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Hypertherm HyPerformance Plasma HPR400, Instruction Manual

The Hypertherm HyPerformance Plasma HPR400 is a high-quality and powerful cutting tool. To make the most out of its capabilities, don't forget to grab the Instruction Manual. Get your free manual download from manualshive.com, and unlock the full potential of this exceptional product.

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OperatiOn

4-34 

HPR400XD Auto Gas  – 

806160

Estimated kerf-width compensation

The widths in the chart below are for reference. Differences between installations and material composition may cause 

actual results to vary from those shown in the table. N/A = data not available.

Metric

Process

thickness (mm)

1.5

3

5

6

8

10

12

15

20

25

30

32

38

40

50

60

70

80

Mild steel

400A O

2

 / Air

N/A N/A N/A N/A N/A N/A 3.40 3.50 3.68 3.76 4.06 N/A N/A 4.88 5.94 6.60 7.80 9.10

260A O

2

 / Air

N/A N/A N/A 2.54 2.54 2.54 2.79 3.43 3.56 3.91 N/A 4.32 4.45 N/A 5.72 N/A N/A N/A

200A O

2

 / Air

N/A N/A 1.93 1.98 2.09 2.20 2.26 2.61 2.95 3.16 N/A 4.19 4.87 N/A 5.45 N/A N/A N/A

130A O

2

 / Air

N/A 1.64 1.77 1.81 1.92 2.04 2.11 2.22 2.65 3.43 N/A 4.26 4.59 N/A N/A N/A N/A N/A

80A O

2

 / Air

N/A 1.37 1.53 1.73 1.79 1.91 2.00 2.11 2.72 N/A N/A N/A N/A N/A N/A N/A N/A N/A

50A O

2

 / O

2

1.52 1.74 1.86 1.86 2.09 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

30A O

2

 / O

2

1.35 1.45 1.54 1.56 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

Stainless steel

400A N

2

 / Air

N/A N/A N/A N/A N/A N/A 3.00 2.90 2.80 3.10 3.30 N/A N/A 5.00 N/A N/A N/A N/A

400A H35 / N

2

N/A N/A N/A N/A N/A N/A N/A N/A 5.10 5.30 5.45 N/A N/A 5.50 5.80 6.35 N/A N/A

400A

H35 and N

2

 / N

2

N/A N/A N/A N/A N/A N/A 3.90 4.00 4.20 4.45 4.65 N/A N/A 5.15 5.65 5.90 6.35 6.95

260A

H35 and N

2

/ N

2

N/A N/A N/A 2.34 3.02 3.71 3.80 3.82 4.32 4.34 N/A 4.58 4.77 N/A 5.63 N/A N/A N/A

260A N

2

 / Air

N/A N/A N/A 2.31 2.39 2.46 2.54 2.76 3.08 3.30 N/A 3.64 4.43 N/A 4.16 N/A N/A N/A

260A H35 / N

2

N/A N/A N/A N/A 3.84 3.83 3.81 3.81 4.06 4.32 N/A 4.53 4.70 N/A 7.46 N/A N/A N/A

200A N

2

 / N

2

N/A N/A N/A N/A 2.10 2.16 2.29 2.47 2.92 N/A N/A N/A N/A N/A N/A N/A N/A N/A

200A H35 / N

2

N/A N/A N/A N/A 3.66 3.68 3.81 3.68 3.94 N/A N/A N/A N/A N/A N/A N/A N/A N/A

200A

H35 and N

2

/ N

2

N/A N/A N/A N/A 3.05 3.05 3.05 2.88 3.30 N/A N/A N/A N/A N/A N/A N/A N/A N/A

130A H35 / N

2

N/A N/A N/A N/A 2.69 2.72 2.77 3.03 2.90 3.25 N/A N/A N/A N/A N/A N/A N/A N/A

130A N

2

 / N

2

N/A N/A N/A 1.83 1.89 1.88 2.42 2.51 3.00 N/A N/A N/A N/A N/A N/A N/A N/A N/A

130A

H35 and N

2

/ N

2

N/A N/A N/A 1.78 2.25 2.73 2.76 3.03 2.90 N/A N/A N/A N/A N/A N/A N/A N/A N/A

80A F5 / N

2

N/A N/A 1.02 1.20 1.05 0.96 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

45A F5 / N

2

0.59 0.38 0.52 0.54 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

45A N

2

 / N

2

0.49 0.23 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

Summary of Contents for HyPerformance Plasma HPR400

Page 1: ...HyPerformance Plasma HPR400XD Auto gas Instruction manual 806160 Revision 4 ...

Page 2: ...______________ Distributor _____________________________________________ ________________________________________________________ ________________________________________________________ Maintenance notes ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________...

Page 3: ...Revision 4 June 2015 Hypertherm Inc Hanover NH USA www hypertherm com 2015 Hypertherm Inc All Rights Reserved Hypertherm HyPerformance HyDefinition LongLife and CommandTHC are trademarks of Hypertherm Inc and may be registered in the United States and or other countries ...

Page 4: ...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: ...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 Power...

Page 10: ...he ignition console 3 14 Placement of the cooler 3 16 Install the metering console 3 17 Placement of the selection console 3 18 Power supply to ignition console leads 3 20 Pilot arc lead 3 20 Negative lead 3 20 Ignition console power cable 3 22 Coolant hoses 3 23 Power supply to cooler cables 3 24 Control cable 3 24 Power cable 3 24 Power supply to selection console cables 3 26 Control cable 3 26 ...

Page 11: ...requirements 3 53 Premixed coolant for standard operating temperatures 3 53 Custom Coolant mix for cold operating temperatures 3 54 Custom Coolant mix for hot operating temperatures 3 55 Water purity requirements 3 55 Fill the cooler with coolant 3 56 Gas requirements 3 57 Setting the supply regulators 3 57 Gas regulators 3 58 Supply gas plumbing 3 59 Connect the supply gases 3 60 Supply gas hoses...

Page 12: ...ch water tube 4 20 Common cutting faults 4 21 How to optimize cut quality 4 22 Tips for table and torch 4 22 Plasma set up tips 4 22 Maximize the life of consumable parts 4 22 Additional factors of cut quality 4 23 Additional improvements 4 25 Cut charts 4 26 Thin stainless steel with HDi technology 4 26 Overview 4 26 Thick stainless steel piercing technique 4 27 Overview 4 27 Fine Feature cutting...

Page 13: ...de troubleshooting error codes 141 to 152 346 to 351 5 22 Error code troubleshooting error codes 153 to 156 354 to 356 5 23 Error code troubleshooting error codes 157 to 159 357 to 359 5 24 Error code troubleshooting error codes 160 to 180 5 25 Error code troubleshooting error code 181 182 298 and 383 5 26 Power supply states 5 27 Plasma system operation with pump time out 5 28 CNC operation with ...

Page 14: ...2 5 53 Selection console power distribution board PCB1 5 54 Selection console AC valve driver board PCB3 5 55 Metering console control board PCB2 5 56 Metering console power distribution board PCB1 5 57 Chopper tests 5 58 Phase loss detection test 5 60 Torch lead test 5 61 Preventive maintenance 5 62 Section 6 Parts List 6 1 Power supply 6 2 Cooler 6 6 Ignition console 6 8 Torch lead junction box ...

Page 15: ... 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 information a 7 Freezing Point of Propylene Glycol Solution a 8 Appendix B CNC Interface Protocol b 1 Interface hardware b 2 Signal list b 2 Signals b 2 Hardware ...

Page 16: ... robotic applications c 2 Torch leads c 2 Ohmic contact extension c 2 Rotational mounting sleeve optional 220864 c 3 Leather overwrap 024866 c 3 Robotic teaching torch laser pointer 228394 c 3 Torch and rotational mounting sleeve dimensions c 3 Rotational mounting sleeve clamp dimensions c 4 HPR400XD auto gas instruction manual revision changes 806160 1 ...

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: ...ion console 2 3 Selection console 2 3 Metering console 2 3 Torch 2 3 Specifications 2 4 System gas requirements 2 4 Power supply 2 5 Cooler 078531 2 6 Ignition console 078172 2 7 Torch lead junction box Optional 078619 2 9 Selection console 078533 2 10 Metering console 078535 2 11 Torch 228354 2 12 IEC symbols 2 13 Symbols and Marks 2 14 ...

Page 26: ...Specifications 2 2 HPR400XD Auto Gas 806160 ...

Page 27: ...orch electrode nozzle gap The high voltage high frequency signal is coupled to the cathode lead and pilot arc lead Selection console The selection console manages the selection and mixing of the plasma gases It contains motor valves solenoid valves and pressure transducers It also contains a control board an AC relay board and a power distribution board The selection console has an LED lamp that i...

Page 28: ...ar 115 psi 4250 l h 150 scfh N2 nitrogen 99 99 pure Clean dry oil free 793 kPa 8 bar 115 psi 11610 l h 410 scfh Air Clean dry oil free per ISO 8573 1 Class 1 4 2 793 kPa 8 bar 115 psi 11330 l h 400 scfh H35 argon hydrogen 99 995 pure H35 65 Argon 35 Hydrogen 793 kPa 8 bar 115 psi 4250 l h 150 scfh F5 nitrogen hydrogen 99 98 pure F5 95 Nitrogen 5 Hydrogen 793 kPa 8 bar 115 psi 4250 l h 150 scfh Ar ...

Page 29: ... supplies will operate between 10 C and 40 C 14 and 104 F Power factor cosϕ 0 98 400 ADC output 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 078523 078570 200 208 3 50 60 262 252 CSA 90 6 078524 078571 220 3 50 60 238 CSA 90 6 078525 078572 240 3 60...

Page 30: ...m the cooler to the power supply is 4 57 meters 15 ft Maximum hose length from the cooler to the ignition console is 76 2 meters 250 ft Allow 1 m 3 ft of space on all sides of the cooler for ventilation and service 457 mm 18 00 895 mm 35 25 895 mm 35 25 622 mm 24 50 76 mm 3 00 To the filter on the rear of the cooler Weight with no coolant 75 kg 165 lb ...

Page 31: ...ting table s bridge See Installation section for details Maximum cable length from the ignition console to the torch lifter station is 15 m 50 ft Allow room to remove the top for servicing The ignition console may be mounted horizontally or vertically 9 1 kg 20 lb 283 mm 11 125 219 mm 8 625 194 mm 7 625 152 mm 6 216 mm 8 5 ...

Page 32: ...Specifications 2 8 HPR400XD Auto Gas 806160 Horizontal mounting Vertical mounting Mounted on table ...

Page 33: ...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 34: ...m 250 ft Maximum cable 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 00 285 75 mm 11 25 311 15 mm 12 25 314 5 mm 12 38 254 0 mm 10 0 13 6 kg 30 lb 0 38 1 mm 1 5 0 76 2 mm 3 0 ...

Page 35: ...e metering console to the torch carriage on larger tables On smaller tables it can be mounted to a bracket just above the bridge The vent hole on the console must be kept clear at all times 153 9 mm 6 1 33 3 mm 1 3 122 2 mm 4 8 0 54 9 mm 2 2 76 2 mm 3 0 6 4 kg 14 lb 282 5 mm 11 1 0 248 9 mm 9 8 Vent hole Do not block 263 53 mm 10 375 155 58 mm 6 125 285 75 mm 11 25 ...

Page 36: ... 228354 The outside diameter of the torch mounting sleeve is 50 8 mm 2 0 in The minimum bend radius for the torch leads is 152 4 mm 6 0 in 1 8 m 6 1 9 kg 4 2 lb 194 mm 7 62 49 mm 1 91 104 mm 4 10 57 mm 2 25 51 mm 2 95 mm 3 74 51 mm 2 00 346 mm 13 63 43 ...

Page 37: ... source either 1 phase or 3 phase Power is OFF Power is ON f1 f2 1 AC Power is ON LED Inlet gas pressure fault LCD Missing or loose consumables LCD Power supply is out of temperature range LCD Volt amp curve drooping characteristic IEC symbols The following symbols may appear on the power supply data plate control labels switches LEDs and LCD screen System fault LED Plate metal cutting Expanded me...

Page 38: ...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 39: ...actices 3 6 Introduction 3 6 Types of grounding 3 6 Grounding practices 3 6 Grounding diagram 3 9 Placement of the power supply 3 11 Lifting the power supply 3 12 Install the ignition console 3 14 Placement of the cooler 3 16 Install the metering console 3 17 Placement of the selection console 3 18 Power supply to ignition console leads 3 20 Pilot arc lead 3 20 Negative lead 3 20 Ignition console ...

Page 40: ...nnect the torch to the torch lead assembly 3 43 Connect the torch to the quick disconnect 3 47 Torch mounting and alignment 3 48 Mounting the torch 3 48 Torch alignment 3 48 Torch lifter requirement 3 49 HyperNet 3 49 Power requirements 3 50 General 3 50 Line disconnect switch 3 51 Main power cable 3 51 Connect the power 3 52 Torch coolant requirements 3 53 Premixed coolant for standard operating ...

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 HPR400XD Auto Gas 806160 Installation requirements A B C D 1 2 3 4 5 6 7 8 9 10 11 13 E 15 14 12 18 17 16 F 17 15 ...

Page 43: ...ooler control cable 6 Cooler power cable 7 Selection console control cable 8 Selection console power cable 9 Selection console to metering console hose and lead assembly 10 CNC interface cable 11 Optional CNC interface cable for systems with multiple power supplies 12 Torch lead assembly 13 Work lead Supply gas hoses 14 Oxygen 15 Nitrogen or argon 16 Air 17 Argon hydrogen H35 or nitrogen hydrogen ...

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 HPR400XD Auto Gas 806160 ...

Page 49: ...an 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 THE WARRANTY Do not place the power supply on an incline greater than 10 to prevent it from toppl...

Page 50: ...raps by qualified personnel should be conducted before each use Worn or damaged straps may not be used nor may they be altered or modified in any way All 4 loops at the ends of the straps must be securely and properly attached to the lifting mechanism The power supply is a nonsymmetrical load ensure that an analysis by a qualified person is performed properly to balance the load to prevent tipping...

Page 51: ...rpretation or application of these or other OSHA regulations you should consult appropriate legal counsel Hypertherm slings are not for sale In Europe where locally purchased slings are required to have CE Marking In the UK the interpretation of the European Directives translated into the following UK Statutory Instruments SI SI 2306 PUWER The Provision and Use of Work Equipment Regulations and SI...

Page 52: ...grounding Install the ignition console Mount the ignition console in a vertical or horizontal position Allow room to remove the top for servicing B 7 mm 0 28 in 4 places 32 mm 1 25 in 32 mm 1 25 in 184 mm 7 25 in 317 5 mm 12 5 in 248 mm 9 75 in 222 25 mm 8 75 in ...

Page 53: ...Installation HPR400XD Auto Gas 806160 3 15 Horizontal RHF mounting Vertical RHF mounting ...

Page 54: ... 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 THE WARRANTY Do not place the cooler on an incline greater than 10 to prevent it from toppling C ...

Page 55: ... 2 mm 4 8 in 0 54 9 mm 2 2 in 76 2 mm 3 0 in 282 5 mm 11 1 in 0 248 9 mm 9 8 in Vent hole Do not block 7 mm 0 28 in 4 places Install the metering console Mount the metering console near the torch lifter station The maximum length of the gas hoses between the metering console and the torch is 1 8 m 6 ft D ...

Page 56: ...cement of the selection console Mount the selection console near the cutting table Allow room to remove the top and right side cover for servicing Preferred orientation is shown in the figure below The maximum length of cables between the power supply and selection console is 75 m 250 ft The maximum length of cables and hoses between the selection console and the metering console assembly is 20 m ...

Page 57: ...Installation HPR400XD Auto Gas 806160 3 19 This page is blank intentionally ...

Page 58: ... 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 123823 20 m 65 ft Part no Length Part no Length 123418 3 m 10 ft 123996 25 m 82 ft 023382 4 5 m 15 ft 123997 35 m 115 ft 023078 7 5 m 25 ft 023081 45 m 150 ft 123994 10 m 35 ft 023188 60 m 200 ft 023079 15 m 50 ft 023815 75 m 250 ft 123995 20 m 65 f...

Page 59: ...Installation HPR400XD Auto Gas 806160 3 21 Pilot arc lead Negative lead Pilot arc lead Negative lead 1 2 2 1 Work lead 2 1 ...

Page 60: ...0 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 123837 60 m 200 ft 123671 15 m 50 ft 123838 75 m 250 ft 123836 20 m 65 ft Cable signal list power supply to ignition console Power supply end Ignition console end Pin No Description Pin No 1 120 VAC Hot 1 2 120 VAC Return 2 3 Ground 3 4 Not used 4 Ignition console...

Page 61: ...gth 128499 1 5 m 5 ft 128984 20 m 65 ft 028652 3 m 10 ft 128078 25 m 85 ft 028440 4 5 m 15 ft 028896 35 m 115 ft 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 Coolant hoses 4 Caution Never use PTFE tape on any joint preparation ...

Page 62: ...round 3 Output Power ground 7 Red Input Output CAN H 7 Input Output CAN communication 9 Red Input Not used 9 Output Not used Cable signal list power supply to cooler Power supply end Cooler end Pin No Wire color Description Pin No Function 8 Black 120 VAC Hot 8 Coolant solenoid V1 13 White 120 VAC Return 13 Coolant solenoid V1 4 Shield 4 Ground 12 Black 240 VAC Hot 12 Cooler fan 16 Yellow 240 VAC ...

Page 63: ...PR400XD Auto Gas 806160 3 25 5 6 5 6 Note The inductor on the pump motor drive board makes a noise during operation that has been described as a hum sing and click This is normal and can be disregarded See note below ...

Page 64: ... 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 Output CAN H 7 Input Output CAN serial communication 3 CAN ground 3 CAN ground reference 9 Not used 9 Not used 8 Not used 8 Not used 4 Not used 4 Not used 5 Not used 5 Not used Part no Length Part no Length 123785 3 m 10 ft 123848 20 m 65 ft 123846 4 5 m 15...

Page 65: ...Installation HPR400XD Auto Gas 806160 3 27 7 8 8 7 ...

Page 66: ...le end Pin 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 Communication cable signal list 9 pin DSUB connectors Metering console end Selection console end Pin No Input Ou...

Page 67: ...Installation HPR400XD Auto Gas 806160 3 29 9 Caution Never use PTFE tape on any joint preparation ...

Page 68: ...as 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 69: ... 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 See example 1 on page 3 33 Caution The CNC cable must be constructed using cable with 360 degree shielding and metal housing conne...

Page 70: ...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 VOIDS 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 re...

Page 71: ...3 31 HPR Power ground 2 Optocoupler interface CNC PLC 24 VDC HPR Power ground Transistor output optocoupler 12V 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 72: ...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 73: ...8296 10 m 35 ft 228297 15 m 50 ft 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 12 Note A 20 m 65 ft torch lead is not available for HPR40...

Page 74: ...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 75: ...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 76: ...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 77: ...Installation HPR400XD Auto Gas 806160 3 39 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 78: ...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 79: ...tallation HPR400XD Auto Gas 806160 3 41 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 80: ...me of work table typical Work table Power supply Part no Length Part no Length 123418 3 m 10 ft 123996 25 m 82 ft 023382 4 5 m 15 ft 123997 35 m 115 ft 023078 7 5 m 25 ft 023081 45 m 150 ft 123994 10 m 35 ft 023188 60 m 200 ft 023079 15 m 50 ft 023815 75 m 250 ft 123995 20 m 65 ft 13 ...

Page 81: ...th 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 Caution Never use PTFE tape on any joint...

Page 82: ...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 HPR400XD 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 83: ...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 84: ... screw it onto the torch assembly 12 Slide the braided cover up to the torch sleeve Make sure that the plasma shield and vent hoses are routed through the hole in the braided cover Loosen the hose clamp on the braided cover slide the braided cover and clamp over the sleeve and tighten the clamp ...

Page 85: ...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 86: ...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 87: ...itive braking A unit which drifts through the stop point is not acceptable HyperNet HyperNet is only used to connect certain Hypertherm components to each other An HPRXD system can be connected to the ArcGlide 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 nee...

Page 88: ...circuits The power supply has a steady state current listed in the table below Use a motor start circuit breaker or equivalent if time delay high inrush fuses are not permitted by local and national codes Time delay fuses and circuit breakers must be capable of withstanding inrush current that is up to 30 times the rated input current FLA for 0 01 seconds and up to 12 times the rated input current...

Page 89: ...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 90: ...ation 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 Ground U U V W DANGER Electric Shock Can Kill The line disconnect switch must b...

Page 91: ...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 92: ...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 93: ...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 94: ...will drop as the coolant circulates through the system and an error code 060 or 093 may occur 3 Turn OFF the power 4 Add coolant to the cooler until the level in the sight glass reaches full and turn ON the power 5 Repeat this process as many times as necessary until the pump can be run continuously This will allow coolant to completely fill the coolant loop and purge any air from the system 6 Rep...

Page 95: ...bar 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 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 within...

Page 96: ...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 Part Number Description Qty 128544 Kit Oxygen 2 stage 1 128545 Kit Inert Gas 2 stage 1 128546 Kit Hydrogen H5 H35 and methane 2 stage 1 128547 Kit Air 2 stage 1 128548 Kit 1 stage for use with cr...

Page 97: ...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 98: ...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 99: ...35 m 115 ft 024134 7 5 m 25 ft 024120 45 m 150 ft 024211 10 m 35 ft 024124 60 m 200 ft 024112 15 m 50 ft 024764 75 m 250 ft 024763 20 m 65 ft Part no Length Part no Length 024671 3 m 10 ft 024740 25 m 82 ft 024658 4 5 m 15 ft 024744 35 m 115 ft 024659 7 5 m 25 ft 024678 45 m 150 ft 024765 10 m 35 ft 024680 60 m 200 ft 024660 15 m 50 ft 024767 75 m 250 ft 024766 20 m 65 ft Part no Length Part no Le...

Page 100: ...Installation 3 62 HPR400XD Auto Gas 806160 ...

Page 101: ...sumable 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 12 Aluminum 4 13 Mild steel bevel cutting 4 14 Mild steel thick piercing bevel cutting 4 14 Stainless steel bevel cutting 4 15 Install and Inspect consumables 4 16 Torch maintenance 4 19 Routine maintenance 4 1...

Page 102: ... quality 4 23 Additional improvements 4 25 Cut charts 4 26 Thin stainless steel with HDi technology 4 26 Overview 4 26 Thick stainless steel piercing technique 4 27 Overview 4 27 Fine Feature cutting 4 29 Overview 4 29 Bevel cutting 4 30 Consumables 4 30 Bevel compensation tables 4 30 Bevel cutting definitions 4 31 Underwater cut charts 4 32 Overview 4 32 Estimated kerf width compensation 4 34 ...

Page 103: ...he 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 Torch Current ring Electrode...

Page 104: ...al 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 105: ...firmware version 4 Manual pump control 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...

Page 106: ...n 4 6 HPR400XD Auto Gas 806160 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 107: ...Operation HPR400XD Auto Gas 806160 4 7 Diagnostic screen ...

Page 108: ...Operation 4 8 HPR400XD Auto Gas 806160 Test screen ...

Page 109: ...Operation HPR400XD Auto Gas 806160 4 9 Cut chart screen ...

Page 110: ... 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 amps 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 marki...

Page 111: ...3 220354 220761 220757 220435 220436 220439 220764 220760 220637 Shield Nozzle Swirl ring Electrode Nozzle retaining cap Shield cap 220552 220553 220554 220555 220754 50 A 220340 220629 220631 220632 220636 220635 220571 260 A 400 A Water tube SilverPlus electrodes are available for these processes Mild steel 130 amp O2 Air 220665 Mild steel 200 amp O2 Air 220666 Mild steel 260 amp O2 Air 220668 ...

Page 112: ...0179 220179 220337 220197 220198 220338 220202 220755 H35 220756 N2 220755 220755 220747 200 A 220307 220342 220343 220762 220758 220307 220405 220406 220763 220758 220637 Shield Nozzle Swirl ring Electrode Nozzle retaining cap Shield cap 220340 Water tube 220709 220708 220707 220712 220571 400 A 220405 260 A ...

Page 113: ...20179 220197 220198 220202 220756 220747 220755 H35 220756 Air 220307 220342 220346 220762 220307 220405 220406 220763 220758 220759 Shield Nozzle Swirl ring Electrode Nozzle retaining cap Shield cap 220637 220709 220708 220707 220712 220571 400 A 220405 260 A 220340 45 A 130 A 200 A Water tube ...

Page 114: ... Electrode Shield cap Water tube 80 A 220802 220179 220806 220742 220845 220541 220436 220542 220741 220740 130 A 220649 220179 220646 220742 220740 220700 220637 220629 220631 220632 220636 220635 400 A 260 A 220571 Mild steel thick piercing bevel cutting 260 A 220899 220436 220898 220571 220897 220896 220637 ...

Page 115: ...tainless steel bevel cutting 220606 220405 220607 220738 220739 Shield Nozzle Swirl ring Electrode 220606 220179 220656 220739 Shield cap Nozzle retaining cap 220738 130 A 220637 220709 220708 220707 220712 400 A 220405 260 A Water tube 220571 ...

Page 116: ...hield 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 go i...

Page 117: ...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 Signs of ...

Page 118: ...a thin film of silicone lubricant if the o rings are dry Electrode 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 amp mild steel electrode and all SilverPlus electrodes replace the electrode when the pit depth is 1 5 mm 0...

Page 119: ...f 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 intern...

Page 120: ...hiny but there should not be any excess or built up grease 5 Replace consumables See Install and inspect consumables in this section Replace torch water tube Torch connections Torch quick disconnect receptacle Coolant in Coolant return Plasma gas Plasma vent Coolant in Pilot arc Shield gas Coolant return Ohmic contact pin Torch WARNING The system is designed to go into an idle mode if the retainin...

Page 121: ... 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 consumable pa...

Page 122: ...Life 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 arc b...

Page 123: ...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 work di...

Page 124: ...ll 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 required...

Page 125: ... allow the torch to descend to cut height until it has cleared the puddle of molten material When pre piercing with the 400 amp O2 air process the arc should be on for a minimum of 4 seconds or the electrode may experience rapid wear This 4 seconds allows the current to properly ramp up and ramp down which is required for the long life process A small torch movement may be necessary if the peirce ...

Page 126: ...e 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 develops sta...

Page 127: ...ized with torch lifter motion In this way the molten material can be kept as far from the torch as possible while also maintaining a sustainable arc voltage Operators should plan the direction of the moving pierce in their part geometry so that this rooster tail of molten metal and hot gases does not get directed at themselves or at the gantry torch lifter controller other torches or other sensiti...

Page 128: ...ntrol signal must be turned off for these processes when the shield gas preflow pressure is lower than the shield gas cutflow pressure This moving pierce technique requires a torch height control THC system that is controllable through the CNC Moving pierce cut charts The moving pierce cut charts are listed by amperage with the other stainless steel cut charts They show the consumable parts the se...

Page 129: ...d 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 in t...

Page 130: ...el 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 an HPR...

Page 131: ...ertical distance from the lowest point of the torch to the surface of the workpiece Torch to work distance The linear distance from the center of the torch outlet to the workpiece surface along the torch center line A range of torch to work distances are listed in the cut chart The smallest number is for a straight cut bevel angle 0 The largest number is for a 45 bevel cut with a clearance of 3 mm...

Page 132: ...ased 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 use co...

Page 133: ...t 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 contact...

Page 134: ...N A N A N A 400A H35 N2 N A N A N A N A N A N A N A N A 5 10 5 30 5 45 N A N A 5 50 5 80 6 35 N A N A 400A H35 and N2 N2 N A N A N A N A N A N A 3 90 4 00 4 20 4 45 4 65 N A N A 5 15 5 65 5 90 6 35 6 95 260A H35 and N2 N2 N A N A N A 2 34 3 02 3 71 3 80 3 82 4 32 4 34 N A 4 58 4 77 N A 5 63 N A N A N A 260A N2 Air N A N A N A 2 31 2 39 2 46 2 54 2 76 3 08 3 30 N A 3 64 4 43 N A 4 16 N A N A N A 26...

Page 135: ... A N A N A 2 64 2 64 2 62 2 79 3 09 3 30 3 56 N A 3 29 3 60 N A 5 37 N A N A N A 200A N2 N2 N A N A N A N A 1 78 2 03 2 58 2 54 3 01 N A N A N A N A N A N A N A N A N A 200A H35 N2 N A N A N A N A 2 44 2 67 2 92 3 18 3 30 N A N A N A N A N A N A N A N A N A 200A H35 and N2 N2 N A N A N A N A 2 79 2 92 3 05 3 30 3 81 N A N A N A N A N A N A N A N A N A 130A H35 N2 N A N A N A N A 2 70 2 72 2 77 2 3...

Page 136: ... N A N A N A N A N A N A N A 200A H35 and N2 N2 N A N A N A 0 120 0 120 0 120 0 111 0 130 N A N A N A N A N A N A N A N A 130A H35 N2 N A N A N A 0 115 0 121 0 123 0 124 0 125 0 129 N A N A N A N A N A 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 N A N A 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 N A N A N A N A N A 80A F5 N...

Page 137: ...as 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 15 200 O 2 Air 220637 220761 220757 220354 220353 220352 220340 16 20 20 260 O 2 Air 220637 220764 220760 ...

Page 138: ...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 6 260 0 5 15 200 O 2 Air 23 42 74 15 130 2 0 1778 8 1 400 0 6 16 20 132 2 3 1678 356 0 8 20 2...

Page 139: ... 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 5 8 200 O 2 Air 220637 220761 220757 220354 220353 220352 220340 3 4 3 4 260 O 2 Air 220637 220764 2207...

Page 140: ... 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 5 8 200 O 2 Air 23 42 74 14 130 0 08 70 0 32 400 0 6 3 4 15 0 09 356 0 8 3 4 260 O 2 Air 22 49 80 47 158 0 ...

Page 141: ...7 0 4 2 5 122 1325 75 3 123 1160 0 5 4 125 905 0 7 6 128 665 1 0 Metric Select Gases Set Preflow Set Cutflow Material Thickness Arc Voltage Torch to Work Distance Cutting Speed Initial Pierce Height Pierce Delay Time Plasma gas Shield gas Plasma gas Shield gas Plasma gas Shield gas in Volts in ipm in Factor Seconds O2 O2 78 17 94 17 0 018 114 0 05 215 0 09 180 0 1 0 024 200 0 030 115 170 0 2 0 036...

Page 142: ... 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 3 119 1 5 1800...

Page 143: ... 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 144: ... Pierce 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 ...

Page 145: ...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 gas S...

Page 146: ...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 147: ...Plasma gas Shield gas Plasma gas Shield gas Plasma gas Shield gas in in Range in ipm in 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 bevel cutting...

Page 148: ...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 Shield...

Page 149: ...me Plasma gas Shield gas Plasma gas Shield gas Plasma gas Shield gas mm Volts mm mm m mm factor seconds O2 Air 23 42 74 18 5 123 3 3 5700 6 6 200 0 2 6 124 5250 8 125 4355 0 3 10 126 3460 12 128 3060 0 5 15 131 4 1 2275 8 2 0 6 20 133 1575 0 8 25 143 5 1 1165 10 2 1 0 32 145 750 Edge start 38 152 510 50 163 255 Select Gases Set Preflow Set Cutflow Material Thickness Arc Voltage Torch to Work Dista...

Page 150: ...g Speed Initial Pierce Height Pierce Delay Time Plasma gas Shield gas Plasma gas Shield gas Plasma gas Shield gas in in Range in ipm in Factor Seconds O2 Air 23 83 69 42 0 08 3 16 0 13 0 33 230 0 26 200 0 2 1 4 200 5 16 171 0 3 3 8 140 1 2 115 0 5 5 8 0 16 0 33 80 0 32 0 6 3 4 65 0 8 1 0 20 0 33 45 0 40 1 0 1 1 4 30 2 7 1 1 2 20 Edge start 2 10 Mild steel bevel cutting O2 Plasma Air Shield 200 A F...

Page 151: ...Shield gas Plasma gas Shield gas Plasma gas Shield gas mm Volts mm mm m mm Factor Seconds O2 Air 23 42 74 18 8 126 3 3 3878 6 6 200 0 3 10 127 3116 12 129 2764 0 5 15 133 4 1 2052 8 2 0 6 220761 220637 220757 220353 220354 220340 220352 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 ...

Page 152: ...flow 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 in Volts in ipm in factor seconds O2 Air 22 49 76 46 1 4 150 0 11 245 0 33 300 0 3 5 16 215 3 8 180 1 2 145 0 4 80 49 5 8 155 0 14 115 0 35 250 0 5 3 4 159 90 0 6 7 8 166 75 0 7 84 1 171 65 0 8 1 1 8 170 0 19 55 0 38 200 ...

Page 153: ... 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 in in Range in ipm in factor seconds O2 Air 22 49 76 46 0 08 1 4 0 11 0 30 245 0 33 300 0 3 5 16 215 3 8 180 1 2 145 0 4 80 49 5 8 0 14 0 30 115 0 35 250 0 5 3 4 90 0 6 7 8 75 0 7 84 1 65 0 8 1 1 8 0 19 0 30 55 0 38 ...

Page 154: ...0 55 0 38 200 1 0 1 1 4 45 1 2 1 1 2 35 3 0 1 3 4 22 Edge start 2 15 2 1 4 12 2 1 2 8 English Select Gases Set Preflow Set Cutflow Amperage Torch to Work Distance Marking Speed Arc Voltage Amps mm in mm m ipm Volts N2 N2 10 10 10 10 18 2 5 0 10 6350 250 122 Ar Air 30 10 30 10 24 3 0 0 12 2540 100 62 Marking Mild steel bevel cutting alternate thick metal piercing O2 Plasma Air Shield 260 A 220897 2...

Page 155: ...m m mm Factor Seconds O2 Air 22 49 76 49 8 150 2 8 4889 8 4 300 0 3 10 3997 12 152 3501 0 4 80 49 15 156 3 6 2830 9 0 250 0 5 20 160 1958 0 6 22 162 1750 0 7 84 25 165 1527 0 8 28 170 4 8 1311 9 6 200 0 9 220764 220637 220760 220436 220439 220340 220435 Select Gases Set Preflow Set Cutflow Material Thickness Arc Voltage Torch to Work Distance Cutting Speed Initial Pierce Height Pierce Delay Time P...

Page 156: ...ic Select Gases Set Preflow Set Cutflow Amperage Torch to Work Distance Marking Speed Arc Voltage Amps mm in mm m ipm Volts N2 N2 10 10 10 10 22 2 5 0 10 1270 50 123 Ar Air 20 10 30 10 25 3 0 0 12 1270 50 55 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...

Page 157: ... 4 580 Edge start 70 380 80 7 9 9 4 180 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 in in Range in ipm in Factor Seconds O2 Air 24 50 60 50 0 08 1 2 0 14 0 37 170 0 28 200 0 4 5 8 150 0 5 3 4 115 0 6 7 8 0 15 0 37 10...

Page 158: ... mm Volts mm mm m mm Factor Seconds O2 Air 24 50 60 50 16 144 3 6 3398 7 2 200 0 5 20 147 2535 0 7 22 150 3 8 2311 7 6 0 8 25 153 4 0 1997 8 0 0 9 30 155 4 6 1624 9 2 1 1 40 160 1039 11 5 250 1 9 220636 220637 220635 220631 220632 220571 220629 Select Gases Set Preflow Set Cutflow Material Thickness Arc Voltage Torch to Work Distance Cutting Speed Initial Pierce Height Pierce Delay Time Plasma gas...

Page 159: ...1 5880 0 1 1 2 5380 0 2 1 5 95 4630 2 97 3935 2 5 101 3270 3 103 2550 0 3 4 1580 Select Gases Set Preflow Set Cutflow Material Thickness Arc Voltage Torch to Work Distance Cutting Speed Initial Pierce Height Pierce Delay Time Plasma gas Shield gas Plasma gas Shield gas Plasma gas Shield gas in Volts in ipm in Factor Seconds N2 N2 35 5 62 49 0 036 94 0 10 240 0 15 150 0 0 0 048 210 0 1 0 060 95 180...

Page 160: ...5 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 in Volts in ipm in 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 16 108 0 0...

Page 161: ...low 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 Distance...

Page 162: ...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 163: ...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 in Volts in ipm in 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 Select Gases Set ...

Page 164: ... 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 165: ...1195 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 in Volts in ipm in Factor Seconds H35 N2 19 51 75 38 32 18 1 4 150 0 12 70 0 24 200 0 3 ...

Page 166: ...ickness 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 Mater...

Page 167: ... 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 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 Equiva...

Page 168: ...d 130 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 in in Range in ipm in Factor 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 28 0 5 5 8 0...

Page 169: ...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 N2 N2 17 42 84 42 8 159 3 8 3000 7 6 200 0 4 10 160 2700 0 5 12 161 2400 0 6 15 163 1800 0 8 20 167 1000 1 0 Select Gases Set Preflow Set Cutflow Material Thickness Arc Voltage Torch to Work Distance ...

Page 170: ...0 7 20 177 820 0 8 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 in Volts in ipm in Factor Seconds H35 N2 17 43 88 52 5 16 175 0 35 70 0 35 100 0 4 3 8 65 0 5 1 2 170 0 30 55 0 30 0 6 5 8 173 45 0 7 3 4 177 35 0 8 Flow rates lpm scfh H...

Page 171: ...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 Mix Gas 1 Mix Gas 2 in Volts in ipm in Factor Seconds H35 N2 17 41 87 41 42 20 5 16 160 0 16 79 0 320 200 0 4 3 8 161 75 0 5 1 2 162 70 0 6 5 8 167 0 18 60 0 270 150 0 8 3 4 171 0 20 45 0 300 1 0 Flow rat...

Page 172: ...ight Pierce Delay Time Plasma gas Shield gas Plasma gas Shield gas Plasma gas Shield gas mm Volts mm mm m mm factor seconds N2 Air 12 47 79 56 6 160 3 8 6375 7 5 200 0 3 8 158 4910 10 157 3440 12 161 2960 0 4 15 163 2520 0 5 20 164 1590 0 6 25 168 1300 0 8 32 171 875 1 0 38 179 515 Edge start 44 190 365 50 195 180 Select Gases Set Preflow Set Cutflow Material Thickness Arc Voltage Torch to Work Di...

Page 173: ...Pierce Delay Time Plasma gas Shield gas Plasma gas Shield gas Plasma gas Shield gas mm Volts mm mm m mm factor seconds H35 N2 12 49 85 60 8 188 11 0 2030 11 0 100 0 3 10 1870 12 173 9 0 1710 9 0 0 4 15 171 7 5 1465 120 0 5 20 175 1085 0 6 25 180 785 0 7 32 185 630 1 0 38 186 510 Edge start 44 189 390 50 200 270 Select Gases Set Preflow Set Cutflow Material Thickness Arc Voltage Torch to Work Dista...

Page 174: ... 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 in Volts in ipm in Factor Seconds H35 N2 12 49 87 60 60 21 1 4 170 0 16 150 0 32 200 0 3 5 16 173 121 3 8 175 90 1 2 176 65 0 5 5 8 177 0 7 3 4 179 55 0 8 40 26 1 182 35 1 0 1 1 4 1...

Page 175: ...ance 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 12 49 85 60 2 0 8 11 0 2030 11 0 100 0 3 10 1870 12 9 0 10 0 1710 9 0 0 4 15 7 5 10 0 1465 120 0 5 20 1085 0 6 25 785 0 7 32 630 1 0 38 510 Edge start 44 390 50 270 Select Gases Set Preflow Set Cutflow Minimum Clearance Equivalent...

Page 176: ...s 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 Air 12 47 79 56 2 0 6 3 8 10 0 6375 7 5 200 0 3 8 4910 10 3440 12 2960 0 4 15 2520 0 5 20 1590 0 6 25 1300 0 8 32 875 1 0 38 515 Edge start 44 365 50 180 Select Gases Set Preflow Set Cutflow Minimum Clearance Equiv...

Page 177: ... 390 50 270 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 in in Range in ipm in Factor Seconds H35 N2 12 49 87 60 60 21 0 08 1 4 0 16 0 40 150 0 32 200 0 3 5 16 121 3 8 90 1 2 65 0 5 5 8 0 7 3 4 55 ...

Page 178: ...187 430 Metric 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 in Volts in ipm in Factor Seconds N2 Air 30 50 85 31 1 2 158 0 15 125 0 39 260 0 3 5 8 159 105 0 4 3 4 162 0 18 95 0 54 300 0 5 1 164 75 0 6 1 1 4 176 0 25 50 0 75 0 ...

Page 179: ...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 in Volts in ipm in Factor Seconds H35 N2 30 45 86 45 3 4 180 0 35 45 0 53 150 0 7 1 181 35 0 75 210 1 0 1 1 4 184 30 1 5 1 1 2 186 25 2 0 1 3 4 189 20 Edge start 2 192 15 2 1 4 198 12 2 1 2 202 10 English 220707 220637 220709 ...

Page 180: ... Volts mm mm m mm Factor Seconds H35 N2 30 45 88 45 60 40 12 157 4 6 2750 14 300 0 4 15 159 2390 0 5 20 166 1810 0 7 25 172 1310 1 0 60 30 186 5 3 1080 16 2 0 40 187 6 4 720 19 3 0 45 635 50 190 520 Edge start 60 192 410 70 194 310 80 210 180 Select Gases Set Preflow Set Cutflow Material Thickness Arc Voltage Torch to Work Distance Cutting Speed Initial Pierce Height Pierce Delay Time Plasma gas S...

Page 181: ...ce 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 in in Range in ipm in Factor Seconds N2 Air 30 50 85 31 0 08 1 2 0 15 0 46 125 0 39 260 0 3 5 8 105 0 4 3 4 0 18 0 46 95 0 54 300 0 5 1 75 0 6 1 1 4 0 25 0 46 50 0 75 0 8 1 1 2 0 18 0 46 25 Edge start 1 3 4 17 Marking Select...

Page 182: ... 30 800 1 5 40 600 2 0 50 400 Edge start 60 280 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 in in Range in ipm in Factor Seconds H35 N2 30 45 86 45 0 08 3 4 0 35 0 46 45 0 53 150 0 7 1 35 0 75 210 1 0 1 1 4 30 1 5 1 ...

Page 183: ...alent 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 in in Range in ipm in Factor Seconds H35 N2 30 45 88 45 60 40 0 08 1 2 0 18 0 46 105 0 5 300 0 4 5 8 90 0 5 3 4 75 0 7 1 50 1 0 60 1 1 4 0 21 0 46 40 0 6 1 5 1 1 2 0 25 0 46 30 0 8 2 0 1 3 4 25 3 0 2 20 Edge star...

Page 184: ... mm m mm mm m Seconds Cut Height Pierce Delay Cut Height Cut Height mm Seconds Seconds 50 19 1 1143 10 6 381 38 1 508 4 8 300 50 500 250 6 4 0 5 5 7 75 25 3 508 63 5 254 8 0 3 0 4 0 220712 Note Torch to work distance is equivalent to cut height Material Thickness First Segment First Speed Second Segment Second Speed Third Segment Third Speed Pierce Delay Time Transfer Height Factor Moving Delay Fa...

Page 185: ...117 3 0 1695 4 5 0 6 Select Gases Set Preflow Set Cutflow Material Thickness Arc Voltage Torch to Work Distance Cutting Speed Initial Pierce Height Pierce Delay Time Plasma gas Shield gas Plasma gas Shield gas Plasma gas Shield gas in Volts in ipm in 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 3 3 16 114 ...

Page 186: ...25 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 in Volts in ipm in Factor Seconds Air Air 19 31 75 23 1 4 153 0 11 90 0 22 200 0 2 5 16 154 0 12 76 0 24 0 3 ...

Page 187: ...reflow 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 in Volts in ipm in 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 scfh H35 N...

Page 188: ...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 Mix Gas 1 Mix Gas 2 in Volts in ipm in 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 Flow rates...

Page 189: ...166 2350 0 6 20 165 1000 0 8 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 in Volts in ipm in Factor Seconds N2 N2 17 43 73 43 5 16 158 0 25 236 0 35 140 0 3 3 8 200 0 4 1 2 120 0 5 5 8 166 80 0 6 3 4 165 50 0 8 Marking Flow rates lpm ...

Page 190: ...flow 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 in Volts in ipm in Factor Seconds H35 N2 17 43 73 43 5 16 152 0 25 197 0 35 140 0 3 3 8 180 1 2 150 140 0 4 5 8 110 0 5 3 4 159 70 0 6 Marking Flow rates lpm scfh H35 N2 Preflow 0 0 113 240 Cutflow 34 72 90 19...

Page 191: ... 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 in Volts in ipm in Factor Seconds H35 N2 17 44 73 44 42 20 5 16 158 0 25 171 0 35 140 0 3 3 8 160 1 2 140 0 4 5 8 162 80 0 5 3 4 170 50 0 6 Marking Flow rates lpm scfh H35 N2 Preflow 0 ...

Page 192: ... 202 320 50 205 215 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 in Volts in ipm in Factor Seconds N2 Air 12 49 74 56 1 4 172 0 25 300 0 35 140 0 2 5 16 253 0 3 3 8 171 200 0 4 1 2 164 0 16 160 0 32 200 0 5 5 8 165 120 0 6 3 4 171 80 ...

Page 193: ...flow 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 in Volts in ipm in Factor Seconds H35 N2 12 49 76 58 1 4 170 0 45 280 0 45 100 0 2 5 16 262 0 3 3 8 0 40 250 0 40 0 4 1 2 162 0 30 190 0 33 110 0 5 5 8 163 130 0 6 3 4 166 90 1 174 75 0 45 150 0 8 1 1 4 175 60...

Page 194: ...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 in Volts in ipm in Factor Seconds N2 Air 30 50 70 31 1 2 155 0 15 170 0 5 330 0 4 5 8 159 140 0 5 3 4 163 0 16 115 0 7 440 0 6 1 169 70 0 7 1 1 4 177 50 Edge start 1 1 2 178 35 1 3 4 198 25 2 206 16 English 220707 ...

Page 195: ...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 in Volts in ipm in Factor Seconds H35 N2 30 45 86 45 3 4 170 0 35 100 0 53 150 0 7 1 175 70 0 74 210 1 0 1 1 4 177 60 1 5 1 1 2 180 50 2 0 1 3 4 184 40 Edge start 2 188 30 2 1 4 200 20 2 1 2 208 15 3 210 10 English...

Page 196: ...45 60 40 12 155 4 6 5190 14 300 0 4 15 157 4710 0 5 20 159 3620 0 7 25 166 2620 1 0 60 30 171 5 3 2170 16 1 5 40 175 6 4 1440 19 2 0 50 185 1000 Edge start 60 195 450 70 200 310 80 208 210 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 ...

Page 197: ...Operation HPR400XD Auto Gas 806160 4 97 ...

Page 198: ... troubleshooting error codes 062 to 067 265 to 267 5 16 Error code troubleshooting error codes 071 to 075 273 to 275 5 17 Error code troubleshooting error codes 076 to 101 276 to 301 5 18 Error code troubleshooting error codes 102 to 111 302 to 308 5 19 Error code troubleshooting error codes 116 to 133 316 5 20 Error code troubleshooting error codes 134 to 140 334 and 338 5 21 Error code troublesh...

Page 199: ...hooting 5 42 Testing the flow sensor 5 42 Gas leak tests 5 43 Leak test 1 inlet leak test 5 43 Leak test 2 system leak test 5 44 Leak test 3 proportional valve test in the metering console 5 44 Power supply control board PCB3 5 45 Power supply power distribution board PCB2 5 46 Start circuit PCB1 5 47 Operation 5 47 Start circuit functional schematic 5 47 Start circuit troubleshooting 5 47 Pilot a...

Page 200: ...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 201: ...he power supply and the selection console Power cable Provides 120 VAC to the ignition console Power cable Provides 120 VAC to the metering console CAN Bus signal cable Provides process and status signals between the power supply and the metering console CAN Bus signal cable Provides process and status signals between the power supply and the cooler Power cable Provides 120 VAC and 240 VAC to the ...

Page 202: ...opper 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 pressure ok Pha...

Page 203: ...n 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 or argon marking process Gas system valve usage The following tables show which ...

Page 204: ...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 205: ... 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 amps Metering console control board Se...

Page 206: ... 5 9 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 207: ... 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 channel 1 is decreasing which indicates a leak Look for leaks and loose connections b...

Page 208: ...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 209: ...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 210: ...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 211: ...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 212: ...r 140 psi in the selection console 1 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 1 ...

Page 213: ...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 214: ... 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 ...

Page 215: ...ntactor 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 temper...

Page 216: ...HPR260XD HPR400XD Only A current less than 10 amps 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 amps 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 work lead ...

Page 217: ... 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 is illuminatin...

Page 218: ...maged 2 Measure voltage across current sensor a Red to black 15 VDC Green to black 15 VDC white to black 0 VDC at idle and varies with current output 4 VDC 100 amps b If possible take a voltage reading on current sensor while trying to cut Ratio is 4 VDC 100 amps 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 ...

Page 219: ... 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 220: ...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 amps 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 amps b If...

Page 221: ...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 222: ...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 223: ...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 224: ... State code Name State code Name 00 Power up idle 11 Cycle complete auto off 02 Purge 12 Test cutflow 03 Ready for start idle2 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 25 Burkert valve flow check ...

Page 225: ...mp 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 START signal Is the flow sensor satisfied Purge timer done Yes Yes Yes START signal removed No No ...

Page 226: ...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 227: ...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 228: ... is 10 greater or more than the other 2 put that leg on U U V W Ground DANGER Shock Hazard There is line voltage at the contactor and the power distribution board PCB2 when the line disconnect switch is on Use extreme care when measuring primary power in these areas Voltages present at the terminal block and contactors can cause injury or death Main power in ...

Page 229: ...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 230: ...ove the return coolant hose red washer on the cooler fitting from the rear of the cooler and put it in a 20 liter 5 gallon container 4 Turn OFF the pump when the coolant stops flowing 3 Turn ON the pump manually using the manual pump control button on your CNC screen 1 Turn OFF all power to the system ...

Page 231: ...ment 1 Turn OFF all power to the system 2 Remove housing 3 Remove and discard filter element 4 Install new filter element 027664 5 Re install housing 6 Refill with new coolant Caution Coolant will flow from the filter when its housing is removed Drain coolant before servicing the filter ...

Page 232: ... 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 233: ...n here are for reference The screens you work with may look different but should have the same functions shown here Before testing Notes It is important to follow the troubleshooting steps in the order in which they are shown in the flow chart on the previous page Coolant must be drained from the system before the in line filter is cleaned step 1 below The coolant in the system will drain out as s...

Page 234: ... Square in both axis 2 Take your reading from the edge shown below Right side orifice Left side orifice Filler cap Bypass valve Bypass valve verification 1 Remove the cooler s filler cap 2 Stand in front of the cooler with the pump running and look inside the coolant tank 3 Coolant should be flowing from the orifice on the right If coolant is flowing from the orifice on the left look for a restric...

Page 235: ...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 236: ... flow rate is less than 0 8 gpm Go to test 2 If there is no flow go to pump and motor troubleshooting Test 2 supply line at ignition console Note Remove the torch lead coolant hoses to access the supply line 1 Turn OFF the power Remove the supply coolant line blue hose with green tape from the RHF LHF console and place it in a 3 8 liter 1 gallon container A Hypertherm coolant container works well ...

Page 237: ...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 238: ...your CNC screen see step 1 under Manual pump operation Write 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 by pass val...

Page 239: ... is power to the motor If you are still not getting flow from the pump verify that the solenoid valve and relief valve are working correctly TP8 D1 PWR GND TP7 24V TP21 TP22 15V 15V 5V S2 CAN SW 0 WDI SW 1 TP18 TP6 3 3V D2 D8 D7 RX TX TP4 5V TP23 TP1 A3 3V TP16 TP10 TP3 TP17 TP15 RESET TP2 TP9 TP 2 TP 9 Testing the flow sensor 1 Turn ON the power 2 Measure the VDC between TP2 and TP9 TP9 is 67 sca...

Page 240: ...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 241: ...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 242: ...ntrol D TP109 Reset TP119 CCC TP208 DAC output A TP110 Digital ground TP120 CRXD CANL TP209 DAC output B TP111 Analog ground TP200 Chopper 1 analog input TP210 Chopper A temperature sensor TP112 A 3 3 V TP201 Chopper control A TP211 Chopper B temperature sensor TP113 3 3 V TP202 Chopper 2 analog input TP212 Chopper C temperature sensor TP114 5 V TP203 Chopper control B TP213 Chopper D temperature ...

Page 243: ...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 244: ...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 245: ... 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 246: ...50 amps 80 amps 130 amps 200 amps 260 amps 400 amps O2 25 30 30 30 30 40 40 60 N2 25 30 30 30 35 40 40 60 H35 25 30 30 30 35 40 40 60 F5 25 30 30 30 35 40 40 60 Air 25 30 30 30 35 40 40 60 Transfer current Plasma gas 30 amps 45 amps 50 amps 80 amps 130 amps 200 amps 260 amps 400 amps O2 10 10 10 10 15 20 20 30 N2 10 10 10 10 15 20 20 30 H35 10 10 10 10 15 20 20 30 F5 10 10 10 10 15 20 20 30 Air 10...

Page 247: ...1 15 V OK On when 15 voltage is OK D10 5 V OK On when 5 voltage is OK D16 3 3 V OK On when 3 3 voltage is OK D30 IPM temperature alarm output Off when OK On when there is a sustained over current condition D31 Temperature Off when OK On when there is a temperature fault D32 IPM alarm output Off when OK On when there is an internal overtemp over current or bad gate supply drive voltage D35 Pump mot...

Page 248: ...Maintenance HPR400XD Auto Gas 806160 5 51 Cooler power distribution board PCB1 Gas console control board LED list LED Signal name Color D2 SV16 Red D4 5 VDC Green ...

Page 249: ...scription TP1 A 3 3 V TP12 Digital ground TP2 Analog ground TP13 3 3 V TP3 Pressure sensor for use in the future TP14 SCIRXD RS422 transmit TP4 5 V TP15 Digital ground TP6 3 3 V TP16 Analog ground TP7 24 V TP17 Reset TP8 Power ground TP18 Reset TP9 Coolant flow sensor input TP21 15 V TP10 Chiller flow input for use in the future TP22 15 V TP11 SCIRXD RS422 receive TP23 Line voltage input Gas conso...

Page 250: ...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 251: ...Maintenance 5 54 HPR400XD Auto Gas 806160 Selection console power distribution board PCB1 Gas console control board LED list LED Signal name Color D2 SV16 Red D4 5 VDC Green ...

Page 252: ...r 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 not used 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 253: ...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 254: ...Maintenance HPR400XD Auto Gas 806160 5 57 Metering console power distribution board PCB1 Gas console control board LED list LED Signal name Color D2 SV16 Red D4 5 VDC Green ...

Page 255: ...error code 106 Chopper 1 high current error code 103 Chopper 2 high current error code 104 Chopper 3 low current error code 075 Chopper 4 low current error code 076 Chopper 3 high current error code 107 Chopper 4 high current error code 095 Chopper 1 failure 1 Turn OFF all power to the system 2 Remove the cover over the main contactor CON1 and inspect the contacts for arcing or damage If the conta...

Page 256: ...o step 2 2 Measure the OCV The chopper outputs are connected in parallel at the I O board and the choppers are tested in sequence 1 3 2 and 4 This means that if you measure the OCV at the NEG and WORK terminals on a fully functional HPR400XD the voltage will be 0 until the contactor CON1 closes Chopper 1 will turn on and you will measure 360 VDC Chopper 1 will turn off and the voltage will decreas...

Page 257: ...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 258: ... value between the nozzle and the plate The reading should be less than 3 ohms A measurement of greater than 3 ohms indicates a faulty connection between the torch and ignition console or between the ignition 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 WARNING Shock Haza...

Page 259: ... 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 260: ...gnition console to junction box leads 6 10 Selection console 6 11 Metering console 6 13 HyPerformance torch 6 14 Torch assembly 6 14 Torch leads 6 15 Ohmic contact wire 6 15 Consumable parts kits 6 16 Consumables for mirror image cutting 6 18 Straight cutting 6 18 Mild steel 6 18 Bevel cutting 6 20 Recommended spare parts 6 22 Warning Label 110647 6 24 ...

Page 261: ...de with labels and handles 1 6 228361 Panel Front with labels 1 7 129633 Green power lamp assembly 8 228604 Kit Hypernet upgrade not shown 1 Power supplies Without Hypernet With Hypernet Voltage AC 078523 078570 200 208 078524 078571 220 078525 078572 240 078526 078573 380 078527 078574 400 078528 078575 440 078529 078576 480 078530 078577 600 Note The Hypernet option is currently used with the Ar...

Page 262: ...9792 Chopper assembly CHA 1 4b 129792 Chopper assembly CHB 1 4c 129792 Chopper assembly CHC 1 4d 129792 Chopper assembly CHD 1 127039 6 fan 230 CFM 115 VAC 50 60 HZ 8 5a 014080 Inductor 100 amp 4 mH L1 1 5b 014080 Inductor 100 amp 4 mH L2 1 5c 014080 Inductor 100 amp 4 mH L3 1 5d 014080 Inductor 100 amp 4 mH L4 1 6 003218 Contactor CON1 1 003233 Contactor CON1 1 200 220 and 240 volt power supplies...

Page 263: ...09004 Current sensor Hall 100 amp 4 volt CS4 1 6 014321 200 volt main transformer 80KW 3 ph 50 HZ T2 1 014322 220 volt main transformer 80KW 3 ph 50 HZ 1 014323 240 volt main transformer 80KW 3 ph 60 HZ 1 014324 380 volt main transformer 80KW 3 ph 50 HZ 1 014325 400 volt main transformer 80KW 3 ph 50 HZ 1 014326 440 volt main transformer 80KW 3 ph 50 HZ 1 014327 480 volt main transformer 80KW 3 ph...

Page 264: ...F2 F3 3 108709 Fuse 10 amp 250 volt F4 1 4 141030 PCB Control PCB3 1 5 027079 10 fan 450 550 CFM 120 VAC 50 60 HZ 3 6 229225 Control transformer 400 volt 50 60 HZ T2 1 229226 Control transformer 380 volt 50 60 HZ 1 229227 Control transformer 480 volt 60 HZ 1 229228 Control transformer 600 volt 60 HZ 1 229230 Control transformer 240 volt 60 HZ 1 229231 Control transformer 200 and 208 volt 50 60 HZ ...

Page 265: ...160 Cooler 2 3 1 Part Item Number Description Designator Qty 078531 Cooler 1 101022 Panel Right side 1 2 127014 Filler cap 1 3 228366 Panel Top with labels 1 4 110507 Panel Left side 1 5 027634 Filter housing 1 027664 Filter element 1 4 5 ...

Page 266: ...CB Console power distribution 1 008756 Fuse 5 amp 250 volt slow blow F1 1 6 027658 Fan 240 volt 240 watt 2910 cfm 1 7 229224 Temperature sensor TS1 1 8 027926 Filter assembly 1 2 NPT low profile 1 9 228171 Kit Pump with clamp 1 10 228230 Kit Motor with clamp 1 3 hp 1 11 229229 Solenoid valve 1 12 006132 Check valve bypass valve 1 4 NPT 200 psi 1 13 109207 Capacitor not visible 1 031122 Pump to mot...

Page 267: ...Auto Gas 806160 Ignition console Part Item Number Description Designator Qty 1 078172 Ignition Console 2 129831 Coil assembly T2 1 3 041817 HF HV Ignition PCB PCB IGN 1 4 129854 Transformer T1 1 5 009045 EMI filter 1 1 2 3 4 5 ...

Page 268: ...t HPR400XD Auto Gas 806160 6 9 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 269: ... 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 270: ...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 271: ...6160 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 272: ... valves 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 ...

Page 273: ... 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 spanner wrench 128879 Torch kit O rings water tube and seal 128880 Quick disconnect kit O ring and connector 2 4 6 5 1 3 ...

Page 274: ... 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 123990 30 m 100 ft 123991 45 m 150 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 Note A 20 m 65 ft torch lead is not available for HPR400XD syst...

Page 275: ...2 220194 Shield 30 A 1 220340 Water tube with o ring 1 220352 Electrode 200 A 2 220353 Swirl ring 200 A 1 220354 Nozzle 200 A 3 220435 Electrode 260 A 2 220436 Swirl ring 260 A 1 220439 Nozzle 260 A 3 220552 Electrode 50 A 2 220553 Swirl ring 50 A 1 220554 Nozzle 50 A 2 220555 Shield 50 A 1 220571 Water tube with o ring bevel 1 220629 Electrode 400 A 3 220631 Swirl ring 400 A 1 220632 Nozzle 400 A...

Page 276: ... 220342 Swirl ring 200 A stainless steel 1 220343 Nozzle 200 A stainless steel 2 220346 Nozzle 200 A aluminum 1 220405 Swirl ring 260 A stainless steel aluminum 1 220406 Nozzle 260 A stainless steel aluminum 2 220571 Water tube with o ring bevel 1 220637 Shield cap 400 A 1 220707 Shield 400 A stainless steel 2 220708 Nozzle 400 A stainless steel 3 220709 Electrode 400 A stainless steel 3 220712 No...

Page 277: ... 220755 220810 220747 200 A 220352 220350 220354 220811 220435 220442 220439 220812 220637 Shield Nozzle Swirl ring Electrode 220552 220549 220554 220555 220810 50 A 400 A 220761 220764 Nozzle retaining cap Shield cap Water tube 220340 220571 220629 220782 220632 220636 220783 260 A Consumables for mirror image cutting Straight cutting Mild steel ...

Page 278: ... 220756 220747 200 A 220307 420334 220343 220762 420335 220307 420330 220406 220763 420335 220637 Shield Nozzle Swirl ring Electrode Nozzle retaining cap Shield cap 220340 Water tube 220709 220708 220707 220885 400 A 420330 260 A 220339 80 A 220305 220337 220338 220756 220571 220307 130 A 220305 220197 220198 220756 H35 220755 N2 ...

Page 279: ...etaining cap Swirl ring Electrode Shield cap Water tube 80 A 220802 220305 220806 220742 220996 220541 220442 220542 220741 220794 220649 220305 220646 220742 220794 220700 220637 260 A 130 A 220629 220782 220632 220636 220783 400 A 220571 Bevel cutting Mild steel ...

Page 280: ... 6 21 Stainless steel 220606 420330 220607 220738 420336 Shield Nozzle Swirl ring Electrode 220606 220305 220656 420336 Shield cap Nozzle retaining cap 220738 130 A 220637 220709 220708 220707 220885 400 A 420330 260 A Water tube 220571 ...

Page 281: ...PCB2 1 108028 Fuse 3 amp 250 volt F5 F6 F7 3 108075 Fuse 6 3 amp 250 volt slow blow F1 F2 F3 3 108709 Fuse 10 amp 250 volt F4 1 228171 Kit Pump with clamp 1 228230 Kit Motor with clamp 1 141027 PCB Pump motor drive PCB7 1 200 208 220 and 240 volt power supplies 380 400 440 480 and 600 volt power supplies Cooler Part Number Description Designator Qty 041897 PCB Console power distribution 1 008756 F...

Page 282: ...er distribution PCB PCB1 1 008756 Fuse 5 amp 250 volt slow blow F1 1 041822 Valve driver PCB PCB3 1 008756 Fuse 5 amp 250 volt slow blow F1 1 228984 Solenoid valve SV3 and SV10 2 006109 Solenoid valve SV1 SV2 SV4 SV9 SV11 SV15 13 005263 Pressure sensor 1 011109 Air filter housing on the rear panel of the selection console 1 011110 Air filter element 1 ...

Page 283: ...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 284: ...o 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 wiring...

Page 285: ...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 286: ...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 287: ...7 4 HPR400XD Auto Gas 806160 Discrete output functionality ...

Page 288: ...r Torch Optional Unit Unit M Work Lead 72 Cooling Return Lead 1X2 Gas Control Cable Negative Lead 1X5 Motor Drive Cable CNC Interface Cable Lifter I O Interface Cable 1x12 12x1 Unit 7 Cooler Cooler Control Cable 1X6 12X2 Cooler Power Cable 4X1 Metering Console 3X2 3X1 3X4 N2 O2 Air Selection Console Unit 3 128930 Power Cable Atm Vent Unit 4 3X3 4X2 4X3 Gas Control Cable Ar F5 H35 H5 1X6 CNC Interf...

Page 289: ...PWM DRV A DRV B PWM DRV C PWM DRV D PWM RED BLK RED BLK BLK RED PA CONTROL POWER JD 6 3C 3A 3B SHLD SHLD SHLD CS5 39 38 39 39 38 39 ENABLE RED 120VAC Supply Vac 24VAC 240VAC YEL RED ORG YEL ORG L2 Fuse L1 PE CUSTOMER SUPPLIED FUSED DISCONNECT E Stop INPUT WIRING ALL SUPPLY VOLTAGE SEE SHEET 12 OF 14 FOR Handle L3 Fuse R10 R11 R12 YEL BLK YEL 38 1 2 1 2 RED RED BLK RED RED BLK J21 J21 J20 J20 A2 A1...

Page 290: ...LK WHT 7 6 WHT BLK REMOTE ON OFF WHT RED TB2 1 2 3 4 5 CABLE 123674 BLK SHD RED RED RED BLK 1X1 6 RED 7 RED BLK CONTROL WHT RED WHT RED AC POWER LIGHT RED BLK RED 2 1 POWER PUMP MOTOR DRIVE COOLOANT SOLONOID POWER BLK WHT PHASE LOSS COOLER POWER RED BLK RED 1 4 5 6 2 3 J2 4 J2 A ORN 240VAC RED 120VAC YEL 24VAC WHT RED HARNESS 229329 FOR ARCGLIDE THC ONLY WHT RED HARNESS 229329 FOR ARCGLIDE THC ONL...

Page 291: ...URGE RELAY 12 10 11 9 7 8 6 4 5 3 J2 5 J5 1 2 D5 HV XFMR HV XFMR D7 MARKING SURGE RELAY MARKING SURGE RELAY WHT BLU BLU WHT RED BLK RED BLK RED BLK RED RED RED PILOT ARC RELAY HF TRANSFORMER 4 3 2 1 CABLE 123670 A B C 4 3 2 D 4 3 2 1 A B C 1 D SHEET 5 D1 Y SHEET 2 D1 M SHEET 2 D1 N SHEET 2 C4 AD SHEET 18 D3 AC F ELEC SCH HPR400XD POWER SUPPLY W AUTO F 013374 SHEET 4 OF 24 ...

Page 292: ...1 3 22 4 23 5 24 6 25 7 26 8 27 9 28 10 29 1130 12 35 16 34 15 33 14 32 13 31 18 36 17 19 37 123887 BLK RED SPARE C SPARE E SHLD SHLD BLK RED SHLD BLK RED SHLD BLK RED J3 307 MARKING SURGE RELAY PA C PA E PHASE LOSS J3 308 3 6 5 4 2 1 J308 BLK RED WHT BLU PHASE LOSS PILOT ARC ENABLE BLU WHT MOTION 2 C MOTION 2 E MOTION 3 C MOTION 3 E MOTION 4 C MOTION 4 E ERROR E ERROR C NOT READY C NOT READY E 1 ...

Page 293: ...D GRN RED GRN BLK WHT WORK LEAD SENSOR J3 306 6 8 7 3 5 4 2 1 J306 PUMP ENABLE A F 5V FAULTOUT RED CLR CLR BLK BLK RED CHOPPER SENSOR B CHOPPER SENSOR A 8 J3 200 GRN RED BLK WHT RED GRN WHT BLK 1 J200 2 3 4 5 7 6 15V 9 10 1 2 1 2 15V COM CHOPPER SENSOR D CHOPPER SENSOR C COM 15V 15V 5 J103 6 1 2 7 3 8 4 9 CAN A CAN B J101 1 2 t 0 4 5 6 SHIELD CABLE 123886 BLK RED BLK RED PUMP ENABLE ALARM 10 9 A B...

Page 294: ... RED BLK RED 1 2 J16 1 2 FAN 3 1 1 J17 2 2 FAN 4 CHP CHP FAN 7 FAN 5 J19 1 2 1 2 1 1 J18 2 2 FAN 8 CHP CHP FAN 6 CHP CHP 7 8 11 9 10 12 FANS PUMPEN C F 5V 2 3 J11 1 PUMPAC1 PUMPAC2 PUMP MOTOR PWR COOLER FAN PWR RED BLK RED 3 A 3 3V THMS 2 5mH 6A 2 5mH 6A 2 J6 1 RT2 PUMP MOTOR DRIVE HEATSINK A B C 4 3 2 D 4 3 2 1 A B C 1 D D1 D10 15V 5V D36 D35 D16 D30 3 3V OUTPUT OVER CURRENT D31 HEAT SINK OVERTEM...

Page 295: ...ACILITY PE L1 WHT BLU F1 F2 L3 L2 L1 EMI FILTER C4 B4 A4 T2 0 VAC C4 B4 A4 480 VAC 3 Phase 50 Hertz T2 L1 L2 L3 V U PE W A4 CON1 B4 C4 V W GRY WHT F1 F2 FROM FACILITY INPUT POWER L1 L2 L3 PE B4 C4 0 VAC A4 T2 L1 L2 L3 V U PE W A4 CON1 B4 C4 V W BLK WHT F1 F2 B4 C4 0 VAC A4 FROM FACILITY INPUT POWER L1 L2 L3 PE 400 VAC 3 Phase 50 Hertz 400VAC 4 TB1 1 3 2 TB1 1 2 4 3 T1 T1 4 TB1 1 3 2 T1 4 TB1 1 3 2...

Page 296: ...F2 FROM FACILITY INPUT POWER L1 L2 L3 PE B4 C4 0 VAC A4 240 VAC 3 Phase 60 Hertz T2 L1 L2 L3 V U PE W A4 CON1 B4 C4 V W BLK WHT F1 F2 FROM FACILITY INPUT POWER L1 L2 L3 PE B4 C4 0 VAC A4 V U PE W 600VAC 440 VAC 3 Phase 50 Hertz T2 L1 L2 L3 V U PE W A4 CON1 B4 C4 V W BLK WHT F1 F2 FROM FACILITY INPUT POWER L1 L2 L3 PE B4 C4 0 VAC A4 200VAC 240VAC T1 4 TB1 1 3 2 T1 4 TB1 1 3 2 T1 4 TB1 1 3 2 4 TB1 1...

Page 297: ... 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 2B J3 ...

Page 298: ... 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 MOTION IN...

Page 299: ...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 13 D4 AA F1 SHEET 15 A4 Z SHEET 3 A1 EE SHEET 13 D3 Y LED ELEC SCH HPR400XD POWER SUPPL...

Page 300: ...D BLK BLK RED 7 6 8 8 6 7 RED YEL BLK RED YEL BLK J2 2 POT 2 POT 1 HPR AUTO GAS SELECTION CONSOLE CONTROL 041828 PCB2 J14 1 6 2 7 3 9 8 4 5 1 4 5 9 422A 7 8 3 422Y 2 6 J4 RS 422 CANB COM 422B 422Z SV16 2 5V J1 1 3 4 5 6 LINE FREQ COM 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 PT1 TP16 PT1 TP13 PT1 COM J2 9 3X3 BLK RED BLK RED SHLD TO M...

Page 301: ...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 302: ...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 SHEET 16 D4 CC F1 SHEET 16 D1 DD SHEET 12 A3 Z LED ELEC SCH HPR40...

Page 303: ...5V GND 15V COM 15V J2 9 4X2 SHLD RED BLK BLK RED METERING VALVE POT FEEDBACK INPUTS POWER IN HPR AUTO GAS METERING CONSOLE CONTROL 041828 PCB2 2 7 3 9 8 4 5 1 4 5 9 422A 7 8 3 422Y 2 6 J4 RS 422 COM 422B 422Z SV16 2 5V J2 1 J1 1 3 4 5 6 LINE FREQ COM 4 7 6 5 8 9 10 11 13 12 16 14 15 BRN BLU BLK BRN BLU BLK BRN BLU BLK TP5 PT1 TP16 PT1 TP13 PT1 COM BLU WHT BLU WHT 4X3 RAMPDOWN VALVE CONTROL OUTPUT ...

Page 304: ...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 HPR400XD POWER SUPPLY W AUTO F 013374 SHEET 17 OF 24 ...

Page 305: ...3 J6 129854 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 RED BLK RED GRN CABLE 123670 CABLE 123666 009045 FLTR HPR HFHV IGNITION 041817 A B C 4 3 2 D 4 3 2 1 A B C 1 D F SHEET 2 D1 AJ SHEET 4 B2 AC ELEC SCH HPR400XD POWER SUPPLY W AUTO F 013374 SHEET 18 OF 24 ...

Page 306: ... 3 4 5 6 7 8 J4 1 2 3 4 5 6 7 8 1 2 J6 1 2 1 2 J3 3 24V 15V 5V 15V PWR GND POWER IN AC LINE DETECT F1 5A AC1 AC2 D4 5V RED BLK WHT TS1 TMS TRST TDI 5V TD0 TCK EMU0 EMU1 JTAG 24V CAN GND CANL CANH S2 1 FLOW SENSOR COOLANT TEMP FA 3 3V 24V CHILLER FLOW 14 13 LINE VOLT IN PRESS SENSOR 041897 POWER DIST BOARD D2 3 3V D1 5V D7 CAN TX D8 CAN RX J1 J4 J3 12X2 J1 1 J1 4 J18 3 J2 4 J2 6 J2 3 RED BLK RED RE...

Page 307: ...3 V14 P1 P2 P3 P4 MV1 MV2 B1 B2 B4 P5 P6 P7 P8 V16 B3 Vent Metering Torch Vent HPR400 Auto Console V15 5 Micron Filter Gas Schematic Console Shield Plasma ELEC SCH HPR400XD POWER SUPPLY W AUTO F 013374 SHEET 20 OF 24 7 24 Plasma gas Plasma vent Coolant in Pilot arc Shield gas Coolant return Ohmic contact pin Torch connections ...

Page 308: ...ed Switch 1 is in the On position Switches 2 8 are in the Off position S301 1 2 3 4 5 6 7 8 Dipswitch setting example 2 1 3 4 5 6 7 8 ON ON 120 RX Termination Termination 120 TX Notes 1 For single system installations set Serial ID S301 and Machine Motion J300 as shown in Unit 1 jumpers J104 and J105 must be closed 2 On multi system installations refer to the illustration Jumpers J104 and J105 are...

Page 309: ...osition 3 Refer to page 3 of the wiring diagram Depress the Gas Console Power switch to the closed position on position 2 For a multi system installation set up as described above set jumpers as shown on the multi system interface page 3 The CNC will need a dedicated I O for each system using the Remote On Off feature contact should be rated for min 24Vac 0 5 Amp BMD J2 BTR J7 RS 232 J9 RS 422 BHS...

Page 310: ...tallation 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 If a ...

Page 311: ...ArcGlide EdgePro Multi System Interface 5 6 7 8 ON J303B J5 141131 ETHERNET INTERFACE BOARD 0 7 1 5 4 6 2 3 SW1 UNIT ADDRESS 141030 CONTROL BOARD 1 2 3 4 S301 1 2 J300 3 4 3 2 1 4 J303A J1 Serial ID Dipswitch Machine Motion Jumper Block J104 2 1 J105 1 2 5 6 7 8 ON J303B J5 0 7 1 5 4 6 2 3 SW1 UNIT ADDRESS 141030 CONTROL BOARD 1 2 3 4 S301 1 2 J300 3 4 3 2 1 4 J303A J1 Serial ID Dipswitch Machine ...

Page 312: ... 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 313: ...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 314: ...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 315: ...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 316: ...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 317: ...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 318: ... 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 319: ...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 320: ... 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 321: ...ning 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 Indicates t...

Page 322: ...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 low dr...

Page 323: ... 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 324: ...LEEP 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 is u...

Page 325: ...N 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 0 003...

Page 326: ...EST_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 Auto gas s...

Page 327: ...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 pump ov...

Page 328: ...10000000B7 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 and op...

Page 329: ...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 accepted ...

Page 330: ... 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 Gas 2 Mi...

Page 331: ...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 shield g...

Page 332: ...r A setpoint 5 130 amps Chopper B setpoint 5 130 amps 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 p...

Page 333: ...as 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 SV3 O2...

Page 334: ...pswitch 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 Test ...

Page 335: ...ssure 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 amp O2 Air consumables and setting the 30 amp 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 mode 0 ...

Page 336: ... 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 system Aut...

Page 337: ...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 amps Chopper D current amps 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 code...

Page 338: ...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 Command ta...

Page 339: ...ommand 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 0 0x3...

Page 340: ...l 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 stat...

Page 341: ...NT 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 amps has been detected by current sensor 3 076 Primary 276 Secondary CURRENT...

Page 342: ...ary 338 Secondary CHOPPER 2 OVERCURRENT Chopper 2 current feedback has exceeded 160 amps 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 auto gas ...

Page 343: ...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 CAN TI...

Page 344: ...FER 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 345: ...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 version vers...

Page 346: ...or 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 of cab...

Page 347: ...Appendix B CNC Interface Protocol b 28 HPR400XD Auto Gas 806160 ...

Page 348: ... 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 349: ... table below Components for robotic applications Torch leads The torch leads listed below have been designed to withstand the added stresses found in robotic or bevel applications They are available with 2 m 6 ft or 2 5 m 8 ft gas leads Note Consumable life will be reduced if the 2 5 m 8 ft gas leads are used 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...

Page 350: ...overwrap 024866 The 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 te...

Page 351: ...Appendix C robotic applications c 4 HPR400XD Auto Gas 806160 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 352: ...ints with some details about moving the power supply with a fork lift Added HPR400XD power supplies with serial number HPR400 000560 or later can be upgraded to a HPR800XD primary or secondary power supply below the bullet points 3 17 and 3 18 Added mounting hole call out 3 23 29 37 53 and 55 Added caution box about not using PTFE tape 3 26 Corrected the 2 cable signal list tables to say selection...

Page 353: ... a problem with excessive slag on the shield or problems with the torch misfiring when using the standard bevel consumables 4 45 Corrected the N2 cutflow flow rate 4 38 4 39 4 46 through 4 60 4 68 through 4 75 Added 8 mm and 5 16 in thicknesses to the cut charts 5 4 Changed heading from Control and signal cables to Power and signal cables 5 5 Corrected the last line under number 2 to read contacto...

Page 354: ... amp 130 amp and 260 amp mild steel bevel cutting Schematics All sheets updated from revision C to revision E Appendix A Updated to the latest information and formatting for the Hypertherm torch coolant data MSDS Appendix B Added the secondary error code ID numbers after the primary error code ID number for all applicable error codes b 6 Added information to the description of the HELLO command b ...

Page 355: ...4 HPR400XD Auto Gas 806160 ...

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