Hypertherm HyPerformance HPR400XD Instruction Manual

HyPerformance®Plasma

HPR400XD

Manual gas

Instruction manual 806170 – Revision 0

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HyPerformance Plasma

HPR400XD Manual Gas

Instruction Manual

(P/N

806170)

Revision 0 – December, 2008

Hypertherm, HyPerformance, HyDefinition, LongLife and CommandTHC are trademarks of Hypertherm, Inc.

and may be registered in the United States and/or other countries.

Hypertherm, Inc.

Hanover, NH USA

www.hypertherm.com

10/14/08

Hypertherm, Inc.

Etna Road, P.O. Box 5010 Hanover, NH 03755 USA 603-643-3441 Tel (Main Office) 603-643-5352 Fax (All Departments) info@hypertherm.com (Main Office Email)

800-643-9878 Tel (Technical Service)

technical.service@hypertherm.com (Technical Service Email) 800-737-2978 Tel (Customer Service) customer.service@hypertherm.com (Customer Service Email)

Hypertherm Automation

5 Technology Drive, Suite 300 West Lebanon, NH 03784 USA 603-298-7970 Tel 603-298-7977 Fax

Hypertherm Plasmatechnik GmbH

Technologiepark Hanau Rodenbacher Chaussee 6 D-63457 Hanau-Wolfgang, Deutschland 49 6181 58 2100 Tel 49 6181 58 2134 Fax

49 6181 58 2123 (Technical Service)

Hypertherm (S) Pte Ltd.

82 Genting Lane Media Centre Annexe Block #A01-01 Singapore 349567, Republic of Singapore 65 6841 2489 Tel 65 6841 2490 Fax

65 6841 2489 (Technical Service)

Hypertherm (Shanghai) Trading Co., Ltd.

Unit A, 5th Floor, Careri Building 432 West Huai Hai Road Shanghai, 200052 PR China 86-21 5258 3330/1 Tel 86-21 5258 3332 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)

Hypertherm Japan Ltd.

801 Samty Will Building 2-40 Miyahara 1-Chome, Yodogawa-ku, Osaka 532-0003, Japan 81 6 6170 2020 Tel 81 6 6170 2015 Fax

HYPERTHERM BRASIL LTDA.

Avenida Doutor Renato de

Andrade Maia 350 Parque Renato Maia CEP 07114-000 Guarulhos, SP Brasil 55 11 2409 2636 Tel 55 11 2408 0462 Fax

ELECTROMAGNETIC COMPATIBILITY (EMC)

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EMC Introduction

Hypertherm’s CE-marked equipment is built in compliance with standard EN60974-10. The equipment should be installed and used in ac cor dance with the information below to achieve elec tro mag net ic compatibility.

The limits required by EN60974-10 may not be adequate to com plete ly eliminate in ter fer ence when the affected equip ment is in close proximity or has a high degree of sensitivity. In such cases it may be nec es sary to use other mea s ures to fur ther reduce interference.

This cutting equipment is designed for use only in an indus tri al environment.

Installation and use

The user is responsible for installing and using the plasma equipment according to the manufacturer’s instructions. If elec tro mag net ic disturbances are detected then it shall be the re spon si bil i ty of the user to re solve the situation with the technical as sis tance of the man u fac tur er. In some cases this remedial action may be as sim ple as earthing the cutting circuit, see Earthing of Workpiece. In other cas es it could in volve con struct ing an elec tro mag net ic screen enclosing the pow er source and the work complete with associated input filters. In all cases electromag net ic dis tur banc es must be reduced to the point where they are no longer trou ble some.

Assessment of area

Before installing the equipment the user shall make an assessment of po ten tial elec tro mag net ic problems in the sur round ing area. The following shall be taken into account:

a. Other supply cables, control cables, signalling and

telephone ca bles; above, below and adjacent to the cutting equip ment.

b. Radio and television transmitters and receivers.

c. Computer and other control equip ment.

d. Safety critical equipment, for example guarding of

industrial equipment.

e. Health of the people around, for example the use of

pacemakers and hear ing aids.

f. Equipment used for calibration or mea sure ment.

g. Immunity of other equipment in the en viron ment. User

shall ensure that other equip ment being used in the environment is com pat i ble. This may require ad di tion al protection measures.

h. Time of day that cutting or other ac tiv i ties are to be

carried out.

The size of the sur round ing area to be considered will depend on the structure of the building and other activities that are tak ing place. The surrounding area may ex tend beyond the bound aries of the pre mises.

Methods of reducing emissions

Mains supply

Cutting equipment must be con nect ed to the mains supply according to the man u fac tur er’s recommendations. If interfer ence occurs, it may be necessary to take additional precautions such as filtering of the mains supply. Consideration should be given to shield ing the supply cable of per ma nent ly installed cutting equip ment, in metallic conduit or equiva lent. Shield ing should be electrical ly continuous through out its length. The shielding should be connected to the cutting mains supply so that good electrical contact is maintained between the conduit and the cutting pow er source enclosure.

Maintenance of cutting equipment

The cutting equipment must be rou tine ly main tained according to the man u fac tur er’s rec om men da tions. All access and service doors and covers should be closed and properly fastened when the cutting equipment is in op er a tion. The cutting equipment should not be modified in any way except for those chang es and adjust ments covered in the manufacturer’s instructions. In par tic u lar, the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer’s rec om men da tions.

Cutting cables

The cutting cables should be kept as short as possible and should be po si tioned close together, running at or close to the floor level.

Equipotential bonding

Bonding of all metallic components in the cutting installation and adjacent to it should be considered. However, metallic com po nents bonded to the workpiece will increase the risk that the op er a tor could receive a shock by touch ing these metallic compo nents and the electrode (nozzle for laser heads) at the same time. The op er a tor should be in su lat ed from all such bonded metallic components.

ELECTROMAGNETIC COMPATIBILITY (EMC)

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Earthing of workpiece

Where the workpiece is not bonded to earth for electrical safety, nor connected to earth because of its size and position, for ex am ple, ship’s hull or building steel work, a con nec tion bonding the work piece to earth may reduce emis sions in some, but not all instances. Care should be taken to prevent the earthing of the work piece in creas ing the risk of injury to users, or damage to other elec tri cal equip ment. Where necessary, the con nec tion of the workpiece to earth should be made by a direct connection to the workpiece, but in some countries where direct connection is not permitted, the bonding should be achieved by suitable capacitances se lect ed according to national regulations.

Note: the cutting circuit may or may not be earthed for safety reasons. Changing the earthing arrangements should only be au tho rized by a person who is competent to assess whether the chang es will in crease the risk of injury, for example, by al low ing parallel cutting cur rent return paths which may damage the earth cir cuits of other equipment. Further guid ance is given in IEC/TS 62081 Arc Welding Equip ment Installation and Use.

Screening and shielding

Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of in ter fer ence. Screening of the entire plasma cutting installation may be con sid ered for special applications.

WARRANTY

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Attention

Genuine Hypertherm parts are the factory-recommended replacement parts for your Hypertherm system. Any damage caused by the use of other than genuine Hypertherm parts may not be covered by the Hypertherm warranty.

You are responsible for the safe use of the Product. Hypertherm does not and cannot make any guarantee or warranty regarding the safe use of the Product in your environment.

General

Hypertherm, Inc. warrants that its Products shall be free from defects in materials and workmanship, if Hypertherm is notified of a defect (i) with respect to the power supply within a period of two (2) years from the date of its delivery to you, with the exception of Powermax brand power supplies, which shall be within a period of three (3) years from the date of delivery to you, and (ii) with respect to the torch and leads within a period of one (1) year from its date of delivery to you, and with respect to torch lifter assemblies within a period of one (1) year from its date of delivery to you, and with respect to laser heads within a period of one (1) year from its date of delivery to you. This warranty shall not apply to any Powermax brand power supplies that have been used with phase converters. In addition, Hypertherm does not warranty systems that have been damaged as a result of poor power quality, whether from phase converters or incoming line power. This warranty shall not apply to any Product which has been incorrectly installed, modified, or otherwise damaged. Hypertherm, at its sole option, shall repair, replace, or adjust, free of charge, any defective Products covered by this warranty which shall be returned with Hypertherm’s prior authorization (which shall not be unreasonably withheld), properly 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. Hypertherm shall not be liable for any repairs, replacement, or adjustments of Products covered by this war ranty, except those made pursuant to this paragraph or with Hypertherm’s prior written consent. The warranty

above is exclusive and is in lieu of all other warranties, express, implied, statutory, or otherwise with respect to the Products or as to the results which may be obtained therefrom, and all implied war ranties or conditions of quality or of merchantability or fitness for a particular purpose or against infringement. The foregoing shall constitute the sole and exclusive remedy for any breach by Hypertherm of its warranty.

Distributors/OEMs may offer different or additional warranties, but Distributors/OEMs are not authorized to give any additional warranty pro tection to you or make any repre sentation to you purporting to be binding upon Hypertherm.

Certification test marks

Certified products are identified by one or more certification test marks from accredited testing laboratories. The certification test marks are located on or near the data plate. Each certification test mark means that the product and its safety-critical components conform to the relevant national safety standards as reviewed by that testing laboratory. Hypertherm places a certification test mark on its products only after that product is manufactured with safety-critical components that have been authorized by the accredited testing laboratory.

Once the product has left the Hypertherm factory, the certification test marks are invalidated if any of the following occurs:

• The product is significantly modified in a manner that creates a hazard or non-conformance.

• Safety-critical components are replaced with unauthorized spare parts.

• Any unauthorized assembly or accessory that uses or generates a hazardous voltage is added.

• There is any tampering with a safety circuit or other feature that is designed into the product as part of the certification.

CE marking constitutes a manufacturer’s declaration of conformity to applicable European directives and standards. Only those versions of Hypertherm products with a CE Marking located on or near the data plate have been tested for compliance with the European Low Voltage Directive and the European EMC Directive. EMC filters needed to comply with the European EMC Directive are incorporated within versions of the power supply with a CE Marking.

Differences in national standards

Differences in standards include, but are not limited to:

• Voltages

• Plug and cord ratings

• Language requirements

• Electromagnetic compatibility requirements

WARRANTY

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These differences in national standards may make it impossible or impractical for all certification test marks to be placed on the same version of a product. For example, the CSA versions of Hypertherm’s products do not comply with European EMC requirements and they do not have a CE marking on the data plate.

Countries that require CE marking or have compulsory EMC regulations must use CE versions of Hypertherm products with the CE marking on the data plate. These include:

• Australia

• New Zealand

• Countries in the European Union

• Russia

It is important that the product and its certification test mark be suitable for the end-use installation site. When Hypertherm products are shipped to one country for export to another country, the product must be configured and certified properly for the end-use site.

Higher-level systems

When a system integrator adds additional equipment; such as cutting tables, motor drives, motion controllers or robots; to a Hypertherm plasma cutting system, the combined system may be considered a higher-level system. A higher-level system with hazardous moving parts may constitute industrial machinery or robotic equipment, in which case the OEM or end-use customer may be subject to additional regulations and standards than those relevant to the plasma cutting system as manufactured by Hypertherm.

It is the responsibility of the end-use customer and the OEM to perform a risk assessment for the higher-level system and to provide protection against hazardous moving parts. Unless the higher-level system is certified when the OEM incorporates Hypertherm products into it, the installation also may be subject to approval by local authorities. Seek advice from legal counsel and local regulatory experts if uncertain about compliance.

External interconnecting cables between component parts of the higher level system must be suitable for contaminants and movement as required by the final end-use installation site. When the external interconnecting cables are subject to oil, dust, or water contaminants, hard usage ratings may be required.

When external interconnecting cables are subject to continuous movement, constant flexing ratings may be required. It is the responsibility of the end-use customer or the OEM to ensure the cables are suitable for the application. Since there are differences in the ratings and costs that can be required by local regulations for higherlevel systems, it is necessary to verify that any external interconnecting cables are suitable for the end-use installation site.

Patent indemnity

Except only in cases of products not manufactured by Hypertherm or manufactured by a person other than Hypertherm not in strict conformity with Hypertherm’s specifications and in cases of designs, processes, formulae, or combinations not developed or purported to be developed by Hypertherm, Hypertherm will defend or settle, at its own expense, any suit or proceeding brought against you alleging that the use of the Hypertherm product, alone and not in combination with any other product not supplied by Hypertherm, infringes any patent of any third party. You shall notify Hypertherm promptly upon learning of any action or threatened action in connection with any such alleged infringement, and Hypertherm’s obligation to indemnify shall be conditioned upon Hypertherm’s sole control of, and the indemnified party’s cooperation and assistance in, the defense of the claim.

Limitation of liability

In no event shall Hypertherm be liable to any person or entity for any incidental, consequential, indirect, or punitive damages (including but not limited to lost profits) regardless of whether such liability is based on breach of contract, tort, strict liability, breach of warranties, failure of essential purpose or otherwise and even if advised of the possibility of such damages.

Liability cap

In no event shall Hypertherm’s liability, whether such liability is based on breach of contract, tort, strict liability, breach of warranties, failure of essential purpose or otherwise, for any claim action suit or proceeding arising out of or relating to the use of the Products exceed in the aggregate the amount paid for the Products that gave rise to such claim.

WARRANTY

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Insurance

At all times you will have and maintain insurance in such quantities and types, and with coverage 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.

National and Local codes

National and Local codes governing plumbing and electrical installation shall take precedent over any instructions contained in this manual. In no event shall Hypertherm be liable for injury to persons or property damage by reason of any code violation or poor work practices.

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 conditions of this Warranty.

Proper disposal of Hypertherm products

Hypertherm plasma cutting systems, like all electronic products, may contain materials or components, such as printed circuit boards, that cannot be discarded with ordinary waste. It is your responsibility to dispose of any Hypertherm product or component part in an environmentally acceptable manner according to national and local codes.

• In the United States, check all federal, state, and local laws.

• In the European Union, check the EU directives, national, and local laws. For more information, visit www.hypertherm.com/weee.

• In other countries, check national and local laws.

TABLE OF CONTENTS

HPR400XD Manual Gas Instruction Manual vii

Electromagnetic Compatibility (EMC) ...................................................................................................................................i

Warranty........................................................................................................................................................................................ii

Section 1 SAFETY ..............................................................................................................................................................1-1

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

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

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

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

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

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

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

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

Grounding safety........................................................................................................................................................................................1-6

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

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

Noise can damage hearing.......................................................................................................................................................................1-7

Pacemaker and hearing aid operation ...................................................................................................................................................1-7

A plasma arc can damage frozen pipes ................................................................................................................................................1-7

Additional safety information....................................................................................................................................................................1-8

Symbols and markings..............................................................................................................................................................................1-8

Warning labels............................................................................................................................................................................................1-9

Dry dust collection information.............................................................................................................................................................1-11

Section 1a SÉCURITÉ ......................................................................................................................................................1a-1

dentifier les consignes de sécurité ......................................................................................................................................................1a-2

Suivre les instructions de sécurité .......................................................................................................................................................1a-2

Le coupage peut provoquer un incendie ou une explosion ...........................................................................................................1a-2

Les chocs électriques peuvent être fatals..........................................................................................................................................1a-3

L’électricité statique peut endommager les cartes de circuits imprimés ....................................................................................1a-3

Les vapeurs toxiques peuvent provoquer des blessures ou la mort ............................................................................................1a-4

L’arc plasma peut provoquer des blessures ou des brûlures ........................................................................................................1a-5

Les rayons de l’arc peuvent brûler les yeux et la peau....................................................................................................................1a-5

Mise à la masse et à la terre..................................................................................................................................................................1a-6

Sécurité des bouteilles de gaz comprimé ..........................................................................................................................................1a-6

Les bouteilles de gaz comprimé peuvent exploser en cas de dommages .................................................................................1a-6

Le bruit peut provoquer des problèmes auditifs ...............................................................................................................................1a-7

Pacemakers et prothèses auditives .....................................................................................................................................................1a-7

Un arc plasma peut endommager les tuyaux gelés..........................................................................................................................1a-7

Symboles et marquage...........................................................................................................................................................................1a-8

Étiquettes de sécurité .............................................................................................................................................................................1a-9

Information sur le dépoussiérage.......................................................................................................................................................1a-11

Section 1b SEGURIDAD .................................................................................................................................................1b-1

Reconocimiento de información de seguridad .................................................................................................................................1b-2

Siga las instrucciones de seguridad ...................................................................................................................................................1b-2

Los cortes pueden provocar incendios o explosiones....................................................................................................................1b-2

El choque eléctrico puede provocar la muerte.................................................................................................................................1b-3

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viii HPR400XD Manual Gas Instruction Manual

Electricidad estática puede dañar tablillas de circuito....................................................................................................................1b-3

Humos tóxicos pueden causar lesiones o muerte ...........................................................................................................................1b-4

El arco de plasma puede causar lesiones y quemaduras ..............................................................................................................1b-5

Los rayos del arco pueden producir quemaduras en los ojos y en la piel .................................................................................1b-5

Seguridad de toma a tierra....................................................................................................................................................................1b-6

Seguridad de los equipos de gas comprimido.................................................................................................................................1b-6

Los cilindros de gas pueden explotar si están dañados.................................................................................................................1b-6

El ruido puede deteriorar la audición...................................................................................................................................................1b-7

Operación de marcapasos y de audífonos ........................................................................................................................................1b-7

Un arco plasma puede dañar tubos congelados..............................................................................................................................1b-7

Símbolos y marcas ..................................................................................................................................................................................1b-8

Etiquetas de advertencia........................................................................................................................................................................1b-9

Información sobre la colección de polvo seco...............................................................................................................................1b-11

Section 2 SPECIFICATIONS .............................................................................................................................................2-1

System description ....................................................................................................................................................................................2-3

General...............................................................................................................................................................................................2-3

Power supply ...................................................................................................................................................................................2-3

Cooler.................................................................................................................................................................................................2-3

Ignition console ................................................................................................................................................................................2-3

Gas console......................................................................................................................................................................................2-3

Off-valve .............................................................................................................................................................................................2-3

Torch ...................................................................................................................................................................................................2-3

Specifications..............................................................................................................................................................................................2-4

System gas requirements ..............................................................................................................................................................2-4

Power supply ....................................................................................................................................................................................2-5

Cooler – 078531.............................................................................................................................................................................2-6

Ignition console – 078172 .............................................................................................................................................................2-7

Gas console – 078532..................................................................................................................................................................2-9

Off-valve – 078534.......................................................................................................................................................................2-10

Torch – 228354.............................................................................................................................................................................2-11

Section 3 INSTALLATION...................................................................................................................................................3-1

Upon receipt................................................................................................................................................................................................3-3

Claims ...........................................................................................................................................................................................................3-3

Installation requirements...........................................................................................................................................................................3-3

Noise levels..................................................................................................................................................................................................3-3

Placement of system components .........................................................................................................................................................3-3

Torque specifications ......................................................................................................................................................................3-3

Installation requirements...........................................................................................................................................................................3-4

System components........................................................................................................................................................................3-5

Cables and hoses............................................................................................................................................................................3-5

Supply gas hoses ............................................................................................................................................................................3-5

Customer supplied power cable..................................................................................................................................................3-5

Recommended grounding and shielding practices............................................................................................................................3-6

Introduction..................................................................................................................................................................................................3-6

Types of grounding ..........................................................................................................................................................................3-6

TABLE OF CONTENTS

HPR400XD Manual Gas Instruction Manual ix

Steps to take.....................................................................................................................................................................................3-7

Grounding diagram.......................................................................................................................................................................3-10

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 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 gas console cables...................................................................................................................................................3-26

Control cable..................................................................................................................................................................................3-26

Power cable....................................................................................................................................................................................3-26

Gas console to off-valve connections.................................................................................................................................................3-28

Cable and gas hose assembly ...................................................................................................................................................3-28

Gas console to off-valve cable...................................................................................................................................................3-28

Off-valve cable ...............................................................................................................................................................................3-28

Power supply to CNC interface cable................................................................................................................................................3-30

Optional multi-system CNC interface cable ...........................................................................................................................3-30

Notes to CNC interface cable run list ......................................................................................................................................3-31

Examples of output circuits.........................................................................................................................................................3-32

Examples of input circuits............................................................................................................................................................3-33

Remote on/off switch..............................................................................................................................................................................3-34

Torch lead assembly................................................................................................................................................................................3-35

Work lead ..................................................................................................................................................................................................3-36

Torch connections....................................................................................................................................................................................3-37

Connect the torch to the torch lead assembly .......................................................................................................................3-37

Connect the torch to the quick-disconnect.............................................................................................................................3-41

Torch mounting and alignment..............................................................................................................................................................3-42

Mounting the torch........................................................................................................................................................................3-42

Torch alignment..............................................................................................................................................................................3-42

Torch lifter requirement...........................................................................................................................................................................3-42

Power requirements ................................................................................................................................................................................3-43

General ............................................................................................................................................................................................3-43

Line disconnect switch ................................................................................................................................................................3-43

Power cable....................................................................................................................................................................................3-43

Connect the power..................................................................................................................................................................................3-44

Torch coolant requirements ...................................................................................................................................................................3-45

Standard installation.....................................................................................................................................................................3-45

Coolant for cold operating temperatures.................................................................................................................................3-46

Coolant for hot operating temperatures...................................................................................................................................3-47

TABLE OF CONTENTS

x HPR400XD Manual Gas Instruction Manual

Water purity requirements......................................................................................................................................................................3-47

Fill the power supply with coolant........................................................................................................................................................3-48

Gas requirements ....................................................................................................................................................................................3-49

Setting the supply regulators .....................................................................................................................................................3-49

Gas regulators..........................................................................................................................................................................................3-50

Supply gas plumbing ..............................................................................................................................................................................3-51

Connect the supply gases ..........................................................................................................................................................3-52

Supply gas hoses ....................................................................................................................................................................................3-53

Section 4 OPERATION........................................................................................................................................................4-1

Daily start-up................................................................................................................................................................................................4-2

Check torch.......................................................................................................................................................................................4-2

Controls and indicators.............................................................................................................................................................................4-3

Main power switch...........................................................................................................................................................................4-3

Power indicators ..............................................................................................................................................................................4-3

Manual gas console operation......................................................................................................................................................4-4

Consumable selection...............................................................................................................................................................................4-5

Standard cutting ..............................................................................................................................................................................4-5

Bevel cuting.......................................................................................................................................................................................4-5

Marking...............................................................................................................................................................................................4-5

Consumables for mirror-image cutting........................................................................................................................................4-5

SilverPlus electrodes.......................................................................................................................................................................4-5

Mild steel............................................................................................................................................................................................4-6

Stainless steel...................................................................................................................................................................................4-7

Aluminum ...........................................................................................................................................................................................4-8

Mild steel bevel cutting...................................................................................................................................................................4-9

Stainless steel bevel cutting..........................................................................................................................................................4-9

Install and inspect consumables ..........................................................................................................................................................4-10

Torch maintenance...................................................................................................................................................................................4-12

Replace torch water tube.......................................................................................................................................................................4-13

Common cutting faults ...........................................................................................................................................................................4-14

How to optimize cut quality...................................................................................................................................................................4-15

Tips for table and torch................................................................................................................................................................4-15

Plasma set-up tips.........................................................................................................................................................................4-15

Maximize the life of consumable parts......................................................................................................................................4-15

Additional Factors of cut quality ................................................................................................................................................4-16

Additional improvements..............................................................................................................................................................4-17

Cut charts..................................................................................................................................................................................................4-18

Bevel cut charts.............................................................................................................................................................................4-18

Bevel cutting definitions.........................................................................................................................................................................4-19

Estimated kerf-width compensation ....................................................................................................................................................4-20

Section 5 MAINTENANCE .................................................................................................................................................5-1

Routine maintenance.................................................................................................................................................................................5-3

TABLE OF CONTENTS

HPR400XD Manual Gas Instruction Manual xi

Control and signal cables ..............................................................................................................................................................5-4

Sequence of operation..............................................................................................................................................................................5-5

Gas system purge cycle ...........................................................................................................................................................................5-6

Gas system valve usage ...........................................................................................................................................................................5-6

Marking process...............................................................................................................................................................................5-8

Error codes ..................................................................................................................................................................................................5-9

Error code troubleshooting – 1 of 16....................................................................................................................................5-10

Error code troubleshooting – 2 of 16....................................................................................................................................5-11

Error code troubleshooting – 3 of 16....................................................................................................................................5-12

Error code troubleshooting – 4 of 16....................................................................................................................................5-13

Error code troubleshooting – 5 of 16....................................................................................................................................5-14

Error code troubleshooting – 6 of 16....................................................................................................................................5-15

Error code troubleshooting – 7 of 16....................................................................................................................................5-16

Error code troubleshooting – 8 of 16 ....................................................................................................................................5-17

Error code troubleshooting – 9 of 16....................................................................................................................................5-18

Error code troubleshooting – 10 of 16 .................................................................................................................................5-19

Error code troubleshooting – 11 of 16 .................................................................................................................................5-20

Error code troubleshooting – 12 of 16 .................................................................................................................................5-21

Error code troubleshooting – 13 of 16 .................................................................................................................................5-22

Error code troubleshooting – 14 of 16 .................................................................................................................................5-23

Error code troubleshooting – 15 of 16 .................................................................................................................................5-24

Error code troubleshooting – 16 of 16 .................................................................................................................................5-25

Power supply states................................................................................................................................................................................5-26

Plasma system operation with pump time-out ..................................................................................................................................5-27

CNC operation with pump time-out ....................................................................................................................................................5-28

Initial checks..............................................................................................................................................................................................5-29

Power measurement ...............................................................................................................................................................................5-30

Air filter element replacement ...............................................................................................................................................................5-31

Coolant system servicing.......................................................................................................................................................................5-32

Draining the coolant system. ......................................................................................................................................................5-32

Coolant system filter................................................................................................................................................................................5-33

Filter replacement..........................................................................................................................................................................5-33

Coolant flow troubleshooting chart .....................................................................................................................................................5-34

Coolant flow tests....................................................................................................................................................................................5-35

Before testing.................................................................................................................................................................................5-35

Bypass valve verification..............................................................................................................................................................5-36

Using the Hypertherm flow meter (128933) ..........................................................................................................................5-36

Manual pump operation ...............................................................................................................................................................5-37

Test 1 – return line......................................................................................................................................................................5-38

Test 2 – supply line at ignition console .................................................................................................................................5-38

Test 3 – change the torch.........................................................................................................................................................5-39

Test 4 – supply line to the torch receptacle.........................................................................................................................5-39

Test 5 – return line from the torch receptacle......................................................................................................................5-39

Test 6 – bucket test at the pump............................................................................................................................................5-40

Pump and motor troubleshooting..............................................................................................................................................5-41

Testing the flow sensor ................................................................................................................................................................5-41

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xii HPR400XD Manual Gas Instruction Manual

Gas leak tests...........................................................................................................................................................................................5-42

Power supply control board PCB3 .....................................................................................................................................................5-43

Power supply power distribution board PCB2.................................................................................................................................5-44

Start circuit PCB1 ...................................................................................................................................................................................5-45

Operation ........................................................................................................................................................................................5-45

Start circuit functional schematic ..............................................................................................................................................5-45

Start circuit troubleshooting .......................................................................................................................................................5-45

Pilot arc current levels..................................................................................................................................................................5-47

Pump motor drive board PCB7............................................................................................................................................................5-48

Cooler power distribution board PCB1 .............................................................................................................................................5-49

Cooler sensor board PCB2 ..................................................................................................................................................................5-50

Gas console control board PCB2.......................................................................................................................................................5-51

Gas console power distribution board PCB1 ..................................................................................................................................5-52

Gas console AC valve-driver board PCB3........................................................................................................................................5-53

Chopper tests...........................................................................................................................................................................................5-54

Phase-loss detection test ......................................................................................................................................................................5-56

Torch lead test ..........................................................................................................................................................................................5-57

Preventive maintenance .........................................................................................................................................................................5-58

Section 6 PARTS LIST ........................................................................................................................................................6-1

Power supply...............................................................................................................................................................................................6-2

Cooler ...........................................................................................................................................................................................................6-6

Ignition console ..........................................................................................................................................................................................6-8

Gas console ................................................................................................................................................................................................6-9

Off-valve.....................................................................................................................................................................................................6-10

HyPerformance torch..............................................................................................................................................................................6-11

Torch assembly ..............................................................................................................................................................................6-11

Torch leads......................................................................................................................................................................................6-11

Consumable parts kit – 228027.......................................................................................................................................................6-12

Consumables for mirror-image cutting ...............................................................................................................................................6-14

Recommended spare parts...................................................................................................................................................................6-15

Section 7 WIRING DIAGRAMS........................................................................................................................................7-1

Wiring Diagrams.........................................................................................................................................................................................7-5

Appendix A BENZOTRIAZOLE / PROPYLENE GLYCOL SAFETY DATA ...............................................................a-1

Section 1 Chemical Product and Company Identification..............................................................................................................a-2

Section 2 Composition / Information on Ingredients.......................................................................................................................a-2

Section 3 Hazards Identification...........................................................................................................................................................a-2

Section 4 First Aid Measures................................................................................................................................................................a-3

Section 5 Fire Fighting Measures.........................................................................................................................................................a-3

Section 6 Accidental Release Measures............................................................................................................................................a-3

Section 7 Handling and Storage..........................................................................................................................................................a-3

Section 8 Exposure Controls / Personal Protection ........................................................................................................................a-4

Section 9 Physical and Chemical Properties ....................................................................................................................................a-4

Section 10 Stability and Reactivity.........................................................................................................................................................a-4

TABLE OF CONTENTS

HPR400XD Manual Gas Instruction Manual xiii

Section 11 Toxicological Information .....................................................................................................................................................a-4

Section 12 Ecological Information..........................................................................................................................................................a-5

Section 13 Disposal Considerations .....................................................................................................................................................a-5

Section 14 Transport Information ...........................................................................................................................................................a-5

Section 15 Regulatory Information.........................................................................................................................................................a-5

Section 16 Other Information..................................................................................................................................................................a-5

Freezing point of Propylene Glycol solution.........................................................................................................................................a-6

Appendix B FUNCTIONAL DESCRIPTION OF SOFTWARE ....................................................................................b-1

Hypertherm 1-1

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Section 1

SAFETY

In this section: