Hypertherm HyPerformance Plasma HPR800XD Auto Gas Instruction Manual

HPR800XD™ Auto Gas

Preventive Maintenance Program

Instruction Manual

808680 | Revision 2 | English

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© 2018 Hypertherm, Inc.

HPR800XD Auto Gas

Preventive Maintenance Program

Instruction Manual

808680

Revision 2

English

November 2018

Hypertherm, Inc.

Hanover, NH 03755 USA

Hypertherm, Inc.

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ENGLISH

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TÜRKÇE / TURKISH

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könyvtár) részben is beszerezhetők.

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(“Documents library”) na www.hypertherm.com.

SLOVENČINA / SLOVAK

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sú k dispozícii aj v sekcii z „knižnice Dokumenty“ na www.hypertherm.com.

Contents

Preventive Maintenance Program ............................................................................................ 9

Overview ............................................................................................................................................................................................. 9

Cleaning and inspection schedule ............................................................................................................................................ 10

Daily .......................................................................................................................................................................................... 11

Do a test of the inlet pressures ................................................................................................................................... 11

Examine all of the air filters .......................................................................................................................................... 11

Do a check of the coolant level and condition ........................................................................................................ 11

Examine and lubricate O-rings .................................................................................................................................... 12

Examine the water tube and torch ............................................................................................................................. 12

Weekly ...................................................................................................................................................................................... 13

Examine hoses and torch leads .................................................................................................................................. 13

Do tests for gas leaks ................................................................................................................................................... 13

Do a check of the coolant flow ................................................................................................................................... 13

Do a check of the coolant level .................................................................................................................................. 13

Monthly ..................................................................................................................................................................................... 14

Clean inside the power supply ................................................................................................................................... 14

Clean the chiller air filter ............................................................................................................................................... 14

Clean inside the chiller ................................................................................................................................................. 15

Examine the coolant system ........................................................................................................................................ 15

Examine the main contactor ........................................................................................................................................ 16

Examine the pilot arc relay ........................................................................................................................................... 16

Do the coolant flow test ............................................................................................................................................... 16

Examine the gas line connections .............................................................................................................................. 17

Examine the hoses ......................................................................................................................................................... 17

Examine the cables ........................................................................................................................................................ 17

Examine the ground connections ............................................................................................................................... 17

Examine the table-to-workpiece connection ........................................................................................................... 17

Component replacement schedule ........................................................................................................................................... 18

HPR800XD Auto Gas Instruction Manual 808680 7

Contents

Cutting area and operation effects .....................................................................................................................................21

External cutting area .......................................................................................................................................................21

Incoming air supply quality ............................................................................................................................................22

Metal dust inside the power supply cabinet .............................................................................................................22

Consumable use .............................................................................................................................................................23

Cut-cycle time .................................................................................................................................................................24

Find arc hour data on a Hypertherm CNC ...............................................................................................................................25

Part numbers for HPR800XD Auto Gas cables and leads ..................................................................................................26

Primary power supply to secondary power supply cables ............................................................................................26

Interface cable .................................................................................................................................................................26

Communication cable ....................................................................................................................................................26

Power supply to ignition console leads .............................................................................................................................26

Pilot arc lead ....................................................................................................................................................................26

Negative lead ...................................................................................................................................................................26

Ignition console power cable .......................................................................................................................................27

Coolant hoses .........................................................................................................................................................................27

Chiller-interface console to ignition console ............................................................................................................27

Chiller to chiller-interface console ..............................................................................................................................27

Power supply to chiller cables .............................................................................................................................................27

Control cable ...................................................................................................................................................................27

Power cable .....................................................................................................................................................................27

Power supply to selection console cables .......................................................................................................................28

Control cable ...................................................................................................................................................................28

Power cable .....................................................................................................................................................................28

Cable and gas hose assembly (selection console to metering console) ..................................................................28

Power supply to CNC interface cable ...............................................................................................................................28

Torch lead .................................................................................................................................................................................29

Work lead .................................................................................................................................................................................29

Ohmic contact wire ................................................................................................................................................................29

Supply gas hoses ...................................................................................................................................................................30

Air hose .............................................................................................................................................................................30

Argon-hydrogen (H35) or nitrogen-hydrogen (F5) hose .......................................................................................30

Nitrogen or argon hose .................................................................................................................................................30

Oxygen hose ....................................................................................................................................................................30

System information .........................................................................................................................................................................31

Model number ..........................................................................................................................................................................31

Serial number ...........................................................................................................................................................................31

System voltage ........................................................................................................................................................................31

Coolant requirements ............................................................................................................................................................31

Notes .................................................................................................................................................................................................32

Maintenance log for HPR800XD Auto Gas plasma systems ..............................................................................................33

8 HPR800XD Auto Gas Instruction Manual 808680

Preventive Maintenance Program

Overview

Congratulations on the purchase of your Hypertherm plasma system.

Hypertherm plasma systems can operate in harsh conditions for many years. To maintain system performance, minimize
operating costs, and lengthen system life, follow the maintenance procedures given in this Preventative Maintenance
Program (PMP).

Hypertherm made this PMP specifically for your plasma system. The PMP has two parts: a cleaning and inspection
schedule and a component replacement schedule.

If you have questions about how 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
page.

This document refers to your system’s instruction manual. If you do not have your instruction manual, you can find it at

www.hypertherm.com/docs

 HPR800XD Auto Gas Instruction Manual: 806500

.

on the “Contact us”

HPR800XD Auto Gas Instruction Manual 808680 9

Preventive Maintenance Program

Cleaning and inspection schedule

This is a daily, weekly, and monthly schedule for cleaning and inspections. The PMP has instructions for each task. These
instructions help your personnel understand what to do and what to look for during each task. In general, an operator can
do the daily and weekly tasks, while maintenance personnel usually do the monthly tasks.

A monthly maintenance log is in the back of this manual. You can make photocopies of the maintenance log to record
tasks.

Table 1

Maintenance task or activity Daily Weekly Monthly

Do a test of the inlet pressures X

Examine all of the air filters X

Do a check of the coolant level and condition X

Examine and lubricate O-rings X

Examine the water tube and torch X

Examine hoses and torch leads X

Do tests for gas leaks X

Do a check of the coolant flow* X

Do a check of the coolant level* X

Clean inside the power supply* X

Clean the chiller air filter* X

Clean inside the chiller* X

Examine the coolant system* X

Examine the main contactor X

Examine the pilot arc relay X

Do the coolant flow test X

Examine the gas line connections X

Examine the hoses X

Examine the cables X

Examine the ground connections X

Examine the table-to-workpiece connection X

*See the chiller manufacturer manual for guidance on chiller maintenance. Chiller manufacturer specifications override Hypertherm’s

recommendations for chiller maintenance.

10 HPR800XD Auto Gas Instruction Manual 808680