applications where molten metal will splash back on the leads Robotic teaching torch laser pointer 228394 Mount the laser pointer in the torch sleeve to provide accurate positioning and alignment of the torch Use for online programming teaching and robotic a...

Page 298: ...Appendix C robotic applications c 4 HPR130XD Auto Gas 806330 Rotational mounting sleeve clamp dimensions 73 7 mm 2 9 in 50 8 mm 2 0in 73 7 mm 2 9 in 57 4 mm 2 26 in 55 9 mm 2 2 in ...

Page 299: ... to the first paragraph under the danger box 3 14 and 3 15 Added mounting hole call out 3 19 23 31 47 and 49 Added caution box about not using teflon tape 3 21 Changed the power cable connection point at the power supply from 1x5 to 1x1 3 25 Added asterisk after note 4 that refers to the note that was added under the caution box 3 36 and 3 37 Removed changing consumables note under torch alignment...

Page 300: ... now the Coolant Override button 5 11 Added error code number 11 Added XD after HPR130 260 and 400 in the Name column all instances Added error code numbers for HPR800XD secondary power supply Removed error code number 18 It is for the original HPR260 not the HPR260XD 5 12 5 13 Removed the Perform chopper test step from error code numbers 020 024 224 025 225 026 226 028 228 034 234 5 14 5 15 and 5...

Page 301: ...or nozzle part number 220182 from 4 to 3 6 14 Added part numbers to Consumables for mirror image cutting for 80 amp and 130 amp mild steel bevel cutting Schematics All sheets updated from revision A to revision B Appendix A Updated to the latest information and formatting for the Hypertherm torch coolant data MSDS Appendix B Added the secondary error code ID numbers after the primary error code ID...

Page 302: ...4 HPR130XD Auto Gas 806330 ...

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