Hypertherm RoboTester Troubleshooting
RoboTester
Troubleshooting Kit
Instruction Manual
804010 - Revision 0
Instruction Manual
P/N 804010
Revision 0 - December 2001
© Copyright 2001 Hypertherm, Inc.
All Rights Reserved
Hypertherm and Command are trademarks of Hypertherm, Inc., and
may be registered in the United States and/or other countries
RoboTester
Hypertherm, Inc.
P.O. Box 5010
Hanover, NH USA
www.hypertherm.com
Hypertherm, Inc.
Etna Road, P.O. Box 5010
Hanover, NH 03755 USA
603-643-3441 Tel (Main Office)
603-643-5352 Fax (All Departments)
800-643-9878 Tel (Technical Service)
800-737-2978 Tel (Customer Service)
Hypertherm Automation
5 Technology Drive
West Lebanon, NH 03755 USA
603-298-7970 Tel
603-298-7977 Fax
Hypertherm Plasmatechnik GmbH
Technologiepark Hanau
Rodenbacher Chaussee 6
63457 Hanau-Wolfgang, Deutschland
49 6181 58 2100 Tel
49 6181 58 2134 Fax
49 6181 58 2123 (Technical Service)
Hypertherm Singapore Pte Ltd
No. 19 Kaki Bukit Road 2
K.B. Warehouse Complex
Singapore 417847, Republic of Singapore
65 841 2489 Tel
65 841 2490 Fax
65 841 2489 (Technical Service)
Japan
1952-14 Yata-Natsumegi
Mishima City, Shizuoka Pref.
411-0801 Japan
81 0 559 75 7387 Tel
81 0 559 75 7376 Fax
Hypertherm UK Ltd
9 Berkeley Court, Manor Park
Runcorn, Cheshire, England WA7 1TQ
44 1928 579 074 Tel
44 1928 579 604 Fax
France
15 Impasse des Rosiers
95610 Eragny, France
0805 050 111 Tel
0805 050 222 Fax
Hypertherm S.r.L.
Via Torino 2
20123 Milano, Italia
39 02 725 46 312 Tel
39 02 725 46 400 Fax
39 02 725 46 314 (Technical Service)
Hypertherm B.V.
Burg. Haverkampstraat 13
7091 CN Dinxperlo, Nederland
31 315 655866 Tel
31 315 655886 Fax
Hypertherm B.V. (ETSO)
Vaartveld 9
4704 SE Roosendaal, Nederland
00 800 49 73 7843 – toll-free in Europa
31 165 596900 Tel
31 165 596901 Fax
Hypertherm Brasil Ltda.
Rua Visconde de Santa Isabel, 20 – Sala 611
Vila Isabel, RJ
Brasil CEP 20560-120
55 21 2278 6162 Tel
55 21 2578 0947 Fax
10/30/01
Section 1 - Safety ....................................................................................................................................................1
Section 2 - Software Installation and overview ................................................................................................2-1
Introduction ......................................................................................................................................................2-2
Software installation ........................................................................................................................................2-3
RoboTester overview........................................................................................................................................2-4
Manipulating machines and devices................................................................................................................2-5
Executing test scripts ......................................................................................................................................2-6
Viewing script results ......................................................................................................................................2-7
Section 3 - Setup and Operation ........................................................................................................................3-1
Figure list..........................................................................................................................................................3-2
Full system set-up ............................................................................................................. ...............................3-3
Robotester startup............................................................................................................................................3-7
Stand alone gas console test ................................................................................................... .......................3-8
Stand alone torch height control (THC) test..................................................................................................3-10
Gas flow test ..................................................................................................................................................3-11
Chopper current test......................................................................................................................................3-15
Chopper voltage test ........................................................................................................... ...........................3-16
Coolant flow test ............................................................................................................................................3-20
Flow switch test..............................................................................................................................................3-21
Missing phase detect test ..............................................................................................................................3-22
Gas leak test..................................................................................................................................................3-23
Section 4 - Parts lists ..........................................................................................................................................4-1
Parts list - Items 1-16 ......................................................................................................................................4-2
Parts list - Items 17-21 ....................................................................................................................................4-3
Parts list - Items 22-33 ....................................................................................................................................4-4
Parts list - Items 34-40 ....................................................................................................................................4-5
RoboTester Instruction Manual i
TABLE OF CONTENTS
RoboTester Instruction Manual 1-1
0
WARNING
ELECTRIC SHOCK CAN KILL
Turn off all electrical power before removing the power supply cover. Put the power
supply circuit breaker in the OFF (0) position and set the line disconnect switch to
OFF. In the U.S., use a "lock-out and tag-out" procedure until the service or
maintenance is complete. In other countries, follow appropriate local or national
safety procedures.
The RoboTester Troubleshooting Software is to be used only by qualified service personnel. It is an inherently
“expert-only” system because it provides full manual control over the plasma system, so the technician can run all
devices. This means you can create hazardous situations if you don’t know what you are doing!
Some simple rules can help prevent accidents:
– Always follow safety precautions in the instruction manual (803760) for the HD4070 system.
– Always disconnect power before touching any machine or device.
– Never let anybody near the system while you are troubleshooting it.
– Never leave a system unattended.
Section 1
SAFETY
2WRENCHES
RoboTester Instruction Manual 2-1
0
In this section:
Introduction ............................................................................................................................................................2-2
Software installation................................................................................................................................................2-3
RoboTester overview..............................................................................................................................................2-4
Manipulating machines and devices ......................................................................................................................2-5
Executing test scripts..............................................................................................................................................2-6
Viewing script results..............................................................................................................................................2-7
Section 2
SOFTWARE INSTALLATION AND OVERVIEW
2-2 RoboTester Instruction Manual
SOFTWARE INSTALLATION AND OVERVIEW
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Introduction
Note: The RoboTester software is only compatible with Windows ’95, ’98 and NT.
The laptop computer being used must have a serial communication port.
The RoboTester is an effort to compensate for the trend toward more complex machines, by creating an
automated troubleshooting tool. The HD4070 is the only product supported at this time, but the RoboTester is a
testing framework that is flexible enough to accommodate other Hypertherm products. Current and future systems
may be incorporated at a later date.
Core features:
– The ability to view and modify the internal state of all machines, down to individual devices. This gives the
troubleshooter full manual control of the plasma cutting system.
– Automated tests. The troubleshooter can execute various testing scripts, see which areas are in good condition,
which ones need attention and save the results to file.
– Troubleshooting database. As more information about each specific product is gathered over its lifetime, we can
make the troubleshooting information increasingly specific, and the suggested remedies more accurate. The
RoboTester is therefore a repository of troubleshooting experience.
Additional features:
– The "Demo mode" lets you learn how to use the RoboTester, without having to connect to real machines.
– Python is the Scripting language: Python is simpler than Visual Basic, and more powerful than Java.
Experienced troubleshooters can create their own scripts.
– There is no installation program for the RoboTester, meaning it doesn't touch your Registry, and is very easy to
upgrade. Also, the scripts and troubleshooting database are all contained in plain text files, which means no
information is “locked” into a proprietary format.
Caution: Failure to use the Optical Isolator when connecting to
the laptop can cause the communication port to be
destroyed.
RoboTester Instruction Manual 2-3
SOFTWARE INSTALLATION AND OVERVIEW
0
Note: The RoboTester software is only compatible with Windows ’95, ’98 and NT.
– Obtain the latest copy of the RoboTester software diskette (available in the RoboTester toolbox). Insert disk into
your laptop.
– The “RoboTester.zip” is just a WinZip file, so you can extract it to any location you want on your hard drive. This
also means that uninstallation and upgrades are just a matter of deleting the RoboTester folder, and unzipping a
newer version.
– After unzipping, you should see something like this in the Windows Explorer
Every testable machine has it’s own
folder
This is the python scripting
language engine used for test
scripts.
The actual RoboTester software.
Double click to start.
There are three
sub-folders inside
every machine
folder. The most
important ones for
the user are the
scripts and
troubleshooting
database files.
Software installation
2-4 RoboTester Instruction Manual
SOFTWARE INSTALLATION AND OVERVIEW
0
RoboTester Overview
E-Stop button
– Puts all machines in a fail-safe mode
– The “break” key (on the laptop) has the
same function
Hierarchical View
– Shows everything that is in the system:
Machines, devices, and scripts in a
“whole part” view
Trouble message view
– Shows the results of test scripts
– Lets you display troubleshooting
information, by right clicking on the
trouble message
Schematic view
– Graphically displays the most important
devices
RoboTester Instruction Manual 2-5
SOFTWARE INSTALLATION AND OVERVIEW
0
Manipulating machines and devices
In general, double-clicking or right-clicking any machine or device in the hierarchical view, the schematic view or
the device list view will let you manipulate it.
Double-clicking usually causes some “default” behavior. For an “on-off” type of device, Double-clicking will toggle it
between the on and off states.
Right click on machine in hierarchical view
– This allows you to manipulate both machines
and devices
– This can also be accomplished by right-
clicking the machine name in the schematic
view
Right-click on device in schematic view
– The fan for the power supply is shown being
turned on by the user
– The user can zoom in more to make the
devices easier to see
Right-click on device in hierarchical view
The user is setting the Cut Height. The same action can
be taken from the “device list” view
2-6 RoboTester Instruction Manual
SOFTWARE INSTALLATION AND OVERVIEW
0
Executing test scripts
Starting and stopping a script
– Right-clicking will allow the user to turn a
script on and off. The menus or toolbar
buttons can also be used
– In the example shown: the user is stopping
the script
Viewing status changes
– The “device list” and “schematic” views will
show updated device and machine
statuses
Knowing if a script is running
– When a script is running, the status bar at
the bottom of the main window displays
it’s name
Understanding what the script is doing
– Awell written script will regularly send trace
messages to the “trouble message” view to
let the user see what it is currently doing
RoboTester Instruction Manual 2-7
SOFTWARE INSTALLATION AND OVERVIEW
0
Showing troubleshooting information
– The user has right-clicked on a trouble
message, and chosen “Troubleshoot”.
The troubleshooting information is
displayed in the “troubleshooting Info”
view
Saving a “Health Report” after a script
– Choose “Health report” from the machine menu to
save the results of a script to file
– The menu item is only available if there are red,
yellow or green trouble messages available
Viewing script results
RoboTester Instruction Manual 3-1
0
In this section:
Figure list................................................................................................................................................................3-2
System set-up ........................................................................................................................................................3-3
Robotester startup..................................................................................................................................................3-7
Stand alone gas console test ................................................................................................................................3-8
Stand alone torch height control(THC) test ..........................................................................................................3-10
Gas flow test ........................................................................................................................................................3-11
Chopper current test ............................................................................................................................................3-15
Chopper voltage test ............................................................................................................................................3-16
Coolant flow test ..................................................................................................................................................3-20
Flow switch test ....................................................................................................................................................3-21
Missing phase detect test ....................................................................................................................................3-22
Gas leak test ........................................................................................................................................................3-23
Section 3
SETUP AND OPERATION
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