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Manual Plasma HPR130

Manual Plasma HPR130

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HyPerformance Plasma

®

Manual gas
Instruction manual 806320 – Revision 1

HPR130XD

®

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HyPerformance Plasma HPR130XD Manual Gas
Instruction Manual (P/N 806320)

Revision 1 – November, 2009

Hypertherm, Inc. Hanover, NH USA www.hypertherm.com

© Copyright 2009 Hypertherm, Inc. All Rights Reserved Hypertherm, HyPerformance, HyDefinition, LongLife and Command THC are trademarks of Hypertherm, Inc. and may be registered in the United States and/or other countries

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 Hypertherm México, S.A. de C.V. Avenida Toluca No. 444, Anexo 1, Colonia Olivar de los Padres Delegación Álvaro Obregón México, D.F. C.P. 01780 52 55 5681 8109 Tel 52 55 5683 2127 Fax

7/1/09

ELECTROMAGNETIC COMPATIBILITY (EMC)

EMC Introduction
Hypertherm’s CE-marked equipment is built in compliance with standard EN60974-10. The equipment should be installed and used in accordance with the information below to achieve electromagnetic compatibility. The limits required by EN60974-10 may not be adequate to completely eliminate interference when the affected equipment is in close proximity or has a high degree of sensitivity. In such cases it may be necessary to use other measures to further reduce interference. This cutting equipment is designed for use only in an industrial environment.

g. Immunity of other equipment in the environment. User shall ensure that other equipment being used in the environment is compatible. This may require additional protection measures. h. Time of day that cutting or other activities are to be carried out. The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.

Methods of reducing emissions
Mains supply
Cutting equipment must be connected to the mains supply according to the manufacturer’s recommendations. If interference occurs, it may be necessary to take additional precautions such as filtering of the mains supply. Consideration should be given to shielding the supply cable of permanently installed cutting equipment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout 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 power source enclosure.

Installation and use
The user is responsible for installing and using the plasma equipment according to the manufacturer’s instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user to resolve the situation with the technical assistance of the manufacturer. In some cases this remedial action may be as simple as earthing the cutting circuit, see Earthing of Workpiece. In other cases it could involve constructing an electromagnetic screen enclosing the power source and the work complete with associated input filters. In all cases electromagnetic disturbances must be reduced to the point where they are no longer troublesome.

Maintenance of cutting equipment
The cutting equipment must be routinely maintained according to the manufacturer’s recommendations. All access and service doors and covers should be closed and properly fastened when the cutting equipment is in operation. The cutting equipment should not be modified in any way except for those changes and adjustments covered in the manufacturer’s instructions. In particular, the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer’s recommendations.

Assessment of area
Before installing the equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area. The following shall be taken into account: a. Other supply cables, control cables, signalling and telephone cables; above, below and adjacent to the cutting equipment. b. Radio and television transmitters and receivers. c. Computer and other control equipment. d. Safety critical equipment, for example guarding of industrial equipment. e. Health of the people around, for example the use of pacemakers and hearing aids. f. Equipment used for calibration or measurement.

Cutting cables
The cutting cables should be kept as short as possible and should be positioned 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 components bonded to the workpiece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode (nozzle for laser heads) at the same time. The operator should be insulated from all such bonded metallic components.

Hypertherm

i
4-08

for example. Note: the cutting circuit may or may not be earthed for safety reasons.ELECTROMAGNETIC COMPATIBILITY (EMC) Earthing of workpiece Where the workpiece is not bonded to earth for electrical safety. but not all instances. nor connected to earth because of its size and position. the connection of the workpiece to earth should be made by a direct connection to the workpiece. the bonding should be achieved by suitable capacitances selected according to national regulations. for example. Further guidance is given in IEC/TS 62081 Arc Welding Equipment Installation and Use. but in some countries where direct connection is not permitted. by allowing parallel cutting current return paths which may damage the earth circuits of other equipment. Changing the earthing arrangements should only be authorized by a person who is competent to assess whether the changes will increase the risk of injury. Screening and shielding Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference. Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users. Screening of the entire plasma cutting installation may be considered for special applications. ship’s hull or building steelwork. ii 4-08 Hypertherm . or damage to other electrical equipment. Where necessary. a connection bonding the workpiece to earth may reduce emissions in some.

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. or adjust. modified.WARRANTY Attention Genuine Hypertherm parts are the factory-recommended replacement parts for your Hypertherm system. to Hypertherm’s place of business in Hanover. Hypertherm. Distributors/OEMs may offer different or additional warranties. at its sole option. Hypertherm does not warranty systems that have been damaged as a result of poor power quality. free of charge. EMC filters needed to comply with the European EMC Directive are incorporated within versions of the power supply with a CE Marking. In addition. CE marking constitutes a manufacturer’s declaration of conformity to applicable European directives and standards. but Distributors/OEMs are not authorized to give any additional warranty protection to you or make any representation to you purporting to be binding upon Hypertherm. Differences in national standards Differences in standards include. • Safety-critical components are replaced with unauthorized spare parts. 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. and (ii) with respect to the torch and leads within a period of one (1) year from its date of delivery to you. or adjustments of Products covered by this warranty. with the exception of Powermax brand power supplies. The foregoing shall constitute the sole and exclusive remedy for any breach by Hypertherm of its warranty. Certification test marks Certified products are identified by one or more certification test marks from accredited testing laboratories. which shall be within a period of three (3) years from the date of delivery to you. The warranty above is exclusive and is in lieu of all other warranties. statutory. shall repair. or to an authorized Hypertherm repair facility. all costs. You are responsible for the safe use of the Product. Once the product has left the Hypertherm factory. 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. properly packed. warrants that its Products shall be free from defects in materials and workmanship. This warranty shall not apply to any Powermax brand power supplies that have been used with phase converters. but are not limited to: • Voltages • Plug and cord ratings • Language requirements • Electromagnetic compatibility requirements Hypertherm iii 4-08 . except those made pursuant to this paragraph or with Hypertherm’s prior written consent. This warranty shall not apply to any Product which has been incorrectly installed. Hypertherm shall not be liable for any repairs. • Any unauthorized assembly or accessory that uses or generates a hazardous voltage is added. Any damage caused by the use of other than genuine Hypertherm parts may not be covered by the Hypertherm warranty. New Hampshire. insurance and freight prepaid. express. any defective Products covered by this warranty which shall be returned with Hypertherm’s prior authorization (which shall not be unreasonably withheld). Hypertherm does not and cannot make any guarantee or warranty regarding the safe use of the Product in your environment. replacement. • There is any tampering with a safety circuit or other feature that is designed into the product as part of the certification. and all implied warranties or conditions of quality or of merchantability or fitness for a particular purpose or against infringement. whether from phase converters or incoming line power. 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. General Hypertherm. or otherwise with respect to the Products or as to the results which may be obtained therefrom. implied. 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. or otherwise damaged. 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. Inc. replace. The certification test marks are located on or near the data plate.

breach of warranties. dust. the installation also may be subject to approval by local authorities. You shall notify Hypertherm promptly upon learning of any action or threatened action in connection with any such alleged infringement. Since there are differences in the ratings and costs that can be required by local regulations for higherlevel systems. the product must be configured and certified properly for the end-use site. Seek advice from legal counsel and local regulatory experts if uncertain about compliance. Liability cap In no event shall Hypertherm’s liability. Hypertherm will defend or settle. or punitive damages (including but not limited to lost profits) regardless of whether such liability is based on breach of contract. infringes any patent of any third party. Higher-level systems When a system integrator adds additional equipment. constant flexing ratings may be required. failure of essential purpose or otherwise and even if advised of the possibility of such damages. formulae. to a Hypertherm plasma cutting system.WARRANTY 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. When Hypertherm products are shipped to one country for export to another country. the defense of the claim. 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. tort. It is the responsibility of the end-use customer or the OEM to ensure the cables are suitable for the application. processes. whether such liability is based on breach of contract. and the indemnified party’s cooperation and assistance in. it is necessary to verify that any external interconnecting cables are suitable for the end-use installation site. 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. 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. alone and not in combination with any other product not supplied by Hypertherm. strict liability. at its own expense. 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. strict liability. or water contaminants. hard usage ratings may be required. iv 4-08 Hypertherm . indirect. Limitation of liability In no event shall Hypertherm be liable to any person or entity for any incidental. 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. such as cutting tables. Unless the higher-level system is certified when the OEM incorporates Hypertherm products into it. When external interconnecting cables are subject to continuous movement. or combinations not developed or purported to be developed by Hypertherm. For example. 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. any suit or proceeding brought against you alleging that the use of the Hypertherm product. failure of essential purpose or otherwise. tort. consequential. the combined system may be considered a higher-level system. 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. motion controllers or robots. A higher-level system with hazardous moving parts may constitute industrial machinery or robotic equipment. motor drives. and Hypertherm’s obligation to indemnify shall be conditioned upon Hypertherm’s sole control of. When the external interconnecting cables are subject to oil. breach of warranties. 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.

state. • In the United States. Hypertherm v 4-08 . • In other countries. Proper disposal of Hypertherm products Hypertherm plasma cutting systems.hypertherm. and local laws. National and Local codes National and Local codes governing plumbing and electrical installation shall take precedent over any instructions contained in this manual. For more information. check national and local laws. 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. 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. In no event shall Hypertherm be liable for injury to persons or property damage by reason of any code violation or poor work practices. visit www. and local laws. like all electronic products. 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. national. check the EU directives.com/weee. • In the European Union. may contain materials or components. check all federal.WARRANTY Insurance At all times you will have and maintain insurance in such quantities and types. such as printed circuit boards.

.........................................................................................................................................................................1-11 Section 1a SÉCURITÉ ...............................................................................................................................................................................................................................1-7 Additional safety information ..........................................................................................................1b-2 Siga las instrucciones de seguridad.............................................................................................................................................................................................................................................1b-3 Electricidad estática puede dañar tablillas de circuito ..................................................................................................................................1a-9 Information sur le dépoussiérage .......................................................................................................................................................................................................................................................1a-7 Un arc plasma peut endommager les tuyaux gelés ........................................................................................................1-7 A plasma arc can damage frozen pipes.....................................................................................................................................1-8 Warning labels........................................................1-2 Electric shock can kill........................................................................................................................................................................................................................................................................1-1 Recognize safety information .1b-1 Reconocimiento de información de seguridad.................................................................................................................................................................................................................................1-9 Dry dust collection information..........................................................................1b-2 El choque eléctrico puede provocar la muerte....................................................................1-3 Toxic fumes can cause injury or death ..................................................................................................................................................................................................................................................................................................................................................................................................................1a-7 Symboles et marquage...............................................................................................1a-7 Pacemakers et prothèses auditives ....................................................................................................1-6 Noise can damage hearing ...........................................1a-5 Les rayons de l’arc peuvent brûler les yeux et la peau........................................................................................................................................................................................................................................................................1a-2 Les chocs électriques peuvent être fatals ..........................................................................................1-2 Follow safety instructions.........................1-5 Grounding safety ..........................................................................................................................................................................1-6 Compressed gas equipment safety...................................................................................................................................................................................................1a-1 Identifier les consignes de sécurité....................................1-7 Pacemaker and hearing aid operation..................................................................1a-5 Mise à la masse et à la terre..............................................................................................................................................................................................................................................................................................................................1a-2 Suivre les instructions de sécurité..........................................................................................................................................................................................................................................................................................................................................1a-3 L’électricité statique peut endommager les cartes de circuits imprimés .1a-4 L’arc plasma peut provoquer des blessures ou des brûlures.........................................................................................................................................................................................1-3 Static electricity can damage circuit boards ......................................................................................................................................1b-2 Los cortes pueden provocar incendios o explosiones ..................................................................................1a-6 Les bouteilles de gaz comprimé peuvent exploser en cas de dommages ..........................................................................1a-2 Le coupage peut provoquer un incendie ou une explosion.......................................................................................................................1-8 Symbols and markings.....................................................................................................................................................................................................1a-6 Sécurité des bouteilles de gaz comprimé...............1a-6 Le bruit peut provoquer des problèmes auditifs.............................................................................................1b-3 HPR130XD Manual Gas Instruction Manual vii ........................1-6 Gas cylinders can explode if damaged..............................................................................i Warranty........1-2 Cutting can cause fire or explosion ..................................................................................................................................................................................................................................................................................................................................iii Section 1 SAFETY ........................................................................................................................................................1-4 A plasma arc can cause injury and burns.............................................................................................................................................1-5 Arc rays can burn eyes and skin............................................................1a-11 Section 1b SEGURIDAD.....................................TABLE OF CONTENTS Electromagnetic Compatibility (EMC)...........................................1a-3 Les vapeurs toxiques peuvent provoquer des blessures ou la mort.........................................................................................................................................................................................................1a-8 Étiquettes de sécurité.............................................................................................................................................................................................................................................................................................................................................

................................................................................................3-1 Upon receipt .....................................................................................................................................................................................................................................................................................................................2-3 Off-valve .........3-6 Introduction ....................................................................................................3-5 Cables and hoses ........................................1b-8 Etiquetas de advertencia ....................................................................3-6 Steps to take ....................................................................3-7 Grounding diagram...................................................................................................................................................................................................1b-6 Los cilindros de gas pueden explotar si están dañados ..................2-3 Gas console ..........................................................................................................................................................1b-9 Información sobre la colección de polvo seco........................................................................................................................................................................................................................................................................................................3-3 Installation requirements .....................................................................................................................................................2-9 Torch – 228354 ........................1b-5 Seguridad de toma a tierra.......................................................................................................1b-6 El ruido puede deteriorar la audición ..........................................................................................................................................................2-3 Power supply..................................................................................................................1b-4 El arco de plasma puede causar lesiones y quemaduras.................................................................................2-5 Ignition console – 078172 ........1b-7 Operación de marcapasos y de audífonos.........................................................................................................................................................................................................................................................................................................................................2-3 Specifications ..............................................................................TABLE OF CONTENTS Humos tóxicos pueden causar lesiones o muerte......................................................................................................................1b-7 Símbolos y marcas.......................................................................................................................................................................3-6 Types of grounding......................................................................................................................................................................................................................................................................................................................................1b-6 Seguridad de los equipos de gas comprimido ........2-4 System gas requirements................................................................................................................................................................................................................................3-5 Supply gas hoses.............................................................................................................................................................................................................................................................................................................................................................................3-5 Customer-supplied power cable .........................2-3 Torch...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3-3 Installation requirements .......................................................................................................................................................................................................3-10 Placement of the power supply ...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2-1 System description.......................................................................................................................................................2-3 Ignition console........................................................................................................................................................................................................................................1b-7 Un arco plasma puede dañar tubos congelados .......................................................................................................................................................................3-3 Claims.........................................................3-3 Torque specifications..........3-4 System components .........................................................................................................3-5 Recommended grounding and shielding practices ..................................................2-6 Gas console – 078532..........................................................................................................1b-5 Los rayos del arco pueden producir quemaduras en los ojos y en la piel .............................................................................................................................................................................................................................................................................................................................................................3-11 viii HPR130XD Manual Gas Instruction Manual .........................................................................................................................................................................................................................................................................................................................................................................................................................................................................2-10 Section 3 INSTALLATION ...................................................2-3 General ......................................................................................................................................................................3-3 Noise levels .............2-8 Off-valve – 078534 ..............................................................................2-4 Power supply.........................................................................................................................................3-3 Placement of system components......................................................................................................................................................................1b-11 Section 2 SPECIFICATIONS.........................................

................................................................................3-41 Custom Coolant mix for hot operating temperatures ......3-30 Torch connections .....3-37 General..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3-45 Supply gas plumbing...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3-40 Premixed coolant for standard operating temperatures .............................................................................................................................3-42 Fill the power supply with coolant ..........................................................................................................................3-44 Gas regulators .........................................................3-19 Power supply to gas console cables .................................................3-39 Torch coolant requirements............................................................................................................................................................................................................................3-43 Gas requirements................................................................................................3-38 Connect the power ...........................................3-16 Ignition console power cable ............................................................3-40 Custom Coolant mix for cold operating temperatures ............................................................................................................................................................................................................................................................................................................................................................................................................................................3-20 Control cable ......................................................3-31 Connect the torch to the quick-disconnect........................................................3-16 Negative lead ....................................................................................................................................................................................................................................................................................................................................3-46 Connect the supply gases .................3-18 Ignition console coolant hoses ......................................................................................................................3-31 Connect the torch to the torch lead assembly.............................................3-37 Line disconnect switch..........................................................................................................................................................................3-15 Power supply to ignition console leads...................3-14 Placement of the gas console......................................3-36 Torch lifter requirement .................................................3-27 Remote on/off switch ................................................................................................................................................................................3-36 Power requirements.................................................3-28 Torch lead assembly .................................................................................................................................3-29 Work lead ..........................................................................................................................................................................................................................................................................................................................................................................................................................................3-47 Supply gas hoses........................................TABLE OF CONTENTS Install the ignition console ........................................................................................................3-22 Power supply to CNC interface cable ..................................................................................................................3-35 Torch mounting and alignment .......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3-36 Mounting the torch ....................................................................................................................................................................................................................3-20 Gas console to off-valve connections ...............................................................................................................................................................................................................3-48 HPR130XD Manual Gas Instruction Manual ix ......................................................................................................................................................................................................................................................................3-20 Power cable ..........................................................................................................................................................................................................................................................................................................................................................................................................................3-22 Cable and gas hose assembly.................................................................3-38 Power cable ...................................................................................................................................................................................................................................................................................................................................................3-16 Pilot arc lead ..............................................................................................................................................................3-26 Examples of input circuits ....3-36 Torch alignment ..........3-24 Optional multi-system CNC interface cable ................................................................................................................................................................................3-25 Examples of output circuits ......................................................................................3-22 Gas console to off-valve cable ............................................................3-22 Off-valve cable .............................................................................................................................................................3-24 Notes to CNC interface cable run list .......................................................................................................................................................................................................................................................................................3-42 Water purity requirements..........................3-44 Setting the supply regulators ..............................................................................................3-12 Install the off-valve ...............

............................................................................................................................................................................................................5-10 Error code troubleshooting – Error codes 000 to 020.............................................................................................................................................................................................................................................................TABLE OF CONTENTS Section 4 OPERATION ...........................................................................................................................................................................................................................4-7 Mild steel bevel cutting ......................................................................................................................................................................................................................4-11 Torch connections ...............................................................4-16 Cut charts......................................................................4-5 Mild steel ............................4-17 Bevel cutting definitions............................................................................................................................................................................................................................................................................................................................................................................4-12 Replace torch water tube ..................4-3 Manual gas console operation..4-8 Install and inspect consumables ..............................................................................................................................................................................................................................................4-9 Torch maintenance ....5-9 Error codes.........................................................................................................................................................................................................................................................................4-14 Tips for table and torch.........................................5-1 Introduction .........................................................................................................4-15 Additional improvements....5-6 Gas system valve usage....................................................................................................................................................................................................................................................................4-6 Aluminum .....................................................................................................................................5-4 Sequence of operation ..............5-11 x HPR130XD Manual Gas Instruction Manual .............................................................................................................4-5 SilverPlus electrodes ...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4-4 Consumable selection ...................................................................................4-8 Stainless steel bevel cutting ................4-5 Standard cutting..............4-2 Check torch ..................................................................................................................4-14 Plasma set-up tips.....................................................................................................................................................................................................................................................................................................5-3 Routine maintenance .......................................................................4-12 Common cutting faults.............................4-5 Bevel cutting...............................................................................................................5-3 System description...............................................................................4-13 How to optimize cut quality...................................................................................................................................4-3 General ................................................................................................................................................................4-14 Maximize the life of consumable parts .................................................................................................................................................................................................................................................................................................................................................................4-18 Estimated kerf width compensation........................................................................................................................................................................................4-6 Stainless steel ........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4-3 Power indicators..................................................................................................................................................................................................................................................................................5-5 Gas system purge cycle................................................................................................................................................................................................................................................................................................4-17 Bevel cut charts.........................................................................................................................................................................................................................................4-19 Section 5 MAINTENANCE.......4-2 Controls and indicators .....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4-14 Additional factors of cut quality .......................................................................................................................................5-6 Marking process ..........................5-8 PCB block diagram ....................4-1 Daily start-up.....4-5 Consumables for mirror-image cutting................................................4-3 Main power switch ............................4-5 Marking .............................................................................................................................................................................................................................................................................................5-4 Control and signal cables....................................................................................................................................................................

.5-36 Using the Hypertherm flow meter (128933).........................................................................................................................................................................................................................................................5-29 Initial checks ................................................5-39 Test 4 – supply line to the torch receptacle .....5-44 Power supply power distribution board PCB2 .....................................................5-43 Power supply control board PCB3...................................................................................................................................................................5-34 Coolant flow troubleshooting chart.........................................................................................................................................................................TABLE OF CONTENTS Error code troubleshooting – Error codes 021 to 028.......................................................................................................................................................................................................................................................................................................................................................5-40 Pump and motor troubleshooting.......................................................5-12 Error code troubleshooting – Error codes 030 to 042.5-45 Start circuit PCB1 .......................................................................................................................................5-14 Error code troubleshooting – Error codes 047 to 053.................................................................................5-34 Filter replacement .........5-42 Gas leak tests .......... ..................................................................................................................................................................................................................................................................5-20 Error code troubleshooting – Error codes 124 to 134.....................................................................................5-25 Error code troubleshooting – Error codes 180 to 181.....................................................................................................................5-38 Test 3 – change the torch ..............................................................................................................................................5-33 Draining the coolant system......................................5-33 Coolant system filter and strainer...................................................................................................................5-41 Testing the flow sensor.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5-13 Error code troubleshooting – Error codes 044 to 046 ..............................................5-18 Error code troubleshooting – Error codes 093 to 105 ..............................5-46 Operation..................................................................................................................................................................................................................................................................................................5-35 Coolant flow tests ...............5-23 Error code troubleshooting – Error codes 155 to 158......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5-38 Test 2 – supply line at ignition console..................5-37 Test 1 – return line ...............................................5-32 Power supply coolant system servicing ......................................5-36 Manual pump operation.......................................................................................................5-46 HPR130XD Manual Gas Instruction Manual xi ...........5-30 Power measurement..................................................................................................................................................................................5-27 Plasma system operation with pump timeout .........................................................................................................................................................................................................................5-28 CNC operation with pump timeout...............................................................................................................5-46 Start circuit functional schematic..........................................................5-26 Power supply states ...........................................................5-17 Error code troubleshooting – Error codes 071 to 076 ...............................................................5-39 Test 5 – return line from the torch receptacle ................................................................................................................5-19 Error code troubleshooting – Error codes 106 to 123 ....................................................................................................5-22 Error code troubleshooting – Error codes 144 to 154...................................................5-16 Error code troubleshooting – Error codes 062 to 067 ..........................................................5-31 Air filter element replacement........................................................................................................................................................5-24 Error code troubleshooting – Error codes 159 to 160.............5-34 Pump strainer cleaning............................................................................................5-40 Test 7 – bypass the check valve................................................................................................................................................................................................................................................................................5-21 Error code troubleshooting – Error codes 138 to 143............................................................................................................................................................................................................................................................................................................................5-36 Before testing ......................................................................................................................5-39 Test 6 – bucket test at the pump ..................................................................................................................................................................................................................................................................................................................................5-15 Error code troubleshooting – Error codes 054 to 061.......................................................................

..............................................6-10 Torch leads ......................................................... AC valve-driver board PCB3..........................................................................5-49 Gas console power distribution board PCB1.......6-11 Consumable parts kit – 128878............................................................................................................................................................................................................................................................6-14 Section 7 WIRING DIAGRAMS .....................a-2 Section 2 Information on Ingredients ...............................................6-1 Power supply ......................................................................7-5 Appendix A PROPYLENE GLYCOL SAFETY DATA / BENZOTRIAZOLE SAFETY DATA ........................................................................................................................................................a-5 Section 16 Other Information.........................................................................................................................................................................................................................................................................................................................................a-1 Section 1 Chemical Product and Company Identification.................................................6-12 Consumables for mirror-image cutting....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5-46 Pilot arc current levels ................................................................................................a-3 Section 8 Exposure Controls / Personal Protection.........6-8 Gas console – 2 of 2 ..................................................................................................................................a-4 Section 9 Physical and Chemical Properties.................................................................................................................................................................................5-48 Gas console control board PCB2 ........................................................................................................................................................................6-2 Ignition console.............................5-52 Phase-loss detection test........................................................................................................................................a-5 Section 15 Regulatory Information...................................................................5-54 Torch lead test..........................a-6 xii HPR130XD Manual Gas Instruction Manual .....................................................................................................................................................................................................................................................................................................................................6-11 Ohmic contact wire ...................................................................................6-9 HyPerformance torch ............................................................................................................................................................................................................................................................................................................................................................................................a-5 Section 13 Disposal Considerations............................................................................................................................................................................................................................................................................................a-3 Section 6 Accidental Release Measures ..............................................................a-3 Section 7 Handling and Storage .........................................................................................................................................................................................................................................................................................................................................................................................TABLE OF CONTENTS Start circuit troubleshooting................................................................................................................................5-56 Section 6 PARTS LIST .........................................a-3 Section 5 Fire Fighting Measures........................................................................................................................................................................................................................................................................................5-50 Gas console....................................................................................................................................................................................................a-2 Section 3 Hazards Identification ................................................................................................................................................................................a-2 Section 4 First Aid Measures..................................................................................................................a-4 Section 10 Stability and Reactivity...................................................................................................................6-10 Torch assembly ................................................7-1 Introduction................................................................................................a-4 Section 12 Ecological Information .......................................................................................................................................................................................................5-51 Chopper tests ....................6-7 Gas console – 1 of 2 .........................................................7-1 Wiring diagrams ....................................................................5-55 Preventive maintenance....................................................................................6-13 Recommended spare parts................................................................................................................................................................................................................................................................................................................................................................6-9 Off-valve................................................................................a-4 Section 11 Toxicological Information .................................................................................................................................................................................................................a-5 Freezing Point of Propylene Glycol Solution .........................................................a-5 Section 14 Transport Information ...................................

...................................................................................................................c-3 Robotic teaching torch (laser pointer) ..................................TABLE OF CONTENTS Appendix B FUNCTIONAL DESCRIPTION OF SOFTWARE .....................................................c-3 HPR130XD Manual Gas Instruction Manual xiii ................................................c-2 Torch leads ..............................c-2 Rotational mounting sleeve (optional)..................................................................c-3 Leather overwrap .....b-1 Appendix C ROBOTIC APPLICATIONS ...............................................................................................................................................................................................................................................................................................................................................................................c-2 Ohmic contact wire..........................................................................c-1 Components for robotic applications..........................................................................................................................................................................................................................................................................................................................................................................

..................................................................................1-3 Static electricity can damage circuit boards..................................................................................................................................................................................................1-6 Compressed gas equipment safety ............................1-7 Pacemaker and hearing aid operation ................................................1-6 Noise can damage hearing............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1-5 Grounding safety....................................................................................................1-5 Arc rays can burn eyes and skin .................................................................................................................................................................................................................................................................................................................................................................................................................................................1-9 Dry dust collection information .....................................................................................1-2 Electric shock can kill ........................................................................................1-4 A plasma arc can cause injury and burns ...........................................................................................................................................................................................1-7 Additional safety information...................1-3 Toxic fumes can cause injury or death.......................................................................................1-7 A plasma arc can damage frozen pipes .................................................................................................................................................................................1-2 Cutting can cause fire or explosion.......................................................................................................................................................................................................................................................................................................................................................................................................Section 1 SAFETY In this section: Recognize safety information...................................................................................1-2 Follow safety instructions ..............................................................1-6 Gas cylinders can explode if damaged ................................................................................1-8 Symbols and markings .............................................................................................................................................1-11 Hypertherm 1-1 11/08 ..................................................1-8 Warning labels ....................

instructions in this manual that may result in minor injury or damage to equipment if not • Keep your machine in proper working condition. FOLLOW SAFETY INSTRUCTIONS • DANGER safety messages precede related instructions in the manual that will result in serious Read carefully all safety messages in this manual and injury or death if not followed correctly. WARNING Explosion Hazard Argon-Hydrogen and Methane Hydrogen and methane are flammable gases that present an explosion hazard. free hydrogen gas may collect under the workpiece and detonate during plasma cutting operations. Do not let anyone operate it • CAUTION safety messages precede related without instruction. or with the water touching the underside of the aluminum. • Do not cut containers that have held combustible materials. DANGER identifies the most serious hazards. A signal word DANGER or WARNING is used with a safety symbol. • Learn how to operate the machine and how to use the controls properly. understand the potential for personal injury. • Quench hot metal or allow it to cool before handling or before letting it touch combustible materials. • Ventilate potentially flammable atmospheres before cutting. safety labels on your machine. Keep a fire extinguisher nearby. or death if not followed correctly. Keep flames away from cylinders and hoses that contain methane or hydrogen mixtures. • Install an aeration manifold on the floor of the water table to eliminate the possibility of hydrogen detonation. • When cutting with oxygen as the plasma gas. • Do not cut pressurized cylinders. CUTTING CAN CAUSE FIRE OR EXPLOSION Fire prevention • Be sure the area is safe before doing any cutting. • Never cut containers with potentially flammable materials inside – they must be emptied and properly cleaned first. followed correctly. • Remove all flammables within 35 feet (10 m) of the cutting area. WARNING Hydrogen Detonation with Aluminum Cutting • When cutting aluminum underwater. Keep flames and sparks away from the torch when using methane or argon-hydrogen plasma. Refer to the Appendix section of this manual for aeration manifold details. • DANGER and WARNING safety labels are located on your machine near specific hazards.SAFETY RECOGNIZE SAFETY INFORMATION The symbols shown in this section are used to identify potential hazards. or any closed container. an exhaust ventilation system is required. DANGER WARNING CAUTION Hypertherm uses American National Standards Institute guidelines for safety signal words and symbols. • WARNING safety messages precede related instructions in this manual that may result in injury Replace missing or damaged labels immediately. Unauthorized modifications to the machine may affect safety and machine service life. and follow the related instructions to avoid the hazard. When you see a safety symbol in this manual or on your machine. pipes. • Keep the safety labels on your machine in good condition. Explosion prevention • Do not use the plasma system if explosive dust or vapors may be present. 1-2 11/08 Hypertherm .

Hypertherm 1-3 11/08 . • Store PC boards in anti-static containers.SAFETY ELECTRIC SHOCK CAN KILL Touching live electrical parts can cause a fatal shock or severe burn. • Never operate the plasma system unless the power supply covers are in place. Do not substitute other torches which could overheat and present a safety hazard. Replace a damaged power cord immediately. use extreme caution. STATIC ELECTRICITY CAN DAMAGE CIRCUIT BOARDS Use proper precautions when handling printed circuit boards. Exposed power supply connections present a severe electrical hazard. workpiece or the water in a water table when the plasma system is operating. • Before checking. disconnect electrical input power. This switch allows the operator to turn off the power supply quickly in an emergency situation. while you cut. • Do not pick up the workpiece. Bare wiring can kill. • When making input connections. Electric shock prevention All Hypertherm plasma systems use high voltage in the cutting process (200 to 400 VDC are common). Take the following precautions when operating this system: • Wear insulated gloves and boots. • Provide a disconnect switch close to the power supply with properly sized fuses. Leave the workpiece in place or on the workbench with the work cable attached during the cutting process. sit or lie on – or touch – any wet surface when using the plasma system. attach proper grounding conductor first. • Inspect the input power cord frequently for damage or cracking of the cover. be sure that it is correctly connected to earth ground. • Operating the plasma system completes an electrical circuit between the torch and the workpiece. • Inspect and replace any worn or damaged torch leads. • Each Hypertherm plasma system is designed to be used only with specific Hypertherm torches. • Wear a grounded wrist strap when handling PC boards. • When using a water table. • Install and ground this equipment according to the instruction manual and in accordance with national and local codes. • Before removing any power supply or system enclosure cover. • Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground. including the waste cutoff. cleaning or changing torch parts. • Never touch the torch body. The workpiece and anything touching the workpiece are part of the electrical circuit. • Do not stand. and keep your body and clothing dry. Wait 5 minutes after disconnecting the main power to allow capacitors to discharge. disconnect the main power or unplug the power supply. If you must work in or near a damp area. • Never bypass or shortcut the safety interlocks.

zinc (galvanized). It is the responsibility of the equipment and site owner to test the air quality in the area where the equipment is used and to ensure that the air quality in the workplace meets all local and national standards and regulations. containing. • Duration of cutting or gouging. although the plasma arc has not been identified as a source of toxic fumes. • Assure that those using welding or cutting equipment. cadmium (in some paints and fillers). as well as air-supplied respiration devices. Depending upon the chemical composition and concentration of the fumes (as well as other factors. Accordingly. or suspected to contain toxic elements. If the workplace must conform to national or local regulations.SAFETY TOXIC FUMES CAN CAUSE INJURY OR DEATH The plasma arc by itself is the heat source used for cutting. Toxic coatings include. air volume. the material being cut can be a source of toxic fumes or gases that deplete oxygen. The air quality level in any relevant workplace depends on site-specific variables such as: • Table design (wet. dry. and composition of coatings. the metal may be coated with a substance that could release toxic fumes. • Do not inhale fumes. • Never cut containers with potentially toxic materials inside. Empty and properly clean the container first. • Volume of material removed. carbon steel. • Other site processes that may produce fumes. Gases produced by plasma cutting vary based on the material to be cut and the method of cutting. In some cases. To reduce the risk of exposure to fumes: • Remove all coatings and solvents from the metal before cutting. Wear an air-supplied respirator when cutting any metal coated with. such as birth defects or cancer. oxides of nitrogen. underwater). • Number of welding and cutting systems in operation. such as ventilation). but are not limited to. hydrogen. stainless steel. • Use local exhaust ventilation to remove fumes from the air. are qualified and trained in the proper use of such equipment. surface finish. • Size. Metals that may release toxic fumes include. but may include ozone. and beryllium. only monitoring or testing done at the site can determine whether the site is above or below allowable levels. • Monitor or test the air quality at the site as needed. 1-4 11/08 Hypertherm . Caution should be taken to minimize exposure to fumes produced by any industrial process. • Personal protective equipment. ventilation and filtration of the work area. but are not limited to. lead (in some paints). there may be a risk of physical illness. hexavalent chromium. and copper. Fumes produced vary depending on the metal that is cut. • Consult with a local expert to implement a site plan to ensure safe air quality. and other substances if such are contained in or released by the material being cut. • Material composition.

Arc current (amps) Less than 40 A 41 to 60 A 61 to 80 A 81 to 125 A 126 to 150 A 151 to 175 A 176 to 250 A 251 to 300 A 301 to 400 A 401 to 800 A Minimum protective Suggested shade shade number number for comfort (ANSI Z49. • Wear eye protection (safety glasses or goggles with side shields. ARC RAYS CAN BURN EYES AND SKIN Eye protection Plasma arc rays produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin.1:2005) 5 6 8 8 8 8 8 8 9 10 5 6 8 9 9 9 9 9 12 14 OSHA 29CFR 1910. • Remove any combustibles. sparks. • Cuffless trousers to prevent entry of sparks and slag. • Use eye protection in accordance with applicable national or local codes. • Gauntlet gloves. • Warn others not to watch the arc. • Keep away from the torch tip. The plasma arc will cut quickly through gloves and skin. • Use protective screens or barriers to protect others from flash and glare. Skin protection Wear protective clothing to protect against burns caused by ultraviolet light.133(a)(5) 8 8 8 8 8 8 Europe EN168:2002 9 9 9 9 10 11 12 13 13 8 8 9 10 Hypertherm 1-5 11/08 . such as a butane lighter or matches. and hot metal.1:2005) (ANSI Z49. from your pockets before cutting. • Never point the torch toward yourself or others. Cutting area Prepare the cutting area to reduce reflection and transmission of ultraviolet light: • Paint walls and other surfaces with dark colors to reduce reflection. • Flame-retardant clothing to cover all exposed areas. and a welding helmet) with appropriate lens shading to protect your eyes from the arc’s ultraviolet and infrared rays. • Do not hold metal near the cutting path. Use placards or signs. safety shoes and hat.SAFETY A PLASMA ARC CAN CAUSE INJURY AND BURNS Instant-on torches Plasma arc comes on immediately when the torch switch is activated.

in accordance with appropriate national or local electrical codes. • Never allow electrical contact between the plasma arc and a cylinder. 1-6 11/08 Hypertherm . • Place the power cord's ground wire on the stud first. COMPRESSED GAS EQUIPMENT SAFETY • Never lubricate cylinder valves or regulators with oil or grease. • Never expose cylinders to excessive heat. Work table Connect the work table to an earth ground.SAFETY GROUNDING SAFETY Work cable Attach the work cable securely to the workpiece or the work table with good metal-to-metal contact. wrench or other tool to open a stuck cylinder valve. Do not connect it to the piece that will fall away when the cut is complete. GAS CYLINDERS CAN EXPLODE IF DAMAGED Gas cylinders contain gas under high pressure. • Use only correct gas cylinders. • Tighten all electrical connections to avoid excessive heating. slag or open flame. If damaged. regulators. sparks. • Keep the protective cap in place over valve except when the cylinder is in use or connected for use. • Never use a hammer. then place any other ground wires on top of the power cord ground. Input power • Be sure to connect the power cord ground wire to the ground in the disconnect box. • Label and color-code all gas hoses to identify the type of gas in each hose. Fasten the retaining nut tightly. a cylinder can explode. hoses and fittings designed for the specific application. • Never use a cylinder that is not upright and secured in place. be sure to connect the power cord ground wire properly. • If installation of the plasma system involves connecting the power cord to the power supply. • Maintain all compressed gas equipment and associated parts in good condition. Consult applicable national or local codes. • Handle and use compressed gas cylinders in accordance with applicable national or local codes.

Hypertherm 1-7 11/08 . To reduce magnetic field hazards: Prolonged exposure to noise from cutting or gouging can damage hearing. Pacemaker and hearing aid wearers should consult a doctor before going near any plasma arc cutting and gouging operations. Frozen pipes may be damaged or can burst if you attempt to thaw them with a plasma torch. • Do not wrap or drape the torch lead or work cable around your body.SAFETY NOISE CAN DAMAGE HEARING PACEMAKER AND HEARING AID OPERATION Pacemaker and hearing aid operation can be affected by magnetic fields from high currents. A PLASMA ARC CAN DAMAGE FROZEN PIPES • Keep both the work cable and the torch lead to one side. • Route the torch leads as close as possible to the work cable. • Use approved ear protection when using plasma system. • Keep as far away from the power supply as possible. • Warn others nearby about the noise hazard. away from your body.

Government Printing Office.org/technical/facts/ SYMBOLS AND MARKS Your Hypertherm product may have one or more of the following markings on or near the data plate. The products were evaluated. 470 Atlantic Avenue. Boston. P. FL 33135 2. CSA Standard W117. AWS Safety and Health Fact Sheets. FL 33135 5. Recommended Safe Practices for Plasma Arc Cutting.2.2. 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 Electromagnetic Compatibility (EMC) Directive. New York. CCC mark The China Compulsory Certification (CCC) mark indicates that the product has been tested and found compliant with product safety regulations required for sale in China. P. Canada 8. NFPA Standard 70–1978. ANSI Standard Z49. GOST-R mark CE versions of Hypertherm products that include a GOST-R mark of conformity meet the product safety and EMC requirements for export to the Russian Federation. tested. Alternatively the product may have a mark by one of the other Nationally Recognized Testing Laboratories (NRTL) accredited in both the United States and Canada.aws. Incorporated (UL) or TÜV. Code for Safety in Welding and Cutting. NFPA Standard 51B.1. AWS F4. Due to differences and conflicts in national regulations. EMC filters needed to comply with the European EMC Directive are incorporated within versions of the product with a CE marking.O. 1-8 11/08 Hypertherm . American National Standards Institute 1430 Broadway. National Electrical Code. CGA Pamphlet P-1. Washington.S.C. 20402 11. Safety in Welding and Cutting. New York. Canadian Standards Association Standard Sales 178 Rexdale Boulevard. NY 10018 4. AWS F5. Safe Handling of Compressed Gases in Cylinders. American National Standards Institute. Miami. Safety and Health Standards. ANSI Standard Z87. S mark symbol The S mark symbol indicates that the power supply and torch are suitable for operations carried out in environments with increased hazard of electrical shock per IEC 60974-1. American Welding Society 550 LeJeune Road. American Welding Society. ANSI Standard Z49. such as Underwriters Laboratories. American Welding Society 550 LeJeune Road. Box 351040. National Fire Protection Association. Arlington.2. VA 22202 7. Box 351020. Safe Practices for Occupation and Educational Eye and Face Protection. Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances. Miami. CSA mark Hypertherm products with a CSA mark meet the United States and Canadian regulations for product safety. Box 351040.1. American Welding Society 550 LeJeune Road. Miami. MA 02210 10. MA 02210 9. 29FR 1910 U. 550 LeJeune Road P. Compressed Gas Association 1235 Jefferson Davis Highway. not all marks are applied to every version of a product.O. P. Cutting and Welding Processes. National Fire Protection Association 470 Atlantic Avenue. FL 33135 www. Rexdale. D. Fire Prevention in the Use of Cutting and Welding Processes. c-Tick mark CE versions of Hypertherm products with a c-Tick mark comply with the EMC regulations required for sale in Australia and New Zealand. Box 351040.O. 1430 Broadway. Miami.1. Boston. and certified by CSA-International. FL 33135 6.SAFETY ADDITIONAL SAFETY INFORMATION 1. OSHA. CE marking The CE marking signifies the manufacturer’s declaration of conformity to applicable European directives and standards.O. Ontario M9W 1R3. NY 10018 3.

3 Se protéger entièrement le corps. or cover this label. Only qualified personnel should operate this equipment.1 Do not inhale fumes. AVERTISSEMENT Le coupage plasma peut être préjudiciable pour l’opérateur et les personnes qui se trouvent sur les lieux de travail. 3. Refer to ANS Z49. 1. 4.1 Ne pas couper près des matières inflammables.1. Arc starts instantly when triggered. Utiliser exclusivement les torches indiquées dans le manual.gov). Les rayons d’arc peuvent brûler les yeux et blesser la peau. les mains et le corps. Cutting and Allied Processes” from American Welding Society (http://www. 3. les yeux.1 Turn off power before disassembling torch. 5.1 Porter un bon équipement de protection pour se protéger la tête. “Safety in Welding. 4.2 Ne pas saisir la pièce à couper de la trajectoire de coupage. 6.2 Protect from shock by insulating yourself from work and ground. Arc rays can burn eyes and injure skin. Replace if it is missing. hands. 1. L’arc plasma peut blesser et brûler. 29 CFR 1910 (http://www. Use welding helmet with the correct shade of filter. eyes. 4. Consulter le manuel avant de faire fonctionner. 2. les oreilles.1 Do not cut near flammables. Risk of electric shock or burn. Hazardous voltage. 4. Utiliser un masque de soudeur avec un filtre de nuance appropriée. employer safety practices. Boutonner le col de la chemise.3 Wear complete body protection.1 Porter des gants isolants. 5. Plasma arc can injure and burn.1 Wear insulating gloves. Chasser les fumées par ventilation. 1.2 Have a fire extinguisher nearby and ready to use. éloigner la buse de soi.2 Use forced ventilation or local exhaust to remove the fumes. Il s’allume instantanément quand on l’amorce. WARNING Plasma cutting can be injurious to operator and persons in the work area. 1. détruire ni couvrir cette étiquette. Seul le personnel qualifié a le droit de faire fonctionner cet équipement. Protéger les oreilles contre le bruit. Le non respect des ces instructions de sécurité peut entraîner la mort. Remove fumes with ventilation.3 Disconnect power before servicing. 4.org) and OSHA Safety and Health Standards. 2. 2. 3. Hypertherm 1-9 11/08 . 7. destroy. It is important that the operator and maintenance technician understand the intent of these warning symbols as described.1 Wear correct and appropriate protective equipment to protect head. 5. Read and follow these instructions. 2. 3. 7. 2. Ne pas enlever. 3. Tension dangereuse. Do not touch live parts. point the nozzle away from yourself. Keep non-qualified personnel and children away.2 Utiliser une ventilation forcée ou un extracteur local pour dissiper les fumées.aws.3 Ne pas couper dans des espaces clos. and material safety data sheets. ears.2 Do not grip the workpiece near the cutting path.SAFETY WARNING LABEL This warning label is affixed to some power supplies. Replace gloves when wet or damaged. 4. Le personnel non qualifié et les enfants doivent se tenir à l’écart. Do not remove. Protect ears from noise. 1. 2.2 Un extincteur doit être à proximité et prêt à être utilisé. 6.3 Do not operate in closed spaces. 1. La remplacer si elle est absente. Risque de choc électrique ou de brûlure. 5. 3. endommagée ou usée (PN 110584 Rev C). 1. or worn (PN 110584 Rev C). Consult manual before operating. Les étincelles de coupage peuvent provoquer une explosion ou un incendie.1 Couper l’alimentation avant de démonter la torche. 3.3 Do not use a drum or other closed container as a cutting table. 2. Plasma fumes can be hazardous. 2. Les fumées plasma peuvent être dangereuses. and body. 1.3 Couper l’alimentation avant l’entretien.osha. Failure to follow all these safety instructions can result in death. Use torches specified in the manual.1 Ne pas inhaler les fumées 4. Remplacer les gants quand ils sont humides ou endommagés. 3. Button shirt collar.3 Ne pas utiliser un fût ou un autre contenant fermé comme table de coupage.2 Se protéger contre les chocs en s’isolant de la pièce et de la terre. Cutting sparks can cause explosion or fire. Suivre une formation. Become trained. damaged. 4. Ne pas toucher les pièces sous tension.

2 Use forced ventilation or local exhaust to remove the fumes.3 Do not use a drum or other closed container as a cutting table. 2.3 Do not operate in closed spaces.3 Disconnect power before servicing. 1-10 11/08 Hypertherm . It is important that the operator and maintenance technician understand the intent of these warning symbols as described. 4. Do not remove. Plasma fumes can be hazardous.1 Wear correct and appropriate protective equipment to protect head. Hazardous voltage. Keep non-qualified personnel and children away. 1.1 Turn off power before disassembling torch. Do not touch live parts. Risk of electric shock or burn. 3. 5. Use torches specified in the manual. 4. 1.3 Wear complete body protection.2 Protect from shock by insulating yourself from work and ground.1 Wear insulating gloves. Only qualified personnel should operate this equipment. eyes. ears.2 Have a fire extinguisher nearby and ready to use. Become trained. Replace gloves when wet or damaged. 6. The numbered text corresponds to the numbered boxes on the label. or worn. Use welding helmet with the correct shade of filter. Button shirt collar. damaged. 1. Plasma arc can injure and burn.1 Do not cut near flammables. Cutting sparks can cause explosion or fire. Arc rays can burn eyes and injure skin. 4.2 Do not grip the workpiece near the cutting path. Protect ears from noise. 2.1 Do not inhale fumes.SAFETY WARNING LABEL This warning label is affixed to some power supplies. 2. and body. 7. 3. 3. destroy. Replace if it is missing. point the nozzle away from yourself. hands. 4. 3. Arc starts instantly when triggered. or cover this label. 1. Remove fumes with ventilation. 2. 5.

and use of devices and systems to vent combustion gases and pressures after any deflagration event. and other terms. maintenance. by the publication of any Hypertherm manual.SAFETY Dry dust collection information At some sites. the 2007 edition of NFPA 68 requires the use of explosion vents designed to the worst-case Kst value (see annex F) that could be generated from dust so that the explosion vent size and type can be designed. AHJ. Note 1 – Hypertherm’s interpretation of these new requirements is that unless a site-specific evaluation has been completed to determine that all dust generated is not combustible. Hypertherm does not.” provides requirements for the design. deflagration index. and this manual may never be construed as doing so. state. but it does apply these new requirements to all dry dust collection systems. location. National Fire Protection Association’s 2007 edition of NFPA standard 68. dry dust can represent a potential explosion hazard. and local laws and regulations. installation. NFPA 68 does not specifically identify plasma cutting or other thermal cutting processes as requiring deflagration venting systems. Note 2 – Users of Hypertherm manuals should consult and comply with all applicable federal.S. “Explosion Protection by Deflagration Venting. adopted by reference. Hypertherm 1-11 11/08 . The U. Consult with the manufacturer or installer of any dry dust collection system for applicable requirements before you install a new dry dust collection system or make significant changes in the process or materials used with an existing dry dust collection system. Refer to NFPA68 for definitions and explanations of regulatory terms such as deflagration. Consult your local “Authority Having Jurisdiction” (AHJ) to determine whether any edition of NFPA 68 has been “adopted by reference” in your local building codes. intend to urge action that is not in compliance with all applicable regulations and standards. the Kst value.

................................................................................................................................................................................1a-5 Les rayons de l’arc peuvent brûler les yeux et la peau ..................................................................1a-7 Symboles et marquage .................................................................1a-9 Information sur le dépoussiérage..........................1a-6 Sécurité des bouteilles de gaz comprimé ..........................................................................................................................................................................1a-7 Pacemakers et prothèses auditives ............................................................................................................................................................................................................................................................1a-6 Les bouteilles de gaz comprimé peuvent exploser en cas de dommages .................................................................................................................................................1a-3 Les vapeurs toxiques peuvent provoquer des blessures ou la mort .................................................................................................................................................................................................................................................................1a-5 Mise à la masse et à la terre ..................................................................................1a-2 Les chocs électriques peuvent être fatals...................................................................................................................................................................................1a-11 Hypertherm 1a-1 11/08 ...............................................................................................................................................................................................................................................................................................................................................................................1a-2 Le coupage peut provoquer un incendie ou une explosion ........................................................1a-7 Un arc plasma peut endommager les tuyaux gelés....................................1a-3 L’électricité statique peut endommager les cartes de circuits imprimés ................................................1a-8 Étiquettes de sécurité ......1a-2 Suivre les instructions de sécurité ...1a-6 Le bruit peut provoquer des problèmes auditifs ..................................................................................Section 1a SÉCURITÉ Dans cette section : Identifier les consignes de sécurité .............................................................................................................................................1a-4 L’arc plasma peut provoquer des blessures ou des brûlures ...........................................................

de tuyaux ou autres récipients fermés et pressurisés. Les signaux DANGER ou AVERTISSEMENT sont utilisés avec un symbole de sécurité. entraînent des blessures graves voire mortelles. ou si l’eau touche la partie inférieure de la pièce d’aluminium. • Éloigner toute matière inflammable à une distance d’au moins 10 m du poste de coupage. s’assurer que la zone de coupage ne présente aucun danger. • Les étiquettes de sécurité DANGER et AVERTISSE MENT sont situées sur la machine pour signaler certains dangers spécifiques. • Apprendre à faire fonctionner la machine et à utiliser correctement les commandes. • Aérer toute atmosphère potentiellement inflammable avant d’utiliser un système plasma. Maintenir toute flamme et étincelle à l’écart de la torche lors de l’utilisation d’un plasma d’argon-hydrogène ou de méthane. Conserver un extincteur à proximité. • Les messages de sécurité DANGER précèdent les directives associées dans le manuel qui. LE COUPAGE PEUT PROVOQUER UN INCENDIE OU UNE EXPLOSION Prévention des incendies • Avant de commencer. aux symboles et à la signalisation de sécurité. • Tremper le métal chaud ou le laisser refroidir avant de le manipuler ou avant de le mettre en contact avec des matériaux combustibles. Remplacer immédiatement les étiquettes manquantes ou abîmées. que ce soit dans ce manuel ou sur l’équipement. de l’hydrogène libre peut s’accumuler sous la pièce à couper et détonner lors du coupage plasma. • Installer un collecteur d’aération au fond de la table à eau afin d’éliminer les risques de détonation de l’hydrogène. • Lors de l’utilisation d’oxygène comme gaz plasma. Si vous trouvez un symbole de sécurité. • Ne pas couper de bouteilles. si elles ne sont pas suivies scrupuleusement. soyez conscient des risques de blessures et suivez les instructions correspondantes afin d’éviter ces risques. Ne laisser personne utiliser la machine sans connaître son fonctionnement. Se référer à l’annexe du manuel pour plus de renseignements sur les collecteurs d’aération. • Garder la machine en bon état. • Ne jamais couper des récipients pouvant contenir des matières inflammables avant de les avoir vidés et nettoyés correctement. • Les messages d’AVERTISSEMENT précèdent les instructions d’utilisation expliquées dans ce manuel et signalent les risques de blessures ou de mort au cas où ces instructions ne seraient pas suivies correctement. DANGER AVERTISSEMENT ATTENTION Hypertherm adopte les lignes directrices de l’American National Standards Institute relativement aux termes. 1a-2 11/08 Hypertherm . SUIVRE LES INSTRUCTIONS DE SÉCURITÉ Lire attentivement toutes les consignes de sécurité dans le présent manuel et sur les étiquettes de sécurité se trouvant sur la machine. • Les étiquettes de sécurité doivent rester lisibles. • Les messages de sécurité ATTENTION précèdent les directives associées dans le manuel qui. • Ne pas couper de récipients contenant des matières combustibles. Prévention des explosions • Ne pas couper en présence de poussière ou de vapeurs. AVERTISSEMENT Détonation de l’hydrogène lors du coupage de l’aluminium • Lors du coupage de l’aluminium sous l’eau. peuvent entraîner des blessures secondaires ou endommager l’équipement. Conserver à l’écart de toute flamme les bouteilles et tuyaux contenant des mélanges à base d’hydrogène ou de méthane. un système de ventilation par aspiration est nécessaire. Des modifications non autorisées sur la machine peuvent engendrer des problèmes de sécurité et raccourcir la durée d’utilisation de l’équipement. AVERTISSEMENT Risque d’explosion argon-hydrogène et méthane L’hydrogène et le méthane sont des gaz inflammables et potentiellement explosifs. DANGER correspondant aux risques les plus sérieux. si elles ne sont pas suivies scrupuleusement.SÉCURITÉ IDENTIFIER LES CONSIGNES DE SÉCURITÉ Les symboles indiqués dans cette section sont utilisés pour identifier les risques éventuels.

La pièce à couper et tout autre élément en contact avec cette pièce font partie du circuit électrique. ni fendu. • Ne pas saisir la pièce à couper ni les chutes lors du coupage. • La mise en fonctionnement du système plasma ferme un circuit électrique entre la torche et la pièce à couper. S’il s’avère nécessaire de travailler dans ou près d’un endroit humide. Ne pas utiliser des torches inappropriées qui pourraient surchauffer et présenter des risques pour la sécurité. Les raccords exposés de la source de courant sont extrêmement dangereux. couper l’alimentation électrique.SÉCURITÉ LES CHOCS ÉLECTRIQUES PEUVENT ÊTRE FATALS Toucher une pièce électrique sous tension peut provoquer un choc électrique fatal ou des brûlures graves. couper l’alimentation ou débrancher la prise de courant. • Lors de l’installation des connexions. • Ne jamais contourner ou court-circuiter les verrouillages de sécurité. • Installer et mettre à la terre l’équipement selon les instructions du présent manuel et conformément aux codes électriques locaux et nationaux. de nettoyer ou de remplacer les pièces de la torche. • On doit ranger les cartes de circuits imprimés dans des contenants antistatiques. la pièce à couper ou l’eau de la table à eau pendant le fonctionnement du système plasma. • Ne pas se tenir. procéder avec une extrême prudence. Attendre ensuite 5 minutes pour que les condensateurs se déchargent. • Ne jamais faire fonctionner le système plasma sans que les capots de la source de courant ne soient en place. Prévention des chocs électriques Tous les systèmes plasma Hypertherm utilisent des hautes tensions pour le coupage (souvent de 200 à 400 V). Un câble dénudé peut tuer. Remplacer immédiatement un cordon endommagé. • Chaque système plasma Hypertherm est conçu pour être utilisé uniquement avec des torches Hypertherm spécifiques. • On doit porter un bracelet antistatique quand on manipule les cartes de circuits imprimés. • Inspecter fréquemment le cordon d’alimentation primaire pour s’assurer qu’il n’est ni endommagé. • Installer un sectionneur avec fusibles appropriés. attacher tout d’abord la prise de terre appropriée. • Avant d’enlever le capot du système ou de la source de courant. On doit prendre les précautions suivantes quand on utilise le système plasma : • Porter des bottes et des gants isolants et garder le corps et les vêtements au sec. le câble de retour connecté lors du coupage. à proximité de la source de courant. Ce dispositif permet à l’opérateur d’arrêter rapidement la source de courant en cas d’urgence. • Ne jamais toucher le corps de la torche. Laisser la pièce à couper en place ou sur la table de travail. • S’isoler de la surface de travail et du sol en utilisant des tapis isolants secs ou des couvertures assez grandes pour éviter tout contact physique avec le travail ou le sol. L’ÉLECTRICITÉ STATIQUE PEUT ENDOMMAGER LES CARTES DE CIRCUITS IMPRIMÉS On doit prendre les précautions qui s’imposent quand on manipule les circuits imprimés. s’assurer que cette dernière est correctement mise à la terre. s’asseoir ou se coucher sur une surface mouillée. • En cas d’utilisation d’une table à eau. • Avant de vérifier. Hypertherm 1a-3 11/08 . • Inspecter et remplacer les câbles de la torche qui sont usés ou endommagés. ni la toucher quand on utilise le système plasma.

sous l’eau). • Autres procédés du site qui peuvent produire des vapeurs. le plomb (dans certaines peintures). ventilation et filtration de la zone de travail. les oxydes d’azote. volume d’air. le cadmium (dans certaines peintures et enduits) et le béryllium. fini de la surface et composition des revêtements. entre autres. le zinc (galvanisé) et le cuivre. Le niveau de qualité de l’air dans tout lieu de travail dépend des variables propres au site comme : • Type de table (humide. Il incombe au propriétaire du matériel et du site de vérifier la qualité de l’air dans le secteur où l’on utilise le matériel et de s’assurer que la qualité de l’air sur les lieux de travail répond aux normes et réglementation locales et nationales. seuls les contrôles ou les essais effectués au site peuvent déterminer si celui-ci se situe au-dessus ou au-dessous des niveaux admissibles. Dans certains cas. l’acier au carbone. • Ne jamais couper les contenants dans lesquels il peut y avoir des matériaux toxiques. En premier lieu. • Durée du coupage ou du gougeage. comme des malformations ou le cancer. Les métaux qui peuvent dégager des vapeurs toxiques comprennent. sèche. • Nombre de systèmes de soudage et de coupage en fonctionnement. Porter un respirateur à adduction d’air quand on coupe des métaux revêtus d’éléments toxiques ou qui en contiennent ou sont susceptibles d’en contenir. • Équipement de protection individuelle. • Contrôler ou éprouver la qualité de l’air au site selon les besoins. Selon la composition chimique et la concentration des vapeurs (ainsi que d’autres facteurs comme la ventilation). Pour réduire le risque d’exposition aux vapeurs : • Éliminer tout revêtement et solvant du métal avant le coupage. vider et nettoyer correctement le contenant. • Utiliser la ventilation d’extraction locale pour éliminer les vapeurs de l’air. le métal peut être revêtu d’une substance susceptible de dégager des vapeurs toxiques. • Volume de matériau enlevé. Les revêtements toxiques comprennent entre autres. • Dimensions. • Ne pas inhaler les vapeurs. • Consulter un expert local pour mettre en œuvre un plan du site afin d’assurer une qualité de l’air sûre. On doit prendre les précautions qui s’imposent pour réduire au minimum l’exposition aux vapeurs produites par tout processus industriel. • Composition du matériau. Si les lieux de travail doivent être conformes aux règlements nationaux ou locaux. 1a-4 11/08 Hypertherm .SÉCURITÉ LES VAPEURS TOXIQUES PEUVENT PROVOQUER DES BLESSURES OU LA MORT L’arc plasma est lui-même la source de chaleur utilisée pour le coupage. Par conséquent. mais ils peuvent comprendre l’ozone. le matériau coupé peut être une source de vapeurs ou de gaz toxiques qui épuisent l’oxygène. le chrome hexavalent. il peut y avoir un risque de maladie physique. Les gaz produits par le coupage plasma varient selon le matériau à couper et la méthode de coupage. l’hydrogène et autres substances présentes dans le matériau coupé ou en émanent. Les vapeurs produites varient selon le métal coupé. • S’assurer que les personnes qui utilisent un matériel de soudage ou de coupage ainsi que les dispositifs de respiration par adduction d’air sont qualifiés et ont reçu la formation sur la bonne utilisation d’un tel matériel. l’acier inoxydable. bien que l’arc plasma n’ait pas été reconnu comme une source de vapeurs toxiques.

• Avant le coupage. Protection de la peau Porter des vêtements de sécurité pour se protéger contre les brûlures que peuvent causer les rayons ultraviolets. • Rester éloigné de l’extrémité de la torche. retirer de ses poches tout objet combustible comme les briquets au butane ou les allumettes. Indice de protection minimum (ANSI Z49. • Ne pas tenir de métal près de la trajectoire de coupe. • Pantalon sans revers pour éviter que des étincelles ou des scories puissent s’y loger. Utiliser des affiches ou des panneaux. • Vêtements ignifuges couvrant toutes les parties exposées du corps.SÉCURITÉ L’ARC PLASMA PEUT PROVOQUER DES BLESSURES OU DES BRÛLURES Torches à allumage instantané L’arc plasma s’allume immédiatement après que la torche soit mise en marche. • Prévenir les autres personnes de ne pas regarder l’arc. • Utiliser des lunettes de sécurité conformément aux codes locaux ou nationaux en vigueur. Zone de coupage Préparer la zone de coupage afin de réduire la réverbération et la transmission de la lumière ultraviolette : • Peindre les murs et autres surfaces de couleur sombre pour réduire la réflexion de la lumière. chaussures et casque de sécurité. • Porter des lunettes de protection (lunettes ou masque muni d’écrans latéraux et encore masque de soudure) avec des verres teintés appropriés pour protéger les yeux des rayons ultraviolets et infrarouges de l’arc. LES RAYONS DE L’ARC PEUVENT BRÛLER LES YEUX ET LA PEAU Protection des yeux Les rayons de l’arc plasma produisent de puissants rayons visibles ou invisibles (ultraviolets et infrarouges) qui peuvent brûler les yeux et la peau. • Ne jamais pointer la torche vers soi ou d’autres personnes. les étincelles et le métal brûlant : • Gants à crispin. L’arc plasma coupe facilement les gants et la peau.1:2005) 5 6 8 8 8 8 8 8 9 10 Indice de protection suggéré pour assurer le confort (ANSI Z49.1:2005) 5 6 8 9 9 9 9 9 12 14 Courant de l’arc (A) Moins de 40 A 41 à 60 A 61 à 80 A 81 à 125 A 126 à 150 A 151 à 175 A 176 à 250 A 251 à 300 A 301 à 400 A 401 à 800 A OSHA 29CFR 1910. • Utiliser des écrans et autres dispositifs de protection afin de protéger les autres personnes de la lumière et de la réverbération.133(a)(5) 8 8 8 8 8 8 Europe EN168:2002 9 9 9 9 10 11 12 13 13 8 8 9 10 Hypertherm 1a-5 11/08 .

• Étiqueter et coder avec des couleurs tous les tuyaux de gaz afin d’identifier le type de gaz contenu dans chaque tuyau. • Ne jamais exposer des bouteilles à une chaleur excessive. • Utiliser uniquement les bouteilles. tuyaux et accessoires appropriés et conçus pour chaque application spécifique. Ne pas fixer le câble de retour à la partie de la pièce qui doit se détacher. des clés ou d’autres outils pour débloquer le robinet des bouteilles. aux scories ou aux flammes nues. • Placer tout d’abord le fil de terre du cordon d’alimentation sur le plot de mise à la terre puis placer les autres fils de terre par-dessus. • S’il est nécessaire de brancher le cordon d’alimentation à la source de courant lors de l’installation du système. Si une bouteille est endommagée. Table de travail Raccorder la table de travail à la terre. • Entretenir l’équipement et les pièces d’équipement à gaz comprimé afin de les garder en bon état. SÉCURITÉ DES BOUTEILLES DE GAZ COMPRIMÉ • Ne jamais lubrifier les robinets des bouteilles ou les régulateurs avec de l’huile ou de la graisse. • Éviter à tout prix le contact électrique entre l’arc plasma et une bouteille. • S’assurer que toutes les connexions sont bien serrées pour éviter la surchauffe. • Manipuler et utiliser les bouteilles de gaz comprimé conformément aux codes locaux ou nationaux. LES BOUTEILLES DE GAZ COMPRIMÉ PEUVENT EXPLOSER EN CAS DE DOMMAGES Les bouteilles de gaz contiennent du gaz à haute pression. régulateurs. • Ne jamais utiliser une bouteille qui n’est pas placée à la verticale et bien assujettie. Bien serrer l’écrou de retenue. conformément aux codes de sécurité locaux ou nationaux appropriés. aux étincelles. • Ne jamais utiliser des marteaux.SÉCURITÉ MISE À LA MASSE ET À LA TERRE Câble de retour Bien fixer le câble de retour (ou de masse) à la pièce à couper ou à la table de travail de façon à assurer un bon contact métal-métal. s’assurer que le fil de terre est correctement branché. 1a-6 11/08 Hypertherm . Se référer aux codes locaux ou nationaux en vigueur. Alimentation • S’assurer que le fil de terre du cordon d’alimentation est connecté à la terre dans le coffret du sectionneur. elle peut exploser. • Le capuchon de protection doit être placé sur le robinet sauf si la bouteille est en cours d’utilisation ou connectée pour utilisation.

• Faire passer le faisceau de la torche le plus près possible du câble de retour. Les personnes portant ce type d’appareil doivent consulter un médecin avant de s’approcher d’un lieu où s’effectue le coupage ou le gougeage plasma. • Garder loin de soi et du même côté du corps le câble de retour et le faisceau de la torche. PACEMAKERS ET PROTHÈSES AUDITIVES Les champs magnétiques produits par les courants à haute tension peuvent affecter le fonctionnement des prothèses auditives et des pacemakers.SÉCURITÉ LE BRUIT PEUT PROVOQUER DES PROBLÈMES AUDITIFS Une exposition prolongée au bruit du coupage ou du gougeage peut provoquer des problèmes auditifs. Hypertherm 1a-7 11/08 . • Se tenir le plus loin possible de la source de courant. • Prévenir les personnes aux alentours des risques encourus en cas d’exposition au bruit. • Ne pas s’enrouler le faisceau de la torche ou le câble de retour autour du corps. Pour réduire les risques associés aux champs magnétiques : UN ARC PLASMA PEUT ENDOMMAGER LES TUYAUX GELÉS Les tuyaux gelés peuvent être endommagés ou éclater si l'on essaie de les dégeler avec une torche plasma. • Utiliser un casque de protection homologué lors de l’utilisation du système plasma.

1a-8 11/08 Hypertherm . Marque CSA Les produits Hypertherm comportant la marque CSA répondent aux règlements des États-Unis et du Canada relatifs à la sécurité du produit. Les produits sont évalués. Seules les versions des produits Hypertherm portant la marque CE placée sur la plaque signalétique ou à proximité ont été mises à l’essai de conformité à la directive européenne sur la basse tension et la compatibilité électromagnétique européenne (CEM). mis à l’essai et certifiés par la CSA-International. Marque CE La marque CE signifie la déclaration de conformité du fabricant aux directives et normes européennes applicables. Symbole marque S Le symbole de marque S indique que la source de courant et la torche conviennent pour les travaux effectués dans les milieux à risque accru de choc électrique selon l’IEC 60974-1. Les filtres CEM qui doivent se conformer à la directive CEM européenne sont intégrés aux versions du produit portant la marque CE. Marque GOST-R Les versions CE des produits Hypertherm qui portent la marque de conformité GOST-R répondent aux exigences de sécurité du produit et de CEM en vue de l’exportation à la Fédération russe. le produit peut porter une marque d’un des laboratoires d’essai reconnus sur le plan national (NRTL) accrédité aux États-Unis et au Canada comme les Underwriters Laboratories. Marque c-Tick Les versions CE des produits Hypertherm portant la marque c-Tick sont conformes aux règlements CEM prescrits pour la vente en Australie et en Nouvelle-Zélande.SÉCURITÉ SYMBOLES ET MARQUAGE Votre produit Hypertherm peut comporter une ou plusieurs des marques suivantes sur sa plaque signalétique ou à proximité. Incorporated (UL) ou TÜV. toutes les marques ne sont pas appliquées à chaque version d’un produit. En raison des différends et des conflits relatifs aux règlements nationaux. Marque CCC La marque de certification obligatoire en Chine (CCC) indique que le produit a été mis à l’essai et déclaré conforme aux règlements de sécurité du produit prescrits pour la vente en Chine. En outre.

Le personnel non qualifié et les enfants doivent se tenir à l’écart. Use welding helmet with the correct shade of filter. Plasma fumes can be hazardous.1 Porter un bon équipement de protection pour se protéger la tête.1 Do not cut near flammables. 4.3 Disconnect power before servicing. Hypertherm 1a-9 11/08 .1 Couper l’alimentation avant de démonter la torche. 7. les mains et le corps.3 Se protéger entièrement le corps. Do not remove.1 Porter des gants isolants. destroy. 5.1 Do not inhale fumes. 1. Button shirt collar. Les étincelles de coupage peuvent provoquer une explosion ou un incendie. employer safety practices. Remplacer les gants quand ils sont humides ou endommagés. 7. Plasma arc can injure and burn. AVERTISSEMENT Le coupage plasma peut être préjudiciable pour l’opérateur et les personnes qui se trouvent sur les lieux de travail. Boutonner le col de la chemise. détruire ni couvrir cette étiquette.2 Protect from shock by insulating yourself from work and ground. “Safety in Welding. Ne pas toucher les pièces sous tension.2 Se protéger contre les chocs en s’isolant de la pièce et de la terre. 4. 2.gov). 2. 3. 6. 1. 1. Replace if it is missing. Keep non-qualified personnel and children away.1 Wear correct and appropriate protective equipment to protect head. Seul le personnel qualifié a le droit de faire fonctionner cet équipement. les yeux. 2.2 Ne pas saisir la pièce à couper de la trajectoire de coupage. Consulter le manuel avant de faire fonctionner. 3. Il s’allume instantanément quand on l’amorce. point the nozzle away from yourself. and material safety data sheets. Refer to ANS Z49.3 Ne pas couper dans des espaces clos. 2. Hazardous voltage. 1. Le non respect des ces instructions de sécurité peut entraîner la mort. 4. Cutting sparks can cause explosion or fire. Read and follow these instructions. éloigner la buse de soi. 3.2 Have a fire extinguisher nearby and ready to use.1 Turn off power before disassembling torch. 5. 3. Utiliser un masque de soudeur avec un filtre de nuance appropriée.3 Do not use a drum or other closed container as a cutting table. Ne pas enlever. 4. 2. and body. Failure to follow all these safety instructions can result in death. Remove fumes with ventilation.3 Ne pas utiliser un fût ou un autre contenant fermé comme table de coupage.3 Couper l’alimentation avant l’entretien. Replace gloves when wet or damaged. Become trained. Les fumées plasma peuvent être dangereuses.osha. Arc rays can burn eyes and injure skin. endommagée ou usée (PN 110584 Rev C). 3. La remplacer si elle est absente. 3. Use torches specified in the manual. Only qualified personnel should operate this equipment. 2. Risque de choc électrique ou de brûlure. 4. ears.3 Do not operate in closed spaces. les oreilles. Arc starts instantly when triggered. 5. Consult manual before operating. eyes. 2. damaged. 1. Utiliser exclusivement les torches indiquées dans le manual. 6. or worn (PN 110584 Rev C). hands. 4. 1. 2. Tension dangereuse.SÉCURITÉ ÉTIQUETTE DE SÉCURITÉ Cette étiquette est affichée sur la source de courant.1 Ne pas couper près des matières inflammables. Cutting and Allied Processes” from American Welding Society (http://www. Les rayons d’arc peuvent brûler les yeux et blesser la peau.1 Wear insulating gloves. Risk of electric shock or burn. 3.org) and OSHA Safety and Health Standards. 1. Protéger les oreilles contre le bruit.2 Un extincteur doit être à proximité et prêt à être utilisé. Do not touch live parts. L’arc plasma peut blesser et brûler. Suivre une formation. or cover this label.1 Ne pas inhaler les fumées 4. 29 CFR 1910 (http://www. Il est important que l’utilisateur et le technicien de maintenance comprennent la signification des symboles de sécurité. 3. 4.2 Utiliser une ventilation forcée ou un extracteur local pour dissiper les fumées.3 Wear complete body protection.1. 1. Chasser les fumées par ventilation.2 Do not grip the workpiece near the cutting path. Protect ears from noise.aws.2 Use forced ventilation or local exhaust to remove the fumes. WARNING Plasma cutting can be injurious to operator and persons in the work area. 5.

les yeux.1 Porter des gants isolants. 5. Il s’allume instantanément quand on l’amorce.3 Ne pas utiliser un fût ou un autre contenant fermé comme table de coupage.1 Couper l’alimentation avant de démonter la torche. détruire ni couvrir cette étiquette. Tension dangereuse. Risque de choc électrique ou de brûlure.2 Un extincteur doit être à proximité et prêt à être utilisé. 2.SÉCURITÉ ÉTIQUETTE DE SÉCURITÉ Cette étiquette est affichée sur la source de courant. Les rayons d’arc peuvent brûler les yeux et blesser la peau. 1. Les numéros de la liste correspondent aux numéros des images. 3.3 Ne pas couper dans des espaces clos.2 Ne pas saisir la pièce à couper de la trajectoire de coupage.3 Se protéger entièrement le corps.1 Ne pas inhaler les fumées. Protéger les oreilles contre le bruit.2 Utiliser une ventilation forcée ou un extracteur local pour dissiper les fumées. Boutonner le col de la chemise. Remplacer les gants quand ils sont humides ou endommagés. Ne pas toucher les pièces sous tension 4. 5. Le personnel non qualifié et les enfants doivent se tenir à l’écart. 4. 1. Les fumées plasma peuvent être dangereuses. Il est important que l’utilisateur et le technicien de maintenance comprennent la signification des symboles de sécurité. Ne pas enlever. Utiliser un masque de soudeur avec un filtre de nuance appropriée. L’arc plasma peut blesser et brûler.2 Se protéger contre les chocs en s’isolant de la pièce et de la terre. 3. les oreilles. 7. les mains et le corps. 2. Seul le personnel qualifié a le droit de faire fonctionner cet équipement. Les étincelles de coupage peuvent provoquer une explosion ou un incendie. 2. 1a-10 11/08 Hypertherm . Chasser les fumées par ventilation. 4. Utiliser exclusivement les torches indiquées dans le manual. 3. 3. Suivre une formation. 1. 2. éloigner la buse de soi. La remplacer si elle est absente.1 Porter un bon équipement de protection pour se protéger la tête. 4.1 Ne pas couper près des matières inflammables. 1. 6. endommagée ou usée (PN 110584 Rev C).3 Couper l’alimentation avant l’entretien.

valeur du pire cas. sauf évaluation particulière du site. à l’emplacement. de demander des mesures qui ne sont pas conformes aux règlements et normes applicables et ce manuel ne peut jamais être interprété dans ce sens. Hypertherm n’a pas l’intention. en publiant un manuel d’Hypertherm. la poussière peut représenter un risque d’explosion potentiel. Consultez l’autorité compétente locale pour déterminer si une édition de la NFPA 68 a été adoptée par référence dans vos codes du bâtiment locaux. Hypertherm 1a-11 11/08 .À certains endroits. autorité compétente. La norme NFPA 68 de la National Fire Protection Association des É. à l’installation. à l’entretien et à l’utilisation de dispositifs et de systèmes pour évacuer à l’air libre les gaz de combustion et les pressions après une éventuelle déflagration. l’édition 2007 de la NFPA 68 exige l’utilisation d’évents d’explosion conçus pour la valeur du pire des cas (voir annexe F) qui pourrait provenir de la poussière de sorte que l’on puisse concevoir la dimension et le type d’évent d’explosion. la poussière peut représenter un risque d’explosion potentiel. Communiquer avec le fabricant ou avec l’installateur pour tout système de dépoussiérage afin de connaître les exigences applicables avant d’installer un tel système neuf ou d’apporter des modifications importantes aux procédés ou aux matériaux utilisés à un système de dépoussiérage existant. indice de déflagration » et autres termes. La NFPA 68 ne stipule pas particulièrement le procédé de coupage plasma particulier ou autres procédés de coupage thermique comme le prescrivent ces nouveaux règlements à tous les systèmes de dépoussiérage. (édition 2007) « Explosion Protection by Deflagration Venting » établit les exigences relatives à la conception. adopté par référence. pour déterminer que toute la poussière produite n’est pas combustible. Voir le document NFPA68 pour obtenir des définitions et des explications des termes réglementaires tels que « déflagration. Note 1 – L’interprétation d’Hypertherm de ces nouvelles exigences est que.-U.SÉCURITÉ Information sur le dépoussiérage À certains endroits. Note 2 – Les utilisateurs des manuels d’Hypertherm doivent consulter tous les règlements et lois fédéraux et locaux applicables et s’y conformer.

..................1b-2 El choque eléctrico puede provocar la muerte ...................................................................................................................................................................1b-2 Siga las instrucciones de seguridad .....1b-9 Información sobre la colección de polvo seco ................................................1b-2 Los cortes pueden provocar incendios o explosiones.............................................................................................................................................................................................................................................................................................................1b-4 El arco de plasma puede causar lesiones y quemaduras ...............................................1b-7 Un arco plasma puede dañar tubos congelados................................................................................................Seccíon 1b SEGURIDAD En esta sección: Reconocimiento de información de seguridad ....................................................................................................................................................1b-6 Seguridad de los equipos de gas comprimido ...............................1b-6 Los cilindros de gas pueden explotar si están dañados.........................................................................................................1b-11 Hypertherm 1b-1 11/08 ................................................................................................................................................................................................................................................1b-3 Humos tóxicos pueden causar lesiones o muerte ...................................................1b-5 Los rayos del arco pueden producir quemaduras en los ojos y en la piel .................................................................1b-3 Electricidad estática puede dañar tablillas de circuito.................................................1b-7 Operación de marcapasos y de audífonos .........................................................................................................1b-7 Símbolos y marcas ...............................................................................................................................................................................................1b-5 Seguridad de toma a tierra ...................................................................................1b-8 Etiquetas de advertencia......................................................................................1b-6 El ruido puede deteriorar la audición........................................................................................................................................................................................................................................................................................................................................................................................................................

PELIGRO ADVERTENCIA PRECAUCIÓN Hypertherm usa las directivas del Instituto Americano de Normas Nacionales (American National Standards Institute) para las palabras y símbolos que señalan seguridad. asegúrese de ventilar bien. Cuando vea un símbolo de seguridad en este manual o en su máquina. si no se siguen correctamente. LOS CORTES PUEDEN PROVOCAR INCENDIOS O EXPLOSIONES Prevención ante el fuego • Asegúrese de que el área sea segura antes de proceder a cortar. • Instale un múltiple de aireación en el fondo de la mesa de agua para eliminar la posibilidad de la detonación del hidrógeno. • Los mensajes de seguridad de CUIDADO o PRECAUCIÓN preceden mensajes relacionados con instrucciones en el manual que puede resultar en lesiones menores. ADVERTENCIA Peligro de explosión Argón-Hidrógeno y metano El hidrógeno y el metano son gases inflamables que suponen un peligro de explosión. colocándolos a por lo menos 10 metros del área de corte. • Encontrará etiquetas de seguridad con las inscripciones PELIGRO y ADVERTENCIA en su máquina. • Al realizar cortes utilizando oxígeno como gas plasma. SIGA LAS INSTRUCCIONES DE SEGURIDAD Lea atentamente todos los mensajes de seguridad de este manual y las etiquetas de seguridad en su máquina. Reemplace las etiquetas que se pierdan o se dañen inmediatamente. 1b-2 11/08 Hypertherm . Mantenga el fuego lejos de los cilindros y las mangueras que contengan mezclas de hidrógeno o metano. • No corte depósitos que hayan contenido materiales combustibles. • Mantenga su máquina en buenas condiciones de funcionamiento.SEGURIDAD RECONOCIMIENTO DE INFORMACIÓN DE SEGURIDAD Los símbolos que se muestran en esta sección se utilizan para identificar los posibles peligros. si no se siguen correctamente. o daño a equipo. • En este manual. • Nunca corte depósitos que contengan materiales inflamables – primero es necesario vaciarlos y limpiarlos debidamente. Las palabras PELIGRO y ADVERTENCIA se utilizan conjuntamente con un símbolo de seguridad. La palabra PELIGRO se utiliza para identificar los mayores peligros. recuerde que existe la posibilidad de que se produzcan lesiones personales y siga las instrucciones correspondientes para evitar el peligro. No permita que sea utilizada por alguien que no conozca su funcionamiento. • No corte depósitos o tubos a presión ni cualquier depósito cerrado. se requiere tener un sistema de ventilación de escape. junto a peligros específicos. • Los mensajes de seguridad de PELIGRO preceden instrucciones relacionadas en el manual que resultarán en lesión grave o muerte si no se las sigue correctamente. Tenga a mano un extinguidor de incendios. Consulte la sección del apéndice de este manual para conocer detalles acerca del múltiple de aireación. • Antes de realizar cortes en atmósferas potencialmente inflamables. • Retire todos los materiales inflamables. puede acumularse gas hidrógeno bajo la pieza a cortar y detonar durante la operación de corte por plasma. ADVERTENCIA Detonación de hidrógeno con el corte de aluminio • Al cortar aluminio bajo agua o con agua en contacto con el lado inferior del aluminio. • Remoje los metales calientes o permita que se enfríen antes de que entren en contacto con materiales combustibles. pueden provocar lesiones e inclusive la muerte. la palabra ADVERTENCIA va seguida de instrucciones que. La realización de modificaciones no autorizadas a la máquina puede comprometer la seguridad y la vida útil de la máquina. Mantenga la llama y las chispas lejos de la antorcha al utilizar metano o argón-hidrógeno como plasma. • Mantenga las etiquetas de seguridad de su máquina en buen estado. Prevención ante explosiones • No corte en atmósferas que contengan polvo o vapores explosivos. • Aprenda a utilizar la máquina y a utilizar los controles de la manera correcta.

• Inspeccione el cordón de alimentación primaria con frecuencia para asegurarse de que no esté dañado ni agrietado. limpiar o cambiar las piezas de la antorcha. • Al utilizar una mesa de agua. • Instale este equipo y conéctelo a tierra según el manual de instrucciones y de conformidad con los códigos locales y nacionales. • Instale un interruptor de corriente adecuado en cuanto a fusibles. Tome las siguientes precauciones cuando se utiliza el equipo de plasma: • Use guantes y botas aislantes y mantenga el cuerpo y la ropa secos. • Al hacer conexiones de entrada. • Use la defensa de muñeca conectada a tierra cuando maneje tablillas PC. Si el cordón de alimentación primaria está dañado. • Cada sistema de plasma Hypertherm está diseñado para ser utilizado sólo con antorchas Hypertherm específicas. Las conexiones expuestas de la fuente de energía presentan un serio riesgo eléctrico. • Inspeccione las mangueras de la antorcha y reemplácelas cuando se encuentren dañadas. desconecte la potencia primaria o desenchufe la fuente de energía. sea muy cauteloso. asegúrese de que ésta se encuentre correctamente conectada a la toma a tierra. en una pared cercana a la fuente de energía. ELECTRICIDAD ESTÁTICA PUEDE DAÑAR TABLILLAS DE CIRCUITO Use precauciones adecuadas cuando maneje tablillas impresas de circuito • Almacene las tablillas PC en recipientes antiestáticos. Si su única opción es trabajar en una área húmeda o cerca de ella. • Antes de retirar la cubierta de una fuente de energía o del gabinete de un sistema. Espere 5 minutos después de desconectar la potencia primaria para permitir la descarga de los condensadores. La pieza a cortar es una parte del circuito eléctrico. Este interruptor permitirá al operador desconectar rápidamente la fuente de energía en caso de emergencia. • Aíslese eléctricamente de la pieza a cortar y de la tierra utilizando alfombrillas o cubiertas de aislamiento secas lo suficientemente grandes como para impedir todo contacto físico con la pieza a cortar o con la tierra. No utilice antorchas diferentes. • Nunca toque el cuerpo de la antorcha. se pare o se ponga sobre cualquier superficie húmeda cuando esté trabajando con el equipo. desconecte la potencia primaria de entrada. • Nunca evite o descuide los bloqueos de seguridad. • Nunca opere el sistema de plasma sin que las tapas de la fuente de energía estén en su lugar. reemplácelo inmediatamente. la pieza a cortar o el agua en una mesa de agua cuando el sistema de plasma se encuentre en funcionamiento.SEGURIDAD EL CHOQUE ELÉCTRICO PUEDE PROVOCAR LA MUERTE El contacto directo con piezas eléctricas conectadas puede provocar un electrochoque fatal o quemaduras graves. conecte el conductor de conexión a tierra en primer lugar. Deje la pieza en su lugar o sobre la mesa de trabajo con el cable de trabajo conectado en todo momento. • Al hacer funcionar el sistema de plasma. • Antes de inspeccionar. • No toque la pieza ni los recortes cuando se está cortando. que podrían recalentarse y ser peligrosas. Un cable pelado puede provocar la muerte. como también cualquier cosa que se encuentre en contacto con ella. • No se siente. Prevención ante el electrochoque Todos los sistemas por plasma de Hypertherm usan alto voltaje en el proceso de corte (son comunes los voltajes CD de 200 a 400). Hypertherm 1b-3 11/08 . se completa un circuito eléctrico entre la antorcha y la pieza a cortar.

bajo agua). • Tamaño. tal como defectos de natividad o cáncer. • Garantice que aquéllos usando equipo de soldar o cortar. • No inhale el humo. acero inoxidable. • Volumen que se quita del material. plomo (en algunas pinturas). estén capacitados y entrenados en el uso apropiado de tal equipo. Es la responsabilidad del dueño del equipo y instalación el comprobar la calidad de aire en el lugar donde se está usando el equipo para garantizar que la calidad del aire en el lugar de trabajo cumpla con todas las normas y reglamentos locales y nacionales. volumen del aire. tales como ventilación). o sospechado de contener. • Otros procesos del lugar que pueden producir humo. puede haber el riesgo de enfermedad física. El nivel de la calidad del aire en cualquier lugar de trabajo relevante depende en variables específicas al sitio tales como: • Diseño de mesa (mojada. Según esto. • La composición del material. y cobre. Si el lugar de trabajo debe cumplir reglamentos nacionales o locales. Use un respirador con fuente propia de aire cuando corte cualquier metal recubierto con. Se debe tener cuidado de minimizar la exposición del humo producido por cualquier proceso industrial. Según la composición química y la concentración del humo (al igual que otros factores. seca. • Número de sistemas de soldar y cortar en la operación. vacíe y limpie el recipiente adecuadamente. pero pueden incluir ozono. Los gases producidos por el corte por plasma varían basándose en el material a cortarse y el método de cortar. • La duración del corte o ranura. ventilación y filtración del lugar de trabajo. hidrógeno. elementos tóxicos. En algunos casos.SEGURIDAD HUMOS TÓXICOS PUEDEN CAUSAR LESIONES O MUERTE El arco plasma es por si solo la fuente de calor que se usa para cortar. • Equipo de protección personal. pero no están limitados a. el acabado de la superficie. al igual que aparatos de respiración con aire propio de aire. 1b-4 11/08 Hypertherm . si están contenidas dentro o liberadas por el material que se corta. cadmio (en algunas pinturas y rellenos). Metales que pueden liberar humo tóxico incluyen. aunque el arco de plasma no ha sido identificado como la fuente de humo tóxico. • Monitoree o compruebe la calidad del aire en el sitio como fuera necesario. acero al carbón. y berilio. pero no están limitados a. • Consulte con un experto local para realizar un plan al sitio para garantizar la calidad de aire seguro. solamente el monitoreo o las pruebas que se hacen en el lugar pueden determinar si el sitio está encima o debajo de los niveles permitidos. el material que se corta puede ser la fuente de humo o gases tóxicos que vacían el oxígeno. Los recubrimientos tóxicos incluyen. • Use ventilación extractora local para quitar humo del aire. y la composición de los recubrimientos. cromo hexavalente. óxidos de nitrógeno. El humo producido varía según el metal que está cortándose. cinc (galvanizado). Para reducir el riesgo de exposición a humo: • Quite todos los recubrimientos y solventes del metal antes de cortar. • Nunca corte recipientes con materiales potencialmente tóxicos adentro. Primero. el metal puede estar recubierto con una sustancia que podría liberar humos tóxicos. y otras substancias.

133(a)(5) 8 8 8 8 8 8 Europa EN168:2002 9 9 9 9 10 11 12 13 13 8 8 9 10 Hypertherm 1b-5 11/08 . Protección para la piel Vista ropa de protección para proteger la piel contra quemaduras causadas por la radiación ultravioleta de alta intensidad. como encendedores a butano e inclusive cerillas. Área de corte Prepare el área de corte para reducir la reflexión y la transmisión de la luz ultravioleta: • Pinte las paredes y demás superficies con colores oscuros para reducir la reflexión. antes de comenzar a cortar. • Retire todo material combustible de los bolsillos. • Nunca apunte la antorcha hacia Ud. LOS RAYOS DEL ARCO PUEDEN PRODUCIR QUEMADURAS EN LOS OJOS Y EN LA PIEL Protección para los ojos Los rayos del arco de plasma producen rayos intensos visibles e invisibles (ultravioleta e infrarrojo) que pueden quemar los ojos y la piel. • Roipa de combustión retardada y que cubra todas las partes expuestas.1:2005) 5 6 8 8 8 8 8 8 9 10 El número de matiz sugerido para comodidad (ANSI Z49. El arco de plasma puede cortar a través de guantes y de la piel con rapidez. • Utilice protección para los ojos de conformidad con los códigos locales o nacionales aplicables.1:2005) 5 6 8 9 9 9 9 9 12 14 Corriente de arco (amps. Utilice carteles o letreros. • Utilice pantallas o barreras protectoras para proteger a los demás de los destellos. • No sostenga el metal junto al trayecto de corte. mismo o hacia otras personas. • Advierta a los demás que no debe mirarse el arco. • Colóquese protectores para los ojos (gafas o anteojos protectores con protectores laterales. y bien un casco de soldar) con lentes con sombreado adecuado para proteger sus ojos de los rayos ultravioleta e infrarrojos del arco.SEGURIDAD EL ARCO DE PLASMA PUEDE CAUSAR LESIONES Y QUEMADURAS Antorchas de encendido instantáneo El arco de plasma se enciende inmediatamente después de activarse el interruptor de la antorcha. zapatos de seguridad y gorro. • Manténgase alejado de la punta de la antorcha. • Pantalones sin dobladillos para impedir que recojan chispas y escorias. El número de matiz protector mínimo (ANSI Z49. por las chispas y por el metal caliente: • Guantes largos.) Menos de 40 A 41 a 60 A 61 a 80 A 81 a 125 A 126 a 150 A 151 a 175 A 176 a 250 A 251 a 300 A 301 a 400 A 401 a 800 A OSHA 29CFR 1910.

de conformidad con los códigos eléctricos nacionales o locales apropiados. • Coloque etiquetas y códigos de color en todas las mangueras de gas para identificar el tipo de gas que conduce cada una. • Si la instalación del sistema de plasma supone la conexión del cordón de alimentación primaria a la fuente de energía.SEGURIDAD SEGURIDAD DE TOMA A TIERRA Cable de trabajo La pinza del cable de trabajo debe estar bien sujetada a la pieza y hacer un buen contacto de metal a metal con ella o bien con la mesa de trabajo. Mesa de trabajo Conecte la mesa de trabajo a una buena toma de tierra. mangueras y conectores de gas correctos que hayan sido diseñados para la aplicación específica. • Asegúrese de que todas las conexiones eléctricas están firmemente realizadas para evitar sobrecalentamientos. excepto cuando el cilindro se encuentre en uso o conectado para ser utilizado. reguladores. SEGURIDAD DE LOS EQUIPOS DE GAS COMPRIMIDO • Nunca lubrique reguladores o válvulas de cilindros con aceite o grasa. No conecte el cable con la parte que va a quedar separada por el corte. • Mantenga todo el equipo de gas comprimido y las piezas relacionadas en buen estado. • Utilice solamente cilindros. Un cilindro dañado puede explotar. • Coloque en primer lugar el alambre de toma a tierra del cordón de alimentación primaria en el espárrago luego coloque cualquier otro alambre de tierra sobre el conductor de tierra del cable. • No emplee nunca martillos. Ajuste firmemente la tuerca de retención. • No use nunca un cilindro que no esté de pie y bien sujeto. • Mantenga la tapa de protección en su lugar encima de la válvula. escorias o llamas. • No permita nunca el contacto eléctrico entre el arco de plasma y un cilindro. chispas. Consulte los códigos locales o nacionales aplicables. llaves u otro tipo de herramientas para abrir de golpe la válvula del cilindro. 1b-6 11/08 Hypertherm . • Manipule y utilice los cilindros de gas comprimido de acuerdo con los códigos locales o nacionales aplicables. • No exponga nunca los cilindros a calor excesivo. asegúrese de conectar correctamente el alambre de toma a tierra del cordón de alimentación primaria. Potencia primaria de entrada • Asegúrese de que el alambre de toma a tierra del cordón de alimentación está conectado al terminal de tierra en la caja del interruptor de corriente. LOS CILINDROS DE GAS PUEDEN EXPLOTAR SI ESTÁN DAÑADOS Los cilindros de gas contienen gas bajo alta presión.

• Advierta a las demás personas que se encuentren en las cercanías acerca del peligro que supone el ruido excesivo. Para reducir los peligros de los campos magnéticos: UN ARCO PLASMA PUEDE DAÑAR TUBOS CONGELADOS Se puede hacer daño a los tubos congelados.SEGURIDAD EL RUIDO PUEDE DETERIORAR LA AUDICIÓN La exposición prolongada al ruido propio de las operaciones de corte y ranurado puede dañar la audición. • Utilice un método de protección de los oídos aprobado al utilizar el sistema de plasma. • Mantenga el cable de trabajo y la manguera de la antorcha a un lado. lejos del cuerpo. • Manténgase tan lejos de la fuente de energía como sea posible. Hypertherm 1b-7 11/08 . • No envuelva el cable de trabajo ni la manguera de la antorcha en su cuerpo. Las personas que lleven marcapasos y audífonos deberán consultar a un médico antes de acercarse a sitios donde se realizan operaciones de corte y ranurado por plasma. OPERACIÓN DE MARCAPASOS Y DE AUDÍFONOS Los campos magnéticos producidos por las elevadas corrientes pueden afectar la operación de marcapasos y de audífonos. • Dirija la manguera antorcha lo más cerca posible del cable de trabajo. si uno trata de descongelarlos con una antorcha por plasma. o se los puede reventar.

Marca CCC La marca de Certificación Obligatoria China (CCC en inglés) indica que el producto ha sido comprobado y se lo ha encontrado que cumple con los reglamentos de seguridad del producto requeridos para venta en China. Estos productos fueron evaluados. la Compatibilidad Electromagnético Europea (EMC). Incorporated (UL) ó TÜV. Marca CSA Los productos de Hypertherm con la marca CSA cumplen con los reglamentos de Estados Unidos y Canadá para la seguridad del producto. 1b-8 11/08 Hypertherm . no todas las marcas se aplican a toda versión del producto.SEGURIDAD SÍMBOLOS Y MARCAS Su producto de Hypertherm puede tener una o más de las marcas que siguen en. tales como Underwriters Laboratories. Sólo aquellas versiones del producto Hypertherm con la marca CE ubicada en o cerca de la placa de datos han sido comprobadas para cumplir con la Directiva Europea de Voltaje Bajo. Símbolo de marca S El símbolo de marca S indica que la fuente de energía y antorcha son aptas para operaciones que se llevan a cabo en entornos con peligro aumentado de choque o descarga eléctrica según IEC 60974-1. comprobados. Marcas CE Las marcas CE significan una declaración del fabricante de conformidad a las directivas y estándares aplicables Europeos. y certificados por CSA-Internacional. Debido a diferencias y conflictos en reglamentos nacionales. o cerca de la placa de datos. el producto puede tener la marca según uno de los otros Laboratorios de Prueba Reconocidos nacionalmente (NRTL siglas en inglés) acreditados en ambos Estados Unidos y Canadá. Marca c-Tick Las versiones CE de los productos Hypertherm con la marca c-Tick cumple con los reglamentos EMC requeridos para venta en Australia y Nueva Zelandia. Marca GOST-R Las versiones de los productos Hypertherm CE que incluye la marca de conformidad GOST-R cumplen con la seguridad del productos y los requisitos EMC para exportarse a la Federación Rusa. Los filtros EMC que necesitan cumplir con la Directiva Europea EMC están incorporados dentro de las versiones del producto con la marca CE. Alternativamente.

ears. 2. 3. Do not touch live parts. 1.2 Ne pas saisir la pièce à couper de la trajectoire de coupage. 29 CFR 1910 (http://www. Le personnel non qualifié et les enfants doivent se tenir à l’écart. “Safety in Welding. Chasser les fumées par ventilation.3 Se protéger entièrement le corps. 3.3 Do not use a drum or other closed container as a cutting table. Button shirt collar. Risk of electric shock or burn. eyes. Le non respect des ces instructions de sécurité peut entraîner la mort.1 Do not cut near flammables. 4. Failure to follow all these safety instructions can result in death. 6. and body. Hazardous voltage.2 Use forced ventilation or local exhaust to remove the fumes. 5. 5. 1. Remplacer les gants quand ils sont humides ou endommagés. 3. Read and follow these instructions.gov). Ne pas enlever. hands. Les étincelles de coupage peuvent provoquer une explosion ou un incendie. détruire ni couvrir cette étiquette.2 Protect from shock by insulating yourself from work and ground. 6. 3.2 Se protéger contre les chocs en s’isolant de la pièce et de la terre. Only qualified personnel should operate this equipment.3 Ne pas utiliser un fût ou un autre contenant fermé comme table de coupage. 4. Use torches specified in the manual. 1. 1. endommagée ou usée (PN 110584 Rev C). 5. damaged. 3. Boutonner le col de la chemise. or cover this label. WARNING Plasma cutting can be injurious to operator and persons in the work area. 4.1 Couper l’alimentation avant de démonter la torche. 1. 7.3 Disconnect power before servicing. Les rayons d’arc peuvent brûler les yeux et blesser la peau. Tension dangereuse. Risque de choc électrique ou de brûlure. La remplacer si elle est absente. Il s’allume instantanément quand on l’amorce. Use welding helmet with the correct shade of filter.osha. les oreilles. Replace gloves when wet or damaged. 2. 2. Arc rays can burn eyes and injure skin. and material safety data sheets. Utiliser exclusivement les torches indiquées dans le manual.1 Porter un bon équipement de protection pour se protéger la tête. Refer to ANS Z49. L’arc plasma peut blesser et brûler.3 Do not operate in closed spaces. 3. Seul le personnel qualifié a le droit de faire fonctionner cet équipement. Ne pas toucher les pièces sous tension. 2. Utiliser un masque de soudeur avec un filtre de nuance appropriée.1 Do not inhale fumes. Arc starts instantly when triggered. 2. 2. 3. Protect ears from noise. 3. Consulter le manuel avant de faire fonctionner.3 Wear complete body protection. Cutting and Allied Processes” from American Welding Society (http://www. 4.3 Couper l’alimentation avant l’entretien.aws. éloigner la buse de soi.1 Wear insulating gloves. 1. 1.2 Utiliser une ventilation forcée ou un extracteur local pour dissiper les fumées.2 Have a fire extinguisher nearby and ready to use. employer safety practices. 4. Become trained. destroy.1 Wear correct and appropriate protective equipment to protect head. 4.3 Ne pas couper dans des espaces clos. or worn (PN 110584 Rev C). Es importante que el operador y el técnico de mantenimiento comprendan el sentido de estos símbolos de advertencia según se describen.1 Ne pas inhaler les fumées 4. les mains et le corps. Hypertherm 1b-9 11/08 . Protéger les oreilles contre le bruit. Plasma fumes can be hazardous. Plasma arc can injure and burn. 7.org) and OSHA Safety and Health Standards. Keep non-qualified personnel and children away. Les fumées plasma peuvent être dangereuses. point the nozzle away from yourself.1 Ne pas couper près des matières inflammables. Remove fumes with ventilation.1. Cutting sparks can cause explosion or fire. Do not remove. 2. 1. 5.SEGURIDAD ETIQUETA DE ADVERTENCIA Esta etiqueta de advertencia se encuentra adherida a la fuente de energía.2 Un extincteur doit être à proximité et prêt à être utilisé. Replace if it is missing.2 Do not grip the workpiece near the cutting path.1 Turn off power before disassembling torch. Suivre une formation. 2. Consult manual before operating. AVERTISSEMENT Le coupage plasma peut être préjudiciable pour l’opérateur et les personnes qui se trouvent sur les lieux de travail.1 Porter des gants isolants. les yeux. 4.

No retire las etiquetas de advertencia ni las cubra con pintura.3 Proteja su cuerpo completamente. La inhalación de los humos provenientes del área de corte puede ser nociva para la salud.3 No corte depósitos cerrados. 4. desconecte el enchufe de entrada o la potencia primaria. 2. 5. 1. 7. 2. 1. 2.1 Mantenga la cabeza fuera de los gases tóxicos. 6. El arco de plasma puede causar quemaduras y lesiones. 4.2 Aíslese de la pieza de trabajo y de la tierra. Proteja su cuerpo completamente. 3.2 Utilice ventilación forzada o un sistema local de escape para eliminar los humos. Es importante que el operador y el técnico de mantenimiento comprendan el sentido de estos símbolos de advertencia según se describen. 1. 3. Las chispas producidas por el corte pueden causar explosiones o incendios. 1b-10 11/08 Hypertherm .1 Utilice un sombrero y gafas de seguridad. Los rayos del arco pueden producir quemaduras en los ojos y en la piel. 1. 3. 4. Protéjase del electrochoque.1 Colóquese guantes aislantes. No utilice guantes dañados o mojados. 4. Utilice un casco de soldar con el filtro de sombreado adecuado.2 Tenga a mano un extinguidor de incendios y asegúrese de que alguien esté preparado para utilizarlo.SEGURIDAD ETIQUETA DE ADVERTENCIA Esta etiqueta de advertencia se encuentra adherida a la fuente de energía.2 No sostenga el material junto al trayecto de corte. El texto numerado corresponde a los cuadros numerados de la etiqueta. 3. 5. capacítese y lea las instrucciones completamente. Utilice protección para los oídos y abróchese el botón del cuello de la camisa.1 Apague la fuente de energía antes de desarmar la antorcha. Los electrochoques provocados por la antorcha o el cableado pueden ser fatales.3 Antes de trabajar en una máquina. 2. Antes de trabajar en la máquina o de proceder a cortar.3 Utilice un ventilador para eliminar los humos.1 Mantenga los materiales inflamables lejos del lugar de corte.

o haga cambios significativos en el proceso o materiales que se usen con un sistema existente de colección de polvo seco. adoptada por referencia. Consulte su “Autoridad que Tenga Jurisdicción” (iniciales en inglés AHJ) local para determinar si cualquier edición de la NFPA 68 ha sido “adoptada por referencia” en los códigos de construcción locales. la edición del 2007 de la NFPA 68 requiere el uso de respiraderos de explosión diseñados para el peor caso del valor Kst (vea anexo F) que pudiera ser generado por el polvo. ubicación. no intenta urgir acción que no esté en cumplimiento con todos los reglamentos y normas. Consulte con el fabricante o instalador de cualquier sistema de colección de polvo seco para los requisitos aplicables antes de que instale un sistema nuevo de colección de polvo seco. pero en realidad aplica estos nuevos requisitos a todos los sistemas de colección de polvos secos. estatales y locales aplicables. La NFPA 68 no identifica específicamente corte por plasma u otros procesos de cortes termales como si requirieran sistemas de respiraderos de deflagración. mantenimiento. AHJ. Remítase a la NFPA 68 para definiciones y explicaciones de los términos reguladores como “deflagración. National Fire Protection Association” iniciales en inglés NFPA (La Asociación Americana Nacional de Protección Contra Incendios) del estándar 68 “Protección de Explosión por medio de Respiradero de Deflagración” proporciona requisitos para el diseño. y uso de aparatos y sistemas para dar salida a gases de combustión y presiones después de todo evento de deflagración. a no ser que se haya completado una evaluación específica del sitio para determinar que todo polvo generado no es combustible. de manera que el tamaño y tipo del respiradero de explosión pueda diseñarse. y este manual nunca debe interpretarse como si lo hiciera así. Hypertherm.S.SEGURIDAD Información sobre la colección de polvo seco En algunos sitios. Nota 1 – La interpretación de Hypertherm de estos nuevos requisitos es que. índice de deflagración” y otros términos. el valor Kst. Nota 2 – Los usuarios de los manuales de Hypertherm deberían consultar y cumplir con todas las leyes y reglamentos federales. instalación. al publicar todo manual de Hypertherm. La edición del 2007 de “U. Hypertherm 1b-11 11/08 . el polvo seco puede representar un peligro potencial de explosión.

...............................................................................................................................................................................2-3 Gas console .................................................................................................................................................................................................................................................................................................................2-10 HPR130XD Manual Gas Instruction Manual 2-1 .......................2-4 System gas requirements...........................................................................................................................................................................2-9 Torch – 228520......................................................................................................................................................................2-3 Off-valve .........................................................................................................................................................................................................................................................................................................................................................................................2-5 Ignition console – 078172 .............................................2-8 Off-valve – 078534 ......................................................................................................................................................................2-6 Gas console – 078532.................................................................................................................................................................................Section 2 SPECIFICATIONS In this section: System description.................................................2-3 Power supply...................................................................................................................................................................................................................................................................................................2-3 Torch...........................................................................................................2-3 Specifications ...................................................................................................................................................................................................................................................................................2-3 Ignition console...........................................2-3 General .................................................................................2-4 Power supply..........................

SPECIFICATIONS 2-2 HPR130XD Manual Gas Instruction Manual .

The maximum severance capability is 38 mm (1. Power may be present at all other components when it is in the ON (l) position. It contains the circuitry to ignite a torch. The assembly interfaces with the machine torch. solenoid valves. 150-VDC constant-current supply. Torch The torch can cut 12 mm mild steel at up to 2032 mm/min (1/2 in at up to 80 ipm). Maximum pierce capability is 32 mm (1. check valves and pressure transducers. The gas console includes motor valves. a heat exchanger and pump to cool the torch. Off-valve The off-valve consists of 5 solenoid valves.25 in) for mild steel and 19 mm (3/4 in) for stainless steel and aluminum. high-frequency signal is coupled to the cathode lead and pilot arc lead. The gas console manages the selection and flow rate of all incoming gases.5 in) for mild steel and 25 mm (1 in) for stainless steel and aluminum. Ignition console The ignition console uses a spark-gap assembly. stainless steel and aluminum. The maximum production cutting capability of the torch is 16 mm (5/8 in) for HyDefinition and conventional cutting. the ignition console and the gas console. The gas console also houses a relay PC board and a control PC board. The ignition console converts 120 VAC control voltage from the power supply into high-frequency and high-voltage pulses (9-10 kV) to break over the torch electrode-nozzle gap. HPR130XD Manual Gas Instruction Manual 2-3 . Gas console The power switch located on the gas console is the main power switch for the system. The highvoltage. a manifold block and a wiring harness with connector. Power supply The power supply is a 130-amp. The power supply has a serial interface to provide communication with a CNC controller.SPECIFICATIONS System description General HyPerformance plasma systems are designed to cut a wide range of thicknesses of mild steel.

• Water – the pressure dewpoint of the humidity must be less than or equal to 3° C (37. oil-free Pressure +/. oil-free 99.4° F).4.10% 793 kPa / 8 bar 115 psi 793 kPa / 8 bar 115 psi 793 kPa / 8 bar 115 psi 793 kPa / 8 bar 115 psi 793 kPa / 8 bar 115 psi 793 kPa / 8 bar 115 psi Flow rate 4250 l/h 150 scfh 7080 l/h 250 scfh 7080 l/h 250 scfh 4250 l/h 150 scfh 4250 l/h 150 scfh 4250 l/h 150 scfh * Oxygen. and air are required for all systems. ** ISO standard 8573-1 Class 1.99% pure Clean. dry.2 99. oil-free ** Clean.4.1 mg per cubic meter of air. dry. nitrogen. Nitrogen is used as a purge gas.5 microns in the largest dimension and 1 particle per cubic meter of air at a Size of 0.98% pure (F5 = 95% Nitrogen. • Oil – the concentration of oil can be no more than 0. dry. 5% Hydrogen) 99.SPECIFICATIONS Specifications System gas requirements Gas quality and pressure requirements Gas type O2 oxygen* N2 nitrogen* Air* H35 argon-hydrogen F5 nitrogen-hydrogen Ar argon Quality 99. oil-free per ISO 8573-1 Class 1.99% pure Clean.995% pure (H35 = 65% Argon. Mild steel Stainless steel Aluminum Gas types Cutting 30 to 50 A Cutting 80 A Cutting 130 A Plasma O2 O2 O2 Shield O2 Air Air Plasma N2 & F5 F5 N2 & H35 Shield N2 N2 N2 Plasma Air – H35 & Air Shield Air – N2 & Air 2-4 HPR130XD Manual Gas Instruction Manual .5 to 5.1 to 0. 35% Hydrogen) 99.2 requirements are: • Particulates – no more than 100 particles per cubic meter of air at a Size of 0. dry.0 microns in the largest dimension.5% pure Clean.

88 @ 130 ADC output Forced air (Class F) Class H Frequency (Hz) 50/60 50/60 60 50/60 50/60 50/60 60 60 Amperage (I1) 62/60 57 52 33 32 28 26 21 Regulatory approval CSA CSA CSA CCC CE/GOST-R CSA CSA CSA Power kW (+/.5 kg 700 lb 967.3" HPR130XD Manual Gas Instruction Manual 2-5 .7 mm 38.5 21.5 21.5 21.10%) (U1 x I1 x 1.5 21.5 * The 380 volt CCC regulatory approval only applies to 50 Hz operation 1079.5" 154.1" 566.5 21.1" 317.4 mm 22.5 21.73) 21.9 mm 6.5 mm 42. 40° C (104° F) Power supplies will operate between -10° C and +40° C (+14° and 104° F) 0.5 21.5 kw.SPECIFICATIONS Power supply General Maximum OCV (U0) Maximum output current (I2) Output voltage (U2) Duty cycle rating (X) Ambient temperature/Duty cycle Power factor (cosϕ) Cooling Insulation AC Voltage Part Phase (U1) number 078538 078539 078540 078541 078542 078543 078544 078545 200/208 220 240 380* 400 440 480 600 3 3 3 3 3 3 3 3 311 VDC 130 Amps 50 – 150 VDC 100% @ 19.

1 kg 20 lb 216 mm 8. See Installation section for details. • Maximum cable length from the ignition console to the torch lifter station is 20 m (65 ft). • The ignition console may be mounted horizontally or vertically.SPECIFICATIONS Ignition console – 078172 • The ignition console may be mounted locally on the power supply (LHF) or remotely on the cutting table’s bridge (RHF).5" 152 mm 6" 2-6 HPR130XD Manual Gas Instruction Manual . Allow room to remove the top for servicing. 219 mm 8.625" 9.625" 283 mm 11.125" 194 mm 7.

SPECIFICATIONS LHF mounting (local) RHF mounting (remote) Mounted on table Horizontal mounting Vertical mounting HPR130XD Manual Gas Instruction Manual 2-7 .

Allow room to open the top for servicing.5" 359 mm 14.5" 14 kg 31 lb 276 mm 10. • Maximum cable length from the gas console to the off-valve assembly is 20 m (65 ft). • Mount the gas console on top of the power supply or near the CNC on the cutting table.125" 317 mm 12.88" 178 mm 7" 2-8 HPR130XD Manual Gas Instruction Manual . 292 mm 11.SPECIFICATIONS Gas console – 078532 • Maximum cable length from the power supply to the gas console is 75 m (250 ft).

• The vent hole on the manifold must be kept clear at all times. • Mount the off-valve assembly to the torch carriage on larger tables.187" 92 mm 3.75" 157 mm 6.75" A Vent hole: Do not block 19 mm 0.18" 165 mm 6. On smaller tables it can be mounted to a bracket just above the bridge. A 70 mm 2.18" 1.5 lb 4.7 mm 0.8 m (6 ft).5" A-A HPR130XD Manual Gas Instruction Manual 2-9 .SPECIFICATIONS Off-valve – 078534 • Maximum cable length from the off-valve to the torch lifter station is 1.1 kg 2.62" 30 mm 1.

0 in).25" 2" 43 ° 345 mm 13.2 lb 2-10 HPR130XD Manual Gas Instruction Manual .0 in).8 mm (2.74" 51 mm 57 mm 2.00" 95 mm 3.4 mm (6.60" 1.SPECIFICATIONS Torch – 228520 • The outside diameter of the torch mounting sleeve is 50. 1. • The minimum bend radius for the torch leads is 152.91" 104 mm 4.8 m 6' 193 mm 7.59" 49 mm 1.9 kg 4.10" 51 mm 2.

.........................................................................................................................................3-16 Pilot arc lead ..................................................................................................................................................................................3-15 Power supply to ignition console leads...................................................................3-5 Recommended grounding and shielding practices ......................................................................................................................................................................................................................................................................................................3-12 Install the off-valve ............................................................................................................3-24 Optional multi-system CNC interface cable ...................................................................................................................................................................................................................................Section 3 INSTALLATION In this section: Upon receipt ..............................3-22 Power supply to CNC interface cable ...............................................................................................................................................................................................3-24 Notes to CNC interface cable run list .........................................................................................................................................................................................................................................................................................3-3 Torque specifications............................................................................................................3-14 Placement of the gas console...........................3-19 Power supply to gas console cables ...............................................................................................................3-16 Ignition console power cable ..........................................................................................................................................3-16 Negative lead ...............................................................................................................................................3-6 Introduction .........................................................................................................3-4 System components ........................................................................................................................................................................................3-22 Off-valve cable ...........................................3-6 Steps to take .......................................................................................................................................................................................................................3-11 Install the ignition console ...........................3-5 Customer-supplied power cable ...............................................................................................................3-3 Claims..................................................................................................................................................................................................................................................3-3 Placement of system components............................................................................................................................................3-22 Cable and gas hose assembly........................................................................................................................................................................................................................3-5 Supply gas hoses.............................................................................................................................................................................................................................3-10 Placement of the power supply .........................................................................................................................................................................................................................................................................................................................3-20 Gas console to off-valve connections ..........................3-22 Gas console to off-valve cable .........................................................................................3-3 Noise levels ...........................................................................................................................................................................................................................................................................................................................................................................................................................3-6 Types of grounding...........................................................................................................................................................................................................................................................................3-3 Installation requirements ......................................................................................3-20 Power cable ..................3-5 Cables and hoses .3-20 Control cable ...................................................................................................................................................................................................................3-7 Grounding diagram.....................................................................................................................................................................3-18 Ignition console coolant hoses ................................................................................................................................................................................................3-25 HPR130XD Manual Gas Instruction Manual 3-1 .................................................................................................3-3 Installation requirements .........................................................................................................................................................................................................................................

....................................................................................................................................................................3-30 Torch connections .................................................................................................................................................................................................3-43 Gas requirements...................................................................................................................................................................................3-36 Torch alignment .......................................................................................................................................................3-36 Power requirements........................................................3-36 Torch lifter requirement .................................................3-41 Custom Coolant mix for hot operating temperatures .....................................................................3-31 Connect the torch to the quick-disconnect..........................................................................................................................................................................................................................................................................3-37 General.....3-47 Supply gas hoses..................................................................................................3-29 Work lead ...............................................................................................................................................................................................................................................................................................................................................................................................................3-36 Mounting the torch ............3-35 Torch mounting and alignment ..............................................................................................................................................................................................................................................................................................3-38 Connect the power .........................................................3-44 Gas regulators ......................................................................................................................................................INSTALLATION Examples of output circuits ...............................3-40 Premixed coolant for standard operating temperatures ...........................................................................................................................................3-31 Connect the torch to the torch lead assembly..........................3-45 Supply gas plumbing.3-48 3-2 HPR130XD Manual Gas Instruction Manual ...........................................3-46 Connect the supply gases .....................................................................................................................3-44 Setting the supply regulators .............................................................................................................................................................................................................................................3-28 Torch lead assembly ................................................3-42 Fill the power supply with coolant .......................................................................................................................................................................................................................................................................................................................................................................................3-37 Line disconnect switch..............................................................................................................................................3-40 Custom Coolant mix for cold operating temperatures ........................................................................................................3-38 Power cable ................................................................................................................................................................................................................................................................................................................................................................................................................3-27 Remote on/off switch ....................................................................................................................3-42 Water purity requirements............................................................................................................................................................................................................................................................................................................................................................................................................................................................................3-39 Torch coolant requirements....................................................................................................................................................................................................................3-26 Examples of input circuits .................................................

If you need additional assistance. Data was taken while cutting at 130 A using an O2/Air process on a dry cutting table. Claims for defective or missing merchandise – If any of the merchandise is defective or missing.4 m (4.6 ft) from the floor and 0. Always wear proper ear protection when cutting or gouging. • Inspect the system components for any physical damage that may have occurred during shipping.6 Lav5. Hypertherm will furnish you with a copy of the bill of lading upon request.34 m (1.2 Max Level. tighten all gas and water connections as shown below: Torque specifications Gas or water hose size Up to 10 mm (3/8") 12 mm (1/2") 2WRENCHES kgf-cm 8. Noise levels Acceptable noise levels as defined by national and local codes may be exceeded by this plasma system. call Customer Service listed in the front of this manual. Direct any technical questions to the nearest Hypertherm Technical Service Department listed in the front of this manual. you must file a claim with the carrier. If there is evidence of damage.8 41. licensed personnel. If you need additional assistance. dBC (MaxP) and 99. See Recommended grounding and shielding practices in this section for details. All communications regarding claims must include the model number and serial number located on the back of the power supply. gas and interface connections.12 ft) above the arc are: 119. call Customer Service listed in the front of this manual.25-7 30-40 HPR130XD Manual Gas Instruction Manual 3-3 . dBA. Placement of system components • Place all system components in position prior to making electrical.4 ft) from the front of torch. • To prevent leaks in the system. contact your supplier. or your authorized Hypertherm distributor. Installation requirements All installation and service of the electrical and plumbing systems must conform to national and local electrical and plumbing codes. refer to Claims.INSTALLATION Upon receipt • Verify that all system components on your order have been received. The decibel readings at 12 m (39.6-9. Contact your supplier if any items are missing.5-55 lbf-in 75-85 360-480 lbf-ft 6. See also Noise can damage hearing in the Safety section of this manual. This work should be performed only by qualified. or your authorized Hypertherm distributor. or your authorized Hypertherm distributor. 1. • Ground all system components to earth. Claims Claims for damage during shipment – If your unit was damaged during shipment. Use the diagram in this section for component-placement guidelines.

INSTALLATION Installation requirements 16 A B 2 4 1 3 C 7 11 D 15 14 10 5 6 13 12 E 8 9 3-4 HPR130XD Manual Gas Instruction Manual .

INSTALLATION System components A Power supply Ignition console Off-valve assembly Gas console Torch B C D E Cables and hoses 1 2 3 4 5 6 7 8 9 10 11 Pilot arc lead Negative lead Ignition console power cable Ignition console coolant hoses Gas control cable Gas power cable Gas console to off-valve hose and lead assembly CNC interface cable Optional CNC interface cable for systems with multiple power supplies Torch lead assembly Work lead Supply gas hoses 12 13 14 15 Oxygen Nitrogen or argon Air Argon-hydrogen (H35) or nitrogen-hydrogen (F5) Customer-supplied power cable 16 Main power cable HPR130XD Manual Gas Instruction Manual 3-5 .

It prevents a shock hazard to any personnel from any of the equipment. All work requiring the removal of the power supply cover must be performed by a qualified technician. on which the workpiece rests. Introduction This document describes the grounding and shielding necessary to protect a plasma cutting system installation against radio frequency interference (RFI) and electromagnetic interference (EMI) noise. This is the grounding system that completes the path of the cutting current from the torch back to the power supply. or the work table. This is the grounding system that limits the amount of electrical “noise” emitted by the plasma and motor drive systems. See Section 1 of the plasma system instruction manual for more safety precautions. The actual methods used to implement these practices may vary from system to system. make good contact with the table and the workpiece. The practices listed here have been used on many installations with excellent results. Note: These procedures and practices are not known to succeed in every case to eliminate RFI/EMI noise issues. There is a diagram on page 3-5 for reference. and we recommend that these practices be a routine part of the installation process. This grounding/shielding process is the main target of this document. In the plasma circuits. The DC power or cutting current ground. C. It requires that the positive lead from the power supply be firmly connected to the work table ground bus with a properly sized cable. 11-08 3-6 HPR130XD Manual Gas Instruction Manual . It also requires that the slats. the ground is carried from the plasma power supply chassis to the chassis of each separate console through the interconnecting cables. It addresses the three grounding systems described below. as well as the supplemental ground rod connected to the work table. Types of grounding A. It also limits the amount of noise that is received by the CNC and other control and measurement circuits.INSTALLATION Recommended grounding and shielding practices DANGER ELECTRIC SHOCK CAN KILL Disconnect electrical power before performing any maintenance. RFI and EMI grounding and shielding. but should remain as consistent as possible across the product line. It includes the service ground coming into the plasma power supply and other systems such as the CNC controller and the motor drivers. B. The safety (PE) or service ground. This is the grounding system that applies to the incoming line voltage.

Under no circumstances should aluminum or steel hardware be used. PE. run a separate EMI ground cable from the far drive motor to the gantry bus bar. as well as any other CNC or motor-drive cabinet or enclosure. It must be electrically insulated from any metal and from any contact with the floor or building. The metal braided shield on the torch leads must be connected firmly to the ignition console and to the torch. even if it is bolted to the power supply or to the cutting machine. 047040) for the EMI ground cables shown on the diagram. The leads can be run in a plastic cable tray (track) or covered with a plastic or leather sheath. not the part mounted on the torch – must be connected to the stationary part of the lifter with copper braid at least 12. The torch lead. and pilot arc leads should be bundled together for as long a distance as possible. serial communication signals. 9. EMI ground point and should have threaded studs welded to the table with a copper bus bar mounted on them. This includes the ignition console. heavy EMI ground cable (4 AWG part no. and service grounds must be connected to all equipment according to local and national codes. AC power. All PE grounds are shown on the diagram in green. For the most effective shielding. 047031) to the table bus bar. The only exception is that the studs welded to the table for mounting the ground bus can be steel. 5. run power and signal cables in separate cable tracks. * The ignition console should be mounted as close as possible to the torch. use only 6 AWG (16 mm2) welding cable (Hypertherm part no. If there are drive motors at each end of the gantry. 6. 10. 2. The valve assembly should also have a separate ground connection to the gantry bus bar.INSTALLATION Steps to take 1. The torch holder and the torch breakaway mechanism – the part mounted to the lifter. 4. and must have a separate ground cable to the bus bar on the cutting table. and interconnections between all parts of the Hypertherm system. Unless noted. All hardware used in the ground system must be brass or copper. work lead. The EMI ground cables for the torch lifter and the RHF console must each run separately to the table ground bus. 11. negative. must have a separate ground cable to the common (star) point on the table. Each Hypertherm component. power supply-to-power supply multi-drop connections. A separate cable must run from the lifter to the bus bar on the gantry. A separate bus bar should be mounted on the gantry as close to each drive motor as possible. and the pilot arc (nozzle) leads may only be run parallel to other wires or cables if they are separated by at least 150 mm (6 in). This is a PE ground and should be connected to the ground bus on the cutting table with 6 AWG green/yellow grounding cable (Hypertherm part number 047121) or equivalent. If possible. * The positive. 7. A ground rod that meets all applicable local and national electrical codes must be installed within 6 m (20 ft) of the table. 3.7 mm (1/2 in) wide. The cutting table is used for the common. 8. or star. * Applies to systems that use a remote high frequency (RHF) console 11-08 HPR130XD Manual Gas Instruction Manual 3-7 . The gantry bus bar should have a separate. use the Hypertherm CNC interface cables for I/O signals.

One acceptable location is inside the plasma power supply. the power supply positive lead. If the gantry runs on rails that are not welded to the table. * Applies to systems that use a remote high frequency (RHF) console 3-8 HPR130XD Manual Gas Instruction Manual . 13. Ground rod Gantry Power supply lead (+) Remote high frequency (RHF) console CNC enclosure Torch holder Power supply chassis Example of a good cutting table ground bus. shielded cable (Belden type 1800F or equivalent). Connectors on these cables should have a metal housing and the shield. the connection from the ground rod. The cable used must have a braided shield. All other signals (analog. 14. the voltage divider board should be mounted as close as possible to the point where the arc voltage is sampled. the RHF console*. serial. the CNC enclosure. Never run the shield or the drain through the connector on any of the pins. These need not go to the common (star) point.INSTALLATION 12. If the Hypertherm voltage divider board is used. and the power supply chassis. encoder) should run in twisted pairs inside a shielded cable. the output signal is isolated from all other circuits. but could take the shortest path to the table. should be connected to the metal housing of the connectors at each end of the cable. The processed signal should be run in twisted. If the OEM is installing a voltage divider to process arc voltage for use in the control system. not the drain. the torch holder. The shield should be connected to the chassis of the power supply and left unconnected at the other end. not a foil shield. digital. then the rails need to be connected with a ground cable from each end of both rails to the table. The picture above shows the connection from the gantry ground bus.

close to the motor. A single heavy cable then goes from the gantry ground bus to the ground bus bolted to the table. It is bolted to the gantry.INSTALLATION Cable to ground bus on the cutting table Component ground cables Example of a good gantry ground bus. All of the individual ground cables from the components mounted on the gantry go to the bus except those from the RHF console* and the torch holder. * Applies to systems that use a remote high frequency (RHF) console HPR130XD Manual Gas Instruction Manual 3-9 .

** RHF console Metering console Gas/Selection console CNC console 3-10 Bus bar INSTALLATION Command THC Gantry Command THC ** Bus bar Cooler Ground rod Cutting table Positive DC Plasma power supply Grounding diagram (some systems will not include all the components shown) Chassis and RFI ground ** The lifter assembly and the RHF console each require a separate path to the cutting table ground bus bar. HPR130XD Manual Gas Instruction Manual AC earth/service ground .

which reduces cooling efficiency and VOIDS THE WARRANTY.INSTALLATION A Placement of the power supply ELECTRICAL SHOCK CAN KILL DANGER Remove all electrical connections to the power supply before moving or positioning. • Place the power supply in an area that is free of excessive moisture. Take care when lifting so that the underside of the power supply is not damaged. Allow 1 m (3 ft) of space on all sides of the power supply for ventilation and service. has proper ventilation and is relatively clean. The power supply can be moved by forklift but the forks must be long enough to extend the entire length of the base. Transporting the unit can cause personal injury and equipment damage. • Do not place the power supply on an incline greater than 10° to prevent it from toppling. HPR130XD Manual Gas Instruction Manual 3-11 . • Cooling air is drawn in through the front panel and is exhausted through the rear of the unit by a cooling fan. Do not place any filter device over the air intake locations.

INSTALLATION

B

Install the ignition console
• Mount the ignition console on the gantry (bridge) for the RHF configuration. • Mount the ignition console on the power supply for the LHF configuration. • Allow room to remove the top for servicing.

32 mm 1.25"

184 mm 7.25" 216 mm 8.50"

32 mm 1.25"

248 mm 9.75" 279 mm 11.00"

7 mm .028" (4 places)

Ignition console grounding

3-12

HPR130XD Manual Gas Instruction Manual

INSTALLATION

Horizontal RHF mounting

Vertical RHF mounting

LHF mounting

HPR130XD Manual Gas Instruction Manual

3-13

INSTALLATION

C Install the off-valve
• Mount the off-valve assembly near the torch lifter station. The maximum length of the gas hoses between the off-valve assembly and the torch is 1.8 m (6 ft).

Off-valve grounding

A A-A
70 mm 2.75"

A
92 mm 3.62"

157 mm 6.18"

4.7 mm 0.187" Vent hole: Do not block 19 mm 0.75" 30 mm 1.18"

165 mm 6.5"

3-14

HPR130XD Manual Gas Instruction Manual

INSTALLATION

D

Placement of the gas console
• Mount the gas console near the cutting table. Allow room to remove the top and right side cover for servicing. Preferred orientation is shown in the figure below. The maximum length of cables between the power supply and gas console is 75 m (250 ft). The maximum length of cables and hoses between the gas console and the offvalve assembly is 20 m (65 ft).

Preferred gas console orientation

Gas console grounding

50.8 mm 2.0"

228.6 mm 9.0"

314.5 mm 12.38"

38.1 mm 1.5"

HPR130XD Manual Gas Instruction Manual

3-15

INSTALLATION

Power supply to ignition console leads
1 Pilot arc lead

Ignition console Part no. 123683* 123820 123821 123666 123822 123667 Length 1.5 m (5 ft) 3 m (10 ft) 4.5 m (15 ft) 7.5 m (25 ft) 10 m (35 ft) 15 m (50 ft) Part no. 123823 123735 123668 123669 123824 123825 Length 20 m (65 ft) 25 m (82 ft) 35 m (115 ft) 45 m (150 ft) 60 m (200 ft) 75 m (250 ft)

I/O board

2 Negative lead
Ignition console Part no. 123702* 123661 123813 123662 123814 123663 Length 1.5 m (5 ft) 3 m (10 ft) 4.5 m (15 ft) 7.5 m (25 ft) 10 m (35 ft) 15 m (50 ft) Part no. 123815 123734 123664 123665 123778 123779 Power supply Length 20 m (65 ft) 25 m (82 ft) 35 m (115 ft) 45 m (150 ft) 60 m (200 ft) 75 m (250 ft)

* Cable numbers 123683 and 123702 are for use with systems that have the ignition console mounted on the power supply

Pilot arc lead

Negative lead

3-16

HPR130XD Manual Gas Instruction Manual

INSTALLATION Work lead 2 Negative lead 1 Pilot arc lead 1 1 Pilot arc lead 2 Negative lead 2 HPR130XD Manual Gas Instruction Manual 3-17 .

INSTALLATION 3 Ignition console power cable Cable signal list – power supply to ignition console Power supply end Pin No.5 m (125 ft) 45 m (150 ft) 60 m (200 ft) 75 m (250 ft) 2 3 4 Description 120 Vac-hot 120 Vac-return Ground Not used Ignition console end Pin No. 1 2 3 4 * Cable number 123865 is for use with systems that have the ignition console mounted on the power supply 3 3-18 HPR130XD Manual Gas Instruction Manual . 123836 123425 123736 123426 123672 123938 123673 123837 123838 Length 20 m (65 ft) 22.1 m (7 ft) 3 m (10 ft) 4.5 m (15 ft) 6 m (20 ft) 7. 123865* 123419 123834 123420 123670 123422 123835 123423 123671 Length 2.5 m (75 ft) 25 m (82 ft) 30 m (100 ft) 35 m (115 ft) 37. 1 Part no.5 m (25 ft) 9 m (30 ft) 10 m (35 ft) 12 m (40 ft) 15 m (50 ft) Part no.

5 ft) 3 m (10 ft) 4.7 m (2.5 m (25 ft) 10 m (35 ft) 15 m (50 ft) Part no. 228030* 028652 028440 028441 128173 028442 Length 0.INSTALLATION 4 Ignition console coolant hoses Red Green Part no.5 m (15 ft) 7. 128984 128078 028896 028445 028637 128985 Length 20 m (65 ft) 25 m (82 ft) 35 m (115 ft) 45 m (150 ft) 60 m (200 ft) 75 m (250 ft) 4 Green Red * Hose set number 228030 is for use with systems that have the ignition console mounted on the power supply HPR130XD Manual Gas Instruction Manual 3-19 .

5 m (25 ft) 10 m (35 ft) 15 m (50 ft) Part no.INSTALLATION Power supply to gas console cables 5 Control cable Part no. 1 6 2 7 3 9 8 4 5 Input/Output Input/Output Input/Output Description Not used Not used CAN L CAN H CAN ground Not used Not used Not used Not used Gas console end Pin No. 123785* 123846 123964 123674 123847 123675 Length 3 m (10 ft) 4. 1 2 3 4 5 6 7 * Cable numbers 123784 and 123785 are for use with systems that have the gas console mounted on the power supply 3-20 HPR130XD Manual Gas Instruction Manual . Part no.5 m (25 ft) 10 m (35 ft) 15 m (50 ft) Part no. 123848 123740 123676 123677 123849 123850 Length 20 m (65 ft) 25 m (82 ft) 35 m (115 ft) 45 m (150 ft) 60 m (200 ft) 75 m (250 ft) 1 2 3 4 5 6 7 Description 120 Vac-hot 120 Vac-return Ground Not used Not used 24 Vac-hot 24 Vac-return Gas console end Pin No.5 m (15 ft) 6 m (20 ft) 7. 123841 123737 123738 123739 123842 123843 Length 20 m (65 ft) 25 m (82 ft) 35 m (115 ft) 45 m (150 ft) 60 m (200 ft) 75 m (250 ft) Cable signal list – power supply to gas console Power supply end Pin No.5 m (15 ft) 6 m (20 ft) 7. 1 6 2 7 3 9 8 4 5 Input/Output Input/Output Input/Output Function Not used Not used CAN serial communication CAN serial communication CAN ground reference Not used Not used Not used Not used 6 Power cable Cable signal list – power supply to gas console Power supply end Pin No. 123784* 123839 123963 123691 123840 123711 Length 3 m (10 ft) 4.

INSTALLATION 1X5 J300 J103 Female Male 5 6 6 3X3 3X1 3X2 5 HPR130XD Manual Gas Instruction Manual 3-21 .

5 m (15 ft) 7. 1 2 3 4 5 6 7 8 9 10 11 Off-valve cable Shield Preflow Shield Cutflow 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Cable signal list – off-valve cable Description End B S P S C P P P C V V Gnd Gnd Gnd Gnd Color Red/black Red Red/black Red Red/black Red Red/black Red Red/black Red Green/Yellow End A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Plasma Preflow Plasma cutflow Vent End B End A (male/pins) Ground 3-22 HPR130XD Manual Gas Instruction Manual .INSTALLATION Gas console to off-valve connections 7 Cable and gas hose assembly Part no.5 m (25 ft) 10 m (35 ft) 15 m (50 ft) 20 m (65 ft) Female end at off-valve Male end at gas console Gas console to off-valve cable Cable signal list – gas console to off-valve cable Gas console end Pin No. 1 2 3 4 5 6 7 8 9 10 11 Description 120 Vac Hot – Shield preflow 120 Vac Return – Shield preflow 120 Vac Hot – Shield cutflow 120 Vac Return – Shield cutflow 120 Vac Hot – Plasma preflow 120 Vac Return – Plasma preflow 120 Vac Hot – Plasma cutflow 120 Vac Return – Plasma cutflow 120 Vac Hot – Plasma vent 120 Vac Return – Plasma vent Ground Off-valve end Pin No. 128989 128990 128782 128967 128786 128991 Length 3 m (10 ft) 4.

INSTALLATION 7 Green Blue Black HPR130XD Manual Gas Instruction Manual Red Green Black Blue Red 3-23 .

123742 123219 123220 123852 123853 Length 35 m (115 ft) 37. CommandTHC requires signal to preflow gases during IHS The CNC initiates the plasma arc Not used Not used Not used Ground Ground Available 24 VDC (200 milliamps maximum) see notes Not connected 4 Output Output Output Output Output Output 1 Input Input Input Input Input Input Input Input Input Input Input Input 2&3 2 2 2 2&3 2&3 2&3 Input/ Output Output Output Input Input Notes Wire color Black Red Black Green Black Blue Black Yellow Black Brown Black Orange Red White Red Green Red Blue Red Yellow Red Brown Red Orange Green White Green Blue Green Yellow Green Brown Green Orange White Black Pin # 1 20 2 21 3 22 4 23 5 24 6 25 7 26 8 27 9 28 10 29 11 30 12 31 13 32 14 33 15 34 16 35 17 36 18 37 19 Input/ Output Input Input Output Output Signal name Rx – Rx + Tx – Tx + RS-422 ground None Output Output Output Output Output Output Output Output Output Output Output Output Output Output Motion 1 E (–) Motion 1 C (+) Error E (–) Error C (+) Rampdown error E (–) Rampdown error C (+) Not ready E (–) Not ready C (+) Motion 2 E (–) Motion 2 C (+) Motion 3 E (–) Motion 3 C (+) Motion 4 E (–) Motion 4 C (+) None None Input Input Input Input Input Input Input Input Corner (–) Corner (+) Pierce (–) Pierce (+) Hold (–) Hold (+) Start (–) Start (+) None None None Power ground Power ground CNC +24 VDC CNC +24 VDC 1 1 1 3-24 HPR130XD Manual Gas Instruction Manual .5 m (45 ft) 15 m (50 ft) 16.5 m (25 ft) 9 m (30 ft) 10 m (35 ft) 12 m (40 ft) Part no. 123210 123211 123212 123022 123213 123214 123215 Length 3 m (10 ft) 4.5 m (55 ft) 20 m (65 ft) 22. Notifies the CNC that an error has occurred Notifies the CNC that a rampdown error has occurred Notifies the CNC that the plasma system is not ready to fire an arc Notifies the CNC that an arc transfer has occurred and to begin machine motion once the CNC’s pierce delay has timed out Notifies the CNC that an arc transfer has occurred and to begin machine motion once the CNC’s pierce delay has timed out Notifies the CNC that an arc transfer has occurred and to begin machine motion once the CNC’s pierce delay has timed out Not used Not used The CNC Notifies the plasma system that a corner is approaching and to reduce cut current (Cut current is CNC selectable or defaults to 50% of cut current) The CNC Notifies the plasma system to maintain the shield preflow until the CNC releases the signal Not required without CommandTHC.5 m (125 ft) 45 m (150 ft) 60 m (200 ft) 75 m (250 ft) To J 300 9 Optional multi-system CNC interface cable (see schematics for installation information) Power supply end CNC end Function RS-422 serial receiver RS-422 serial receiver RS-422 serial transmitter RS-422 serial transmitter RS-422 serial ground Not used Notifies the CNC that an arc transfer has occurred and to begin machine motion once the CNC’s pierce delay has timed out.5 m (75 ft) 25 m (82 ft) 30 m (100 ft) Part no.INSTALLATION 8 Power supply to CNC interface cable Part no. 123216 123023 123494 123851 123217 123741 123218 Length 13.5 m (15 ft) 6 m (20 ft) 7.

They require 24 VDC at 7. or dry-contact closure. Inputs are optically isolated. open collector. CNC +24 VDC provides 24 VDC at 200 mA maximum. Caution: The CNC cable must be constructed using cable with 360 degree shielding and metal housing connectors at each end. The maximum rating is 24 VDC at 10 mA.022μF 100 V or higher) in parallel with the relay contacts. A jumper is required on J304 to use 24 V power. Note 4. The external relay’s life may be improved by adding a metallized-polyester capacitor (0. Machine motion is selectable and is used for configurations with multiple plasma systems. The shielding must be terminated to the metal housings at each end to ensure proper grounding and to provide the best shielding.3 mA. Outputs are optically isolated. Note 3. HPR130XD Manual Gas Instruction Manual 3-25 . transistors.INSTALLATION Notes to CNC interface cable run list Note 1. Note 2.

Logic interface. Warranty will be void.INSTALLATION Examples of output circuits 1. Do not use this configuration. active-low 5 VDC-24 VDC 10K (optional) HPR C + E CNC/PLC High-impedance (≤10 mA) 3. HPR C + E Any voltage V WA OI D RR S AN TY 3-26 HPR130XD Manual Gas Instruction Manual . active-high HPR C + E 10K (optional) 5 VDC-24 VDC CNC/PLC High-impedance (≤10 mA) 2. Logic interface. Relay interface CNC +24 V +24 VDC °t J304 HPR C + E CNC/PLC High-current contact closure inputs (AC or DC) CNC +24 V Install a Jumper 108056 Power ground External relay 24 VDC low-power coil ≤10 mA or ≥2400 ohms All relay coils require a freewheeling diode across the relay coil 4.

Amplified-output interface +24 VDC HPR CNC/PLC 12 V-24 VDC Active-high drive Power ground Power ground HPR130XD Manual Gas Instruction Manual 3-27 . 1. Relay interface +24 VDC Output from CNC/PLC External relay (AC or DC) Power ground HPR 2. Optocoupler interface +24 VDC CNC/PLC HPR Transistor-output optocoupler Power ground 3.022μF 100 V or higher) in parallel with the relay contacts.INSTALLATION Examples of input circuits Note: The external relay's life may be improved by adding a metallized-polyester capacitor (0.

TB2 1 2 1 3 3 Note: The main power switch on the gas console must be in the ON position for the remote switch to function. TB2 1 1 2 3 3 3. TB2 location 2. Locate terminal block 2 (TB2) in the power supply. 3-28 3 3 1 1 Note: Use a switch. 1. See the Safety section in this manual for more safety precautions. relay or solid-state relay that is compatible with 24 VAC @ 100 mA. Remove wire 1 as shown and connect it to terminal 2. not a momentary-contact switch. Connect switch to terminals 1 and 2 as shown.INSTALLATION Remote ON/OFF switch (provided by customer) WARNING ELECTRIC SHOCK CAN KILL Disconnect electrical power before performing any maintenance. It must be a maintained-contact switch. HPR130XD Manual Gas Instruction Manual .

HPR130XD Manual Gas Instruction Manual 3-29 .5 m (25 ft) 10 m (35 ft) 15 m (50 ft) 20 m (65 ft) Blue Black Plasma-gas vent hose (white) Caution: The length of the hoses from the torch to the off-valve are critical to cut quality and consumable life. Locate the exposed end of the plasma-gas vent hose away from sparks caused by piercing to avoid ignition and possible damage to the torch leads. Caution: 10 Do not alter the length of the hoses. 228291 228292 228293 228294 228295 228296 228297 228547 Length 2 m (6 ft) 3 m (10 ft) 4.5 m (15 ft) 6 m (20 ft) 7.INSTALLATION 10 Torch lead assembly Part no.

5 m (15 ft) 7.INSTALLATION Work lead Work table Part no. 123661 123813 123662 123814 123663 123815 Length 3 m (10 ft) 4.5 m (25 ft) 10 m (35 ft) 15 m (50 ft) 20 m (65 ft) Part no. 123734 123664 123665 123778 123779 Power supply Length 25 m (82 ft) 35 m (115 ft) 45 m (150 ft) 60 m (200 ft) 75 m (250 ft) 11 Work lead Work lead Lower frame of work table (typical). 3-30 HPR130XD Manual Gas Instruction Manual .

Uncoil the first 2 meters (6. 3. 2. Connect the coolant return hose (red). Align the torch with the hoses in the lead assembly. Push back the braided cover and slide the sleeve over the leads. They are taped together to help prevent twisting. The hoses must not be twisted. Hold the torch assembly in place with the spanner wrench (104269) and remove the mounting sleeve from the torch assembly. Coolant return hose 2WRENCHES HPR130XD Manual Gas Instruction Manual 3-31 . Sleeve Braided cover 4.5 ft) of the leads on a flat surface.INSTALLATION E Torch connections Connect the torch to the torch lead assembly 1.

5 m (25 ft) 9 m (30 ft) 12 m (40 ft) 15 m (50 ft) 23 m (75 ft) 30 m (100 ft) 45 m (150 ft) 3-32 HPR130XD Manual Gas Instruction Manual . 6a. Shown for reference only) Part no. Connect the pilot arc lead (yellow). Sleeve Braided cover 6b. Connect the optional ohmic contact wire. 123983 123984 123985 123986 123987 123988 123989 123990 123991 Length 3 m (10 ft) 6 m (20 ft) 7.INSTALLATION 5. Insert the connector into the torch receptacle and turn it by hand until it is tight. Route the ohmic contact wire through the opening in the braided cover and the torch sleeve. Insert the connector into the torch receptacle and turn it by hand until it is tight. 6. Ohmic contact wire part numbers (Not part of the HPR130XD system.

).INSTALLATION 7. connector-collar 8. Note: The connectors in steps 7–10 are push-to-connect fittings. push the hose fitting into the appropriate connector until it stops. Connect the plasma gas hose (black). 9. 10. 13 mm (0. To disconnect a fitting. and pull the hose away from the torch.5 in. push the connector-collar toward the torch. HPR130XD Manual Gas Instruction Manual 3-33 . Connect the plasma-gas vent hose (white). Connect the shield gas hose (blue). To make a connection. Connect the coolant supply hose (green).

slide the braided cover and clamp over the sleeve and tighten the clamp. shield and vent hoses are routed through the hole in the braided cover. Loosen the hose clamp on the braided cover. Slide the braided cover up to the torch sleeve. 3-34 HPR130XD Manual Gas Instruction Manual . Slide the torch sleeve over the connections and screw it onto the torch assembly. 12. Make sure that the plasma.INSTALLATION 11.

Be certain that there is no space between the torch body and the o-ring on the torch leads. See also Torch connections earlier in this section for torch lead connections to ignition console. HPR130XD Manual Gas Instruction Manual 3-35 .INSTALLATION Connect the torch to the quick-disconnect Apply a thin film of silicone lubricant to each o-ring Torch body 220706 Torch quick-disconnect receptacle 220705 Installation note Align the torch body to the torch leads and secure by screwing completely together.

3-36 HPR130XD Manual Gas Instruction Manual . Position the torch below the mounting bracket. Upper torch sleeve Lower torch sleeve Torch mounting bracket (customer supplied) 2. Tighten the securing screws. See figure above. Quick-disconnect receptacle Torch alignment To align the torch at right angles to the workpiece. motorized torch lifter with sufficient travel to cover all cutting thickness requirements. See also Changing consumables in Section 4 to install consumables in the torch.INSTALLATION Torch mounting and alignment Mounting the torch Installation 1. Torch lifter requirement The system requires a high-quality. Install the torch (with torch leads attached) in the torch mounting bracket. so that the bracket is around the lower portion of the torch sleeve but not touching the torch quick-disconnect. A unit which drifts through the stop point is not acceptable. Note: The bracket should be as low on the torch sleeve as possible to minimize vibration at the tip of the torch. 3. The unit should have the capability of maintaining a constant speed of up to 5080 mm/min (200 ipm) with positive braking. The lifter must provide 203 mm (8 in) of vertical travel. use a square.

product inrush characteristics. The power supply must be wired into one of the branch-feed circuits. high inrush fuse size 85 amps 85 amps 65 amps 40 amps 40 amps 35 amps 35 amps 30 amps Recommended Cable size for 15 m (50 feet) maximum length Rated for 60° C 26. Use a separate.3 mm2 (8 AWG) 8.INSTALLATION Power requirements General All switches. and regulatory requirements. Input voltage 200/208 VAC 220 VAC 240 VAC 380 VAC 400 VAC 440 VAC 480 VAC 600 VAC Note: Phase 3 3 3 3 3 3 3 3 Rated input current (FLA) @ 19.3 mm2 (8 AWG) 5. Use a motor-start circuit breaker or equivalent if time delay high inrush fuses are not permitted by local and national codes. however actual sizes required will vary based on individual site electrical line conditions (including but not limited to source impedance. Installation must be performed by a licensed electrician. line impedance.01 seconds and up to 12 times the rated input current (FLA) for 0. Recommendations on fuse and circuit breaker sizing are listed below. The power supply has a steady-state current listed in the table below.3 mm2 (8 AWG) 8. and line voltage fluctuation).7 mm2 (3 AWG) 26.3 mm2 (10 AWG) Cable AWG recommendations taken from table 310-16 of the National Electric Code handbook (USA).5 kW output 62/60 amps 57 amps 52 amps 33 amps 32 amps 28 amps 26 amps 21 amps Recommended time delay.3 mm2 (8 AWG) 8. primary.2 mm2 (4 AWG) 8. slow-blow fuses and power cables are customer-supplied and must be chosen as outlined by applicable national and local electrical codes. Time delay fuses and circuit breakers must be capable of withstanding inrush current that is up to 30 times the rated input current (FLA) for 0. HPR130XD Manual Gas Instruction Manual 3-37 .1 seconds.7 mm2 (3 AWG) 21. line disconnect switch for the power supply. The main feed protection device (Circuit Breaker or Fuse) must be sized to handle all branch-feed loads for both inrush and steady-state current.

16 (USA). The switch should: • Isolate the electrical equipment and disconnect all live conductors from the supply voltage when in the “OFF” position • Have one “OFF” and one “ON” position clearly marked with “O” (OFF) and “l” (ON) • Have an external operating handle capable of being locked in the “OFF” position • Contain a power-operated mechanism that serves as an emergency stop • Have slow-blow fuses installed for the proper breaking capacity (see table above). 3-38 HPR130XD Manual Gas Instruction Manual . Installation must be performed by a licensed electrician and according to applicable national and local codes. table 310. Use a 4-conductor Type SO input power cable with a conductor temperature rating of 60° C (140° F). The wire sizes listed in the table above were taken from the National Electric Code 1990 handbook. Installation must be performed by a licensed electrician. SWITCH BOX 16 Main power cable Wire sizes vary based on the distance of the receptacle from the main box. Install this switch near the power supply for easy access by the operator.INSTALLATION Line disconnect switch The line disconnect switch serves as the supply-voltage disconnecting (isolating) device.

In other countries. Connect the power cord leads to the line disconnect switch following national and local electrical codes. 2. In the U.. 5. 4. use a “lock-out/tag-out” procedure until installation is complete.S. 1. follow appropriate national and local safety procedures. North American wire colors U = Black V = White W = Red (PE) Earth ground = Green/Yellow European wire colors U = Black V = Blue W = Brown (PE) Earth ground = Green/Yellow DANGER Line disconnect switch (PE) W V U Power cable TB1 HPR130XD Manual Gas Instruction Manual 3-39 . Verify that the line disconnect switch is in the OFF position and remains in the OFF position for the remainder of the installation of the system. 3. Connect the ground lead (PE) to the GND terminal of TB1 as shown below. Connect the power leads to the terminals of TB1 as shown below. Insert the power cable through the strain relief at the rear of the power supply.INSTALLATION Connect the power ELECTRICAL SHOCK CAN KILL The line disconnect switch must be in the OFF position before making the power cable connections.

Premixed coolant for standard operating temperatures Use Hypertherm premixed coolant (028872) when operating in a temperature range of -12° C to 40° C (10° F to 104° F). 30% propylene glycol. Caution: Never use automotive anti-freeze in place of propylene glycol. Hypertherm premixed coolant consists of 69. and harmful or fatal if swallowed.INSTALLATION Torch coolant requirements The system is shipped without any coolant in the tank. Antifreeze contains corrosion inhibitors that will damage the torch coolant system. If swallowed. determine what coolant mix is correct for your operating conditions.9% water. Before filling the coolant system. 10/16/08 3-40 HPR130XD Manual Gas Instruction Manual . Observe the warning and cautions below. Upon contact. DANGER COOLANT CAN BE IRRITATING TO SKIN AND EYES AND HARMFUL OR FATAL IF SWALLOWED Propylene glycol and benzotriazole are irritating to skin and eyes. flush skin or eyes with water. Always use purified water in the coolant mixture in order to prevent damage to the pump and corrosion in the torch coolant system. Refer to the Material Safety Data Sheets Appendix for data on safety. and 0.1% benzotriazole. handling and storage of propylene glycol and benzotriazole. Refer to the custom coolant mix recommendations. if temperatures during operation are ever outside of this range. seek immediate medical attention.

Note: Maximum percentage of glycol should never exceed 50%.INSTALLATION Custom Coolant mix for cold operating temperatures (below -12° C / 10° F) Caution: For operating temperatures colder than the temperature stated above. Mix 100% glycol (028873) with the premixed Hypertherm coolant (028872) to increase the percentage of glycol. hoses or other damage to the torch coolant system due to freezing. The 100% glycol solution can also be mixed with purified water (see next page for water purity requirements) to achieve the required protection from freezing. Failure to do so could result in a cracked torch head. Use the chart below to determine what percentage of propylene glycol to use in the mixture. the percentage of propylene glycol must be increased. °C 4 -1 -7 -12 °F 40 30 20 10 0 -10 -20 -30 -40 -50 -60 -70 0 10 20 30 40 50 60 Maximum glycol percentage Hypertherm pre-mix (028872) Temperature -18 -23 -29 -34 -40 -46 -51 -57 % of Propylene Glycol Freezing Point of Propylene Glycol Solution 10/16/08 HPR130XD Manual Gas Instruction Manual 3-41 .

Water purity requirements It is critical to maintain a low level of calcium carbonate in the coolant to avoid reduced performance of the torch or cooling system. reverse osmosis. BZT (128020) acts as a corrosion inhibitor for the copper based coolant system contained in the plasma system.054 0. Treated water refers to a mixture of purified water. etc. Use water purified by any method (deionization. Water purity measurement method Conductivity S/cm at 25° C 0. that meets the specifications below. Water that does not meet the maximum purity specifications below can also cause problems.5 495 Grains per gallon (gpg of CaCO2) 0 0. Water that does not meet the minimum purity specifications below can cause excessive deposits on the nozzle that will alter the water flow and produce an unstable arc. Contact a water specialist for advice in choosing a water filtration system. water softeners. Deionized water that is too pure will cause leaching problems with the coolant system plumbing.5 18 1000 Resistivity mΩ-cm at 25° C 18.001 Dissolved solids (ppm of NaCl) 0 0.INSTALLATION Custom Coolant mix for hot operating temperatures (above 38° C / 100° F) Treated water (with no propylene glycol) can only be used as coolant when operating temperatures are never below 0° C (32° F). For operations in very warm temperatures treated water will provide the best cooling properties.3 2 0. and 1 part benzotriazole (BZT) to 300 parts of water.206 8. Always use water that meets the minimum and maximum specifications in the table below when using a custom coolant mix. sand filters.055 0.) as long as the water purity meets the specifications in the table below.43 25 Water purity Pure water (for reference only) Maximum purity Minimum purity Maximum potable water (for reference only) 10/16/08 3-42 HPR130XD Manual Gas Instruction Manual .010 0.

The display will show the current again. Refer to torch coolant requirements in this section for more information.INSTALLATION Fill the power supply with coolant The system will take 11. HPR130XD Manual Gas Instruction Manual 3-43 . 4 Add coolant to the power supply until the tank is full and replace the filler cap. When the flow rate is constant and greater than 22. 1 Add coolant to the power supply until the tank is full. release the knob. 2 Press and hold the current selection knob (8) and press power switch on the gas console. 3 The current display shows the flow rate. The pump will continue to run.6 gpm).7 lpm (0. Caution: Using the wrong coolant can cause damage to the system.1 liters (3 to 4 gallons) of coolant depending on the length of the torch leads and if the system has a local or remote ignition console.4 – 15. The pump will run continuously while (8) is pressed. Do not over fill the coolant tank.

If the purity level of the gas is too low (or too high in the case of methane) or if there are leaks in the supply hoses or connections. Gas supply pressures not within the specifications in Section 2 can cause poor cut quality. Move switch (7) to the CUTFLOW position (right position). 2-stage pressure regulator located within 3 m (10 ft) of the gas console. See Section 2 for gas and flow specifications. 8.3 bar (120 psi). move switch (7) on the gas console to SET PREFLOW. Turn OFF the power to the system. poor consumable life and operational problems. • • • • Cut speeds can decrease Cut quality can deteriorate Cutting thickness capability can decrease Parts life can shorten Caution: Setting the supply regulators 1. Set all gas regulator pressures to 8. Move switch (7) to the RUN position. 3-44 HPR130XD Manual Gas Instruction Manual .3 bar (120 psi). 3. Note: Oxygen. 6. Nitrogen is used as a purge gas. While gas is flowing adjust the supply regulator for the plasma gas to 8. After the purge cycle stops. 5.3 bar (120 psi).INSTALLATION Gas requirements The customer must furnish all gases and gas-supply regulators for the system. Turn ON the power to the system. Use a high-quality. Move switch (7) back to the RUN position (center). 2. 7. 4. See gas regulators in this section for recommendations. air and nitrogen are required for all systems. While gas is flowing adjust the supply regulator for the shield gas pressure to 8.

2-stage Air. Use a high-quality. 2-stage Kit: Hydrogen (H5. H35 and methane) 2-stage Kit: Air. 2-stage* Kit: Inert Gas. 1-stage Qty. 2-stage Hydrogen/methane.S. 2-stage Line regulator. The high-quality gas regulators listed below are available from Hypertherm and meet U.INSTALLATION Gas regulators Low-quality gas regulators do not provide consistent supply pressures and can result in poor cut quality and system operation problems. 2-stage. gas regulator to maintain consistent gas supply pressure. if using liquid cryogenic or bulk storage. 2-stage Kit: 1-stage (for use with cryogenic liquid nitrogen or oxygen) Oxygen. Use a high-quality. 1-stage. select gas regulators that conform to national and local codes. Compressed Gas Association (CGA) specifications. 1 1 1 1 1 1 1 3 1 1 * Kits include appropriate fittings HPR130XD Manual Gas Instruction Manual 3-45 . 2-stage Inert gas. gas regulator to maintain consistent gas supply pressure from high pressure gas cylinders. 2-stage regulator Single stage regulator Part Number 128544 128545 128546 128547 128548 022037 022038 022039 022040 022041 Description Kit: Oxygen. In other countries.

air must also be connected to the gas console to achieve the proper mixtures in the preflow and cutflow conditions. make sure that all hoses. CUTTING WITH OXYGEN CAN CAUSE FIRE OR EXPLOSION Cutting with oxygen as the plasma gas can cause a potential fire hazard due to the oxygen-enriched atmosphere that it creates. Flashback arrestors are required (unless not available for specific gases or required pressures) to prevent fire from propagating to supply gas. hose connections and fittings are acceptable for use with oxygen. For flexible-hose systems. Note: When cutting with oxygen as the plasma gas. use a hose designed for inert gas to carry air. Caution: When configuring the gas console to the supply gases. Installation must be made in accordance with national and local codes. Do not use steel or aluminum pipe.5 mm (1/2 in) for lengths > 23 m (75 ft). nitrogen or argon-hydrogen. WARNING 3-46 HPR130XD Manual Gas Instruction Manual . pressurize the entire system and check for leaks. argon-hydrogen and methane.INSTALLATION Supply gas plumbing Rigid copper plumbing or suitable flexible hose may be used for all gas supplies. After installation. Recommended hose diameters are 9. As a precaution.5 mm (3/8 in) for lengths < 23 m (75 ft) and 12. Hypertherm recommends that an exhaust ventilation system be installed when cutting with oxygen.

RH. RH. LH. JIC. Torch leads must be purged between gas changes. HPR130XD Manual Gas Instruction Manual 3-47 . because particulates can migrate into the valves. #6 9/16 – 18. internal (inert gas) “B” 9/16 – 18. Fitting N2 / Ar Air H35 / F5 O2 Size 5/8 – 18. (fuel gas) “B” 9/16 – 18. (oxygen) “B” Caution: Replacing the fittings on the gas console may cause the internal valves to malfunction.INSTALLATION Connect the supply gases Connect the supply gases to the gas console.

INSTALLATION Supply gas hoses 12 Oxygen hose Part no.5 m (25 ft) 10 m (35 ft) 15 m (50 ft) 20 m (65 ft) Part no. 024739 024451 024120 024124 024764 Length 25 m (82 ft) 35 m (115 ft) 45 m (150 ft) 60 m (200 ft) 75 m (250 ft) 14 Air hose Part no.5 m (25 ft) 10 m (35 ft) 15 m (50 ft) 20 m (65 ft) Part no. 024210 024203 024134 024211 024112 024763 Length 3 m (10 ft) 4. 024741 024742 024743 024771 024772 Length 25 m (82 ft) 35 m (115 ft) 45 m (150 ft) 60 m (200 ft) 75 m (250 ft) 3-48 HPR130XD Manual Gas Instruction Manual .5 m (15 ft) 7. 024671 024658 024659 024765 024660 024766 Length 3 m (10 ft) 4.5 m (25 ft) 10 m (35 ft) 15 m (50 ft) 20 m (65 ft) Part no.5 m (15 ft) 7. 024738 024450 024159 024333 024762 Length 25 m (82 ft) 35 m (115 ft) 45 m (150 ft) 60 m (200 ft) 75 m (250 ft) 13 Nitrogen or argon hose Part no. 024740 024744 024678 024680 024767 Length 25 m (82 ft) 35 m (115 ft) 45 m (150 ft) 60 m (200 ft) 75 m (250 ft) 15 Argon-hydrogen (H35) or nitrogen-hydrogen (F5) Part no. 024768 024655 024384 024769 024656 024770 Length 3 m (10 ft) 4.5 m (25 ft) 10 m (35 ft) 15 m (50 ft) 20 m (65 ft) Part no.5 m (15 ft) 7.5 m (15 ft) 7. 024607 024204 024205 024760 024155 024761 Length 3 m (10 ft) 4.

...................................................................................................................................4-12 Replace torch water tube ...............................................................................................................................4-2 Controls and indicators ...................................................................................................................................................4-14 Tips for table and torch.............................................................................4-5 Bevel cutting......................................................................4-5 Marking ...................................................................................................................................................4-13 How to optimize cut quality..................................................................................................................................4-3 Main power switch .................................................................................4-2 Check torch ........................................4-4 Consumable selection ...................................................................................................................................................................................................................................4-12 Common cutting faults............4-16 Cut charts......................................4-14 Maximize the life of consumable parts .......................................................................................................................................................................................................................................................................................................................................4-6 Aluminum .......................................................................................................................................................................................................................................4-14 Additional factors of cut quality ...................................................................................................................................4-17 Bevel cut charts................................................................................................................................................................4-8 Stainless steel bevel cutting ..................................................................................................................................................................................................................................................4-9 Torch maintenance ....................................................................................................................................4-18 Estimated kerf width compensation............................................................................................................................4-3 General .............................................................................................................................................................................4-17 Bevel cutting definitions....................................................................................................................................................................Section 4 OPERATION In this section: Daily start-up.............................................................4-3 Manual gas console operation...........................................................................4-7 Mild steel bevel cutting .............................................................................................................................................................................................................................4-11 Torch connections ..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4-14 Plasma set-up tips..............................................................................................................................................................................................................4-5 Consumables for mirror-image cutting...................................................4-3 Power indicators........................4-5 Standard cutting............4-19 HPR130XD Manual Gas Instruction Manual 4-1 .................................................................................................................................................................................................................................................................................................................................4-6 Stainless steel ..................................................................................4-5 SilverPlus electrodes ....................................................................................................................................................................................................................................................................................................4-15 Additional improvements.....................................................................................................................................................................................................................................................................................................................................................................................................................4-5 Mild steel .........................................................................................................................................................................4-8 Install and inspect consumables ...................................................

oil-free surface after removing. Dirty consumables can cause the torch to malfunction. 2. 4. • Refer to the Cut charts to choose the correct consumables for your cutting needs. Turn main disconnect switch to the power supply OFF. Always place the consumables on a clean. ensure that your cutting environment and that your clothing meet the safety requirements outlined in the Safety section of this manual. 1. dry. Refer to Install and inspect consumables later in this section for details. 3.OPERATION Daily start-up Prior to start-up. Shield cap Shield Nozzle retaining cap Nozzle Swirl ring Electrode Current ring Torch 4-2 HPR130XD Manual Gas Instruction Manual . Check torch WARNING Before operating this system. Ensure that the torch is perpendicular to the workpiece. you must read the Safety section thoroughly! Turn OFF the power supply’s main disconnect switch before proceeding with the following steps. • Refer to Install and inspect consumables later in this section for details and for parts inspection tables. Replace consumable parts. Remove the consumables from the torch and check for worn or damaged parts.

There is no power switch on the power supply. The gas console controls all system functions.OPERATION Controls and indicators General The main power switch for the HyPerformance plasma system is located on the gas console. Error codes are shown in the LED display over the current select knob. to turn on the power supply. Power indicators AC Green Indicator: Illuminates when the power switch is in the on position. Off Position (O) AC power is cut off to the control transformer. Main power switch On Position (I) AC power is sent to the control transformer. to turn off the power supply. HPR130XD Manual Gas Instruction Manual 4-3 .

Switch 8 can be in any position while operating. Position # 1 2 3. 4 & 7 5. Position switch (7) to RUN. 6 & 7 7 8 Instruction Select PLASMA GAS. Position switch (7) to SET PREFLOW (3-4). Set plasma cutflow (5). The current shown during cutting may vary by +/. * The 3-digit display is for reference. System is ready to cut. Set shield cutflow (6). Set shield preflow (4). Turn ON the power. Follow instructions below using the settings provided in the Cut charts. 3-digit display* Position number 1.2 amps from the current shown when the amperage is set. 4-4 HPR130XD Manual Gas Instruction Manual .OPERATION Manual gas console operation The term “position number” refers to the numbers on the front panel of the gas console. 2. Set amperage using knob above switch (8). Set plasma preflow (3). Select SHIELD GAS. Position switch (8) to SET AMPS. Position switch (7) to SET CUTFLOW (5-6).

060 in or 16 gauge). or the depth can be decreased by increasing the marking speed. Bevel cutting (0° to 45°) Consumables for 130 amp and 260 amp bevel cutting are specifically designed for bevel cutting. For best mark quality. when the torch is perpendicular to the workpiece. use the argon marking process settings. SilverPlus electrodes SilverPlus electrodes provide increased life when the average cut duration is short (< 60 seconds). Marking Any of the consumable sets can also be used for marking with argon or nitrogen. For all marking processes the depth of the mark can be increased by reducing the marking speed. Argon marking currents can be increased by up to 30% to increase the depth of the mark. and material surface finish. Poor quality marking or burn-through may occur with material less than 1. 200 amp. Marking parameters are shown at the bottom of each cut chart. cut process. and 260 amp mild steel O2 / Air cutting. 400 amp cut charts are provided for convenience. Consumables for mirror-image cutting See the Parts List section in this manual for part numbers.5 mm (. 400 amp consumables can be used for standard cutting and bevel cutting. and cut quality is not the most critical requirement.OPERATION Consumable selection Standard cutting (0°) Most of the consumables on the following pages are designed for standard (straight) cutting. HPR130XD Manual Gas Instruction Manual 4-5 . but bevel-specific. The quality of the marks will vary depending on the marking process. material type. SilverPlus electrodes are available for 130 amp. material thickness. Part numbers can be found on the following page.

O2 / Air – 220665 Stainless steel Shield cap 45A 220202 220755 220201 220180 220308 Shield Nozzle retaining cap Nozzle Swirl ring Electrode Water tube 80A 220340 220747 220338 220755 220337 220179 220339 130A 220198 220755 (H35) 220756 (N2) 220197 220179 220307 4-6 HPR130XD Manual Gas Instruction Manual .OPERATION Mild steel Shield cap Shield Nozzle retaining cap Nozzle Swirl ring Electrode Water tube 30A 220194 220754 220193 220180 220192 50A 220555 220754 220554 220553 220552 220340 220747 80A 220189 220756 220188 220179 220187 130A 220183 220756 220182 220179 220181* * SilverPlus electrodes are available for the following process. Mild steel. 130 amp.

OPERATION Aluminum Shield cap 45A 220202 220756 220201 220180 220308 220340 220747 Shield Nozzle retaining cap Nozzle Swirl ring Electrode Water tube 130A 220198 220755 (H35) 220756 (Air) 220197 220179 220307 (H35) 220181 (Air) HPR130XD Manual Gas Instruction Manual 4-7 .

OPERATION Mild steel bevel cutting Shield cap 80 A Nozzle retaining cap Swirl ring Shield Nozzle Electrode Water tube 220637 220742 220845 220806 220179 220802 220700 130 A 220637 220742 220740 220646 220179 220649 220700 Stainless steel bevel cutting Shield cap Shield Nozzle retaining cap Nozzle Swirl ring Electrode Water tube 130 A 220637 220738 220739 220656 220179 220606 220571 4-8 HPR130XD Manual Gas Instruction Manual .

Install the nozzle retaining cap 5. Always disconnect power to the power supply before inspecting or changing torch consumable parts. Use gloves when removing consumables.OPERATION Install and Inspect consumables WARNING The system is designed to go into an idle mode if the retaining cap is removed. Install the nozzle and swirl ring 4. The o-ring should look shiny. DO NOT CHANGE CONSUMABLE PARTS WHILE IN THE IDLE MODE. bring the torch to the edge of the cutting table. Install the shield 6. Install consumables Check the consumable parts daily for wear before cutting. However. Install the shield cap HPR130XD Manual Gas Instruction Manual 4-9 . Before removing consumables. Tool: 104119 1. Install the electrode 2. Wipe the internal and external surfaces of the torch with a clean cloth or paper towel. but there should not be any excess or built-up grease. Install the swirl ring 3. with the torch lifter raised to its highest point to prevent the consumables from dropping into the water of the water table. The torch might be hot. Note: Do not overtighten parts! Only tighten until mating parts are seated. Apply a thin film of silicone lubricant on each o-ring.

04 inches or greater.a pit forms as the emitter wears. replace the electrode when the pit depth is 0. O-rings: Damage Lubricant 4-10 HPR130XD Manual Gas Instruction Manual . missing material Shield cap Cracks Burned surface General: Erosion or missing material Molten material attached Blocked gas holes Shield Center hole: Must be round O-rings: Damage Lubricant General: Damage to insulating ring Action Replace shield cap Replace shield cap Replace shield cap Replace shield Replace shield Replace shield Replace the shield when the hole is no longer round Replace shield Apply a thin film of silicone lubricant if the o-rings are dry Replace nozzle retaining cap Nozzle retaining cap Insulating ring Poor cut quality after Replace nozzle retaining cap replacing other consumables General: Erosion or missing material Blocked gas holes Replace nozzle Replace nozzle Replace the nozzle when the hole is no longer round Replace nozzle Replace nozzle Apply a thin film of silicone lubricant if the o-rings are dry Replace swirl ring Replace swirl ring Clean and check for damage. Replace electrode Apply a thin film of silicone lubricant if the o-rings are dry Nozzle Always replace the nozzle and electrode as a set. For the 400 amp mild steel electrode and all SilverPlus electrodes. replace the electrode when the pit depth is 0. Center hole: Must be round Signs of arcing O-rings: Damage Lubricant General: Chips or cracks Blocked gas holes Swirl ring Dirt or debris O-rings: Damage Lubricant Emitter Electrode Always replace the nozzle and electrode as a set.OPERATION Inspect consumables Inspect Look for Erosion.06 inches or greater. replace when damaged Replace swirl ring Apply a thin film of silicone lubricant if the o-rings are dry In general. Center surface: Emitter wear .

but there should not be any excess or built-up grease. but there should not be any excess or built-up grease. 3. The torch should not be subjected to hard impacts that can cause critical features to become misaligned. 4. The o-rings should look shiny. The torch should be stored in a clean location when not in use. Hypertherm provides a kit (128879) of replacement parts. and use compressed air to blow them off before they are installed again. If they are not damaged. Use compressed air to blow away any remaining dirt and debris from internal and external surfaces. Kits should be kept in stock and be used as part of your routine maintenance schedule. Front view of the torch External o-rings (2) Quick-disconnect maintenance The following steps should be completed every 5-10 times consumables are changed: 1. O-rings (5) External threads Rear view of the torch Maintenance kit Even with proper care. A cotton swab can be used to access hard-to-reach internal surfaces. This is especially critical for the nozzle retaining cap. Routine maintenance The following steps should be completed each time consumables are changed: 1. The o-rings should look shiny. Use compressed air to blow off all internal surfaces at the rear of the torch. use a clean cloth to wipe them off. The torch is manufactured to very tight tolerances to maximize cut quality. HPR130XD Manual Gas Instruction Manual 4-11 . 2. Replace any damaged o-rings. Apply a thin film of silicone lubricant on each external o-ring. If consumables will be reused. Use compressed air to blow off all internal surfaces and the external threads. the o-rings at the rear of the torch will need to be replaced periodically. 4. Use a clean cloth to wipe off the torch inside and outside. to avoid contamination of critical surfaces and passages. apply a thin film of silicone lubricant on each o-ring. Remove the torch from the quick-disconnect assembly. 3.OPERATION Torch maintenance Poor cut quality and premature failure may occur if the HPR torch is not maintained properly. Inspect each of the 5 o-rings at the rear of the torch for nicks or cuts. 2.

Apply a thin film of silicone lubricant on the o-ring. Replace torch water tube WARNING The system is designed to go into an idle mode if the retaining cap is removed. but there should not be any excess or built-up grease. However. 1. See Install and inspect consumables in this section.OPERATION Torch connections Plasma vent Shield gas Ohmic contact pin Plasma gas Coolant in Torch Pilot arc Coolant return Coolant return Coolant in Torch quick-disconnect receptacle Note: The coolant in and the coolant return lines in the quick-disconnect are in opposite positions from the torch coolant lines. and install a new water tube. Remove the old water tube. See Install and inspect consumables in this section. Always disconnect power to the power supply before removing torch consumable parts. Note: The water tube may seem loose when correctly inserted. Use gloves when removing consumables. 3. 4. 4-12 HPR130XD Manual Gas Instruction Manual . Turn OFF all power to the system. This helps reduce the coolant temperature. 5. Replace consumables. The torch might be hot. DO NOT REMOVE CONSUMABLE PARTS WHILE IN THE IDLE MODE. The o-ring should look shiny. but any side-to-side looseness will disappear after the electrode is installed. Remove consumables from torch. 2.

travel speed. 5. motion delay. 2. To achieve consumable long life. 3. HPR130XD Manual Gas Instruction Manual 4-13 . • Short consumable life. Arc current. Causes can be: 1. Torch parts are worn (see Install and inspect consumables). 4. See Section 5.OPERATION Common cutting faults • Torch pilot arc will initiate. Causes can be: 1. Attempting to cut highly magnetic metal plate. • Cut angle is not square. Work cable connection on the cutting table is not making good contact. Long consumable life is difficult to achieve when cutting plate that is magnetized or becomes magnetized easily. Cut speed is too high (check Cut chart information). 3. 4. Arc current is set too low (check Cut chart information). 2. Torch parts are worn (see Install and inspect consumables). or initial torch height not set as specified in the Cut charts. will shorten consumable life. arc voltage. Damaged consumable parts (see Install and inspect consumables). Causes can be: 1. Cutting speed is not correct (check Cut chart information). Causes can be: 1. Causes can be: 1. Metal being cut is too thick. Torch-to-work distance is too high. 2. 3. Beginning or ending the cut off the plate surface. but will not transfer. 3. gas flow rates. Cutting speed is not correct (check Cut chart information). Torch-to-work distance is not correct (check Cut chart information). • The workpiece is not totally penetrated. 2. • Dross forms on the bottom of the cut. all cuts must begin and end on the plate surface. Wrong direction of machine travel. Current is set too low (check Cut chart information). High-quality side is on the right with respect to the forward motion of the torch. such as armor plate with a high nickel content. Arc current is not correct (check Cut chart information). 2. 3. Malfunction in the system. and there is excessive sparking on top of the workpiece.

– Stop the arc before the part is completely cut. • The torch should never fire into the air. See Cut charts. to minimize erosion of the electrode’s center surface. and remember that a chain cut of long duration will cause electrode wear. do not allow the path to lead off the workpiece and back on. – To start with a pierce. smooth and dross-free cuts. so the path of the torch can lead directly from one cut part into the next. as long as the arc is not fired in the air. Maximize the life of consumable parts Hypertherm’s LongLife® process automatically “ramps up” the gas and current flows at the start and ramps them down at the end of each cut. Note: 4-14 HPR130XD Manual Gas Instruction Manual . try one or more of the following: – Reduce the cutting speed during the final part of the cut. to avoid arc blow-outs (ramp-down errors). Contact can damage the shield and nozzle.5 to 2 times the torch-to-work distance. Plasma set-up tips Follow carefully each step in the Daily start-up procedure described earlier in this section. straight. The LongLife process also requires that cuts start and stop on the workpiece. Tips for table and torch • Use a square to align the torch at right angles to the workpiece. and affect the cut surface. • Each cut should end with the arc still attached to the workpiece. However. for proper ramp-down. check and “tune” the rails and drive system on the cutting table.OPERATION How to optimize cut quality The following tips and procedures will help produce square. • If arc blow-outs occur. check that the arc stays attached to the edge of the workpiece. • The torch may travel more smoothly if you clean. • The torch must not touch the workpiece during cutting. to allow completion of the cut during the ramp-down. Purge the gas lines before cutting. – Starting the cut at the edge of the workpiece is acceptable. – When cutting drop parts (small parts that drop down after being cut from the workpiece). without stopping and starting the arc. Unsteady machine motion can cause a regular. use a pierce height that is 1. – Program the path of the torch into the scrap area for ramp-down. Note: Use a “chain cut” if possible. It may be difficult to achieve the full benefits of the LongLife process in some conditions. wavy pattern on the cut surface.

the first cut in a series of cuts will likely produce the least dross. For example. check the torch-to-work distance. previous page). It is welded to the bottom of the cut and is difficult to remove. Next. especially if cut angles are all positive or all negative. Decrease arc voltage to lower the torch. To reduce high-speed dross: • Decrease the cutting speed. Dross Low-speed dross forms when the torch’s cutting speed is too slow and the arc shoots ahead. bubbly deposit at the bottom of the cut and can be removed easily. As the workpiece heats up. Worn or damaged consumables may produce intermittent dross. Increase arc voltage to raise the torch. to decrease the torch-to-work distance. linear bead of solid metal attached very close to the cut. the problem is in the drive system. To determine whether a cut-angle problem is being caused by the plasma system or the drive system. (Only HyDefinition and HT4400 systems can accommodate mixed-gas shield gases. rotate the torch 90° in its holder and repeat the process.) Notes: Dross is more likely to form on warm or hot metal than on cool metal.OPERATION Additional factors of cut quality Cut angle A cut part whose 4 sides average less than 4° of cut angle is considered acceptable. High-speed dross forms when the cutting speed is too fast and the arc lags behind. more dross may form on subsequent cuts. make a test cut and measure the angle of each side. Increase the speed to reduce the dross. Note: Note: The squarest cut angle will be on the right side with respect to the forward motion of the torch. Problem Cause Solution Negative cut angle Square cut Positive cut angle \ The torch is too low. It forms as a heavy. Dross is more likely to form on mild steel than on stainless steel or aluminum. The torch is too high. It forms as a thin. • Decrease arc voltage. If the angles are the same in both tests. HPR130XD Manual Gas Instruction Manual 4-15 . • Increase O2 in the shield gas to increase the range of dross-free cutting speeds. • A negative cut angle results when more material is removed from the bottom of the cut. If a cut-angle problem persists after “mechanical causes” have been eliminated (see Tips for table and torch. • A positive cut angle results when more material is removed from the top of the cut than from the bottom.

Trade-off: This may reduce starting reliability.OPERATION Straightness of the cut surface A typical plasma cut surface is slightly concave. The cut surface may become more concave. When piercing materials close to the maximum thickness for a specific process. In particular. • Different material chemistries can have an adverse effect on the pierce capability of the system. a stationary or edge start is recommended. which provides additional protection for the consumables. increasing the shield preflow pressure can help in some cases. starting torch motion immediately after transfer and during the pierce process) can extend the piercing capability of the system in some cases. • Using a “flying pierce” (i. but not so long that it allows the arc to “wander” while trying to find the edge of a large pierce hole. A convex cut surface occurs when the torch-to-work distance is too great or the cutting current is too high. try the consumables designed for the lower current. Correct torch height is required to keep the cut surface acceptably close to straight. then reduce the cutting current. Hypertherm calculates mild steel pierce parameters with certified A-36 plate. this delay time may need to be increased. Additional improvements Some of these improvements involve trade-offs. Piercing The pierce delay should allow sufficient time to penetrate the full thickness of the material. Trade-off: This will increase the negative cut angle. 50 mm (2 in) material requires a 50 mm lead-in. Increase the arc voltage to increase the torch-to-work distance and straighten the cut surface. 4-16 HPR130XD Manual Gas Instruction Manual . • To avoid damage to the shield from the build up of molten material created by the pierce. Using the “pierce complete” signal during piercing maintains the shield-gas pressure at the higher preflow pressure. A strongly concave cut surface occurs when the torch-to-work distance is too low. or convex. Note: The torch must not touch the workpiece while piercing or cutting. • If the system has difficulty piercing a specific material or thickness. How to increase cutting speed • Decrease the torch-to-work distance. as described.e. If there is overlap between different cutting currents for that thickness. Pierce delay times given in the cut charts are based on average delay times throughout the life of the consumables. First. do not allow the torch to descend to cut height until it has cleared the puddle of molten material. high-strength steel and steel with a high manganese or silicon content can reduce the maximum pierce capability. Because this can be a complex process that can damage the torch or other components. reduce the arc voltage. there are several important factors to consider: • Allow a lead-in distance that is about the same as the thickness of the material being pierced. As consumables wear.

Bevel cut charts The bevel cut charts are slightly different from the standard cut charts. Equivalent thicknesses and the arc voltages will vary depending on the angle of the cut. HPR130XD Manual Gas Instruction Manual 4-17 . cutting speeds and the gas and torch settings required for each process. The torch-to-work distance is a range rather than a single value. Because of differences between installations and material composition.OPERATION Cut charts The following Cut charts show the consumable parts. a column for minimum clearance has been added. See Bevel cutting definitions on the next page for more detailed information. adjustments may be required to obtain desired results. The angle for bevel cutting can range from 0° to 45°. material thickness is given as an equivalent value. and there is no column for arc voltage. The numbers shown in the Cut charts are recommended to provide high-quality cuts with minimal dross.

Equivalent thickness is equal to the nominal thickness divided by the cosine of the bevel angle. the bevel angle is zero. The vertical distance from the lowest point of the torch to the surface of the workpiece. Nominal thickness Equivalent thickness Clearance Torch-to-work distance Arc voltage Torch center-line 0° Bevel angle Torch-to-work distance Clearance Nominal thickness Equivalent thickness 4-18 HPR130XD Manual Gas Instruction Manual . The largest number is for a 45° bevel cut with a clearance of 3 mm (0. The maximum bevel angle is 45°. The length of the cut edge. The smallest number is for a straight cut (bevel angle = 0°). If the torch is perpendicular to the workpiece.120 in). or the distance the arc travels through the material while cutting. The linear distance from the center of the torch outlet to the workpiece surface along the torch center-line. The arc voltage setting on one system may be different from a second system even if the workpiece is the same thickness. Equivalent thicknesses are listed in the cut chart. The arc voltages for bevel cutting are not supplied in the bevel cut charts. A range of torch-to-work distances are listed in the cut chart.OPERATION Bevel cutting definitions Bevel angle The angle between the center line of the torch and a line that is perpendicular to the workpiece. The vertical thickness of the workpiece. The arc voltage setting is dependent on the bevel angle and the setup of the cutting system.

879 2.082 0.071 0.184 2.483 0.107 0.083 1.114 0.229 1.803 1.108 2.072 0.057 0.372 1.135" 1/4" 3/8" 1/2" 3/4" 1" HPR130XD Manual Gas Instruction Manual 4-19 .092 2.042 0.642 3.006 0.047 0.073 0.718 2.068 0.381 0.584 0.448 1.083 2.107 0.075 0.054 0.245 2.769 2.896 1.053 0.718 1.109 0.104 0.009 0.OPERATION Estimated kerf-width compensation The widths in the chart below are for reference.854 2.740 1.015 0.021 0.114 0.023 0. Differences between installations and material composition may cause the specific user results to vary from those shown in the table.516 1.019 0.043 0.060 0.109 0.074 0.095 0.533 0.346 1.083 0.032 1.086 0.082 0.429 1.049 0.152 2.5 3 6 10 12 20 25 English Thickness (in) Process Mild steel 130A O2 / Air 80A O2 / Air 50A O2 / O2 30A O2 / O2 Stainless steel 130A H35 / N2 130A N2 / N2 80A F5 / N2 45A F5 / N2 45A N2 / N2 Aluminum 130A H35 / N2 130A Air / Air 45A Air / Air 0.073 0.060" 0.194 0.829 1.080 0.896 0. Metric Thickness (mm) Process Mild steel 130A O2 / Air 80A O2 / Air 50A O2 / O2 30A O2 / O2 Stainless steel 130A H35 / N2 130A N2 / N2 80A F5 / N2 45A F5 / N2 45A N2 / N2 Aluminum 130A H35 / N2 130A Air / Air 45A Air / Air 1.413 2.905 2.769 2.135 0.067 1.727 1.

5 2.3 180 0.5 0.5 English Select Gases Set Preflow Set Cutflow Material Thickness in 0.3 180 0.050 in ipm 215 200 170 155 110 85 60 50 40 30 25 Initial Pierce Height in factor % Pierce Delay Time seconds 0.7 1.048 0.10 Marking Speed mm/min 6350 2540 ipm 250 100 Arc Voltage Volts 105 80 * Pierce complete is recommended for these thicknesses 4-20 HPR130XD Manual Gas Instruction Manual .5 in 0.5 2 2.2 0. It is used as the preflow gas Flow rates – lpm/scfh O2 Preflow Cutflow 0/0 22 / 46 Air 46 / 97 0/0 220747 220194 220754 220193 220180 220192 220340 Metric Select Gases Set Preflow Set Cutflow Material Thickness mm 0.3 0.2 2.036 0.5 0.2 1.110 0.060 Marking Select Gases N2 Ar N2 Air Set Preflow 10 90 10 10 Set Cutflow 10 90 10 10 Amperage Amps 15 9 Torch-to-Work Distance mm 2.075 0.8 1 1.0 Plasma Shield Plasma Shield Plasma Shield 15 15 1.135* 3/16* 1/4* Arc Torch-to-Work Cutting Voltage Distance Speed Volts 114 115 116 117 119 120 122 123 128 0.7 1.5 0.105 0.0 Plasma Shield Plasma Shield Plasma Shield 15 15 O2 O2 80 35 92 5 75 0.024 0.4 0.018 0.090 0.060 0.OPERATION Mild steel O2 Plasma / O2 Shield 30 A Cutting Note: Air must be connected to use this process.1 0.10 0.5 3* 4* 6* Arc Torch-to-Work Cutting Voltage Distance Speed Volts 114 115 116 117 119 120 122 123 125 128 mm mm/m 5355 4225 3615 2865 2210 1490 1325 1160 905 665 Initial Pierce Height mm factor % Pierce Delay Time seconds 0.3 O2 O2 80 35 92 5 75 1.030 0.1 0.4 2.7 0.

10 factor % Pierce Delay Time seconds Plasma Shield Plasma Shield Plasma Shield O2 O2 70 30 75 15 0.2 0.3 0.0 factor % Pierce Delay Time seconds Plasma Shield Plasma Shield Plasma Shield English Select Gases Set Preflow Set Cutflow Material Thickness in 0.2 1.05 200 0.5 3.10 0.5 Marking Select Gases N2 Ar N2 Air Set Preflow 10 90 10 10 Set Cutflow 10 90 10 10 Amperage Amps 15 9 Torch-to-Work Distance mm 2.048 0.5 2.16 0.1 0.3 mm 1.0 1.6 200 0.08 0.0 0.075 0.2 0.04 ipm 270 210 160 125 110 80 60 50 35 25 Initial Pierce Height in 0.5 3 4 5 6 7 8 Arc Torch-to-Work Cutting Voltage Distance Speed Volts 110 111 112 114 115 117 119 121 122 126 128 130 2.0 0.1 0.0 2.105 0.5 1.5 in 0.0 mm/m 6500 5000 4150 3200 2700 2200 1800 1400 1200 950 780 630 4.08 0.10 Marking Speed mm/min 6350 2540 ipm 250 100 Arc Voltage Volts 118 77 HPR130XD Manual Gas Instruction Manual 4-21 .06 0.3 0.030 0.036 0.5 2 O2 O2 70 30 75 15 2.135 3/16 1/4 5/16 Arc Torch-to-Work Cutting Voltage Distance Speed Volts 110 112 114 115 118 120 121 125 130 in 0. It is used as the preflow gas Flow rates – lpm/scfh O2 Preflow Cutflow 0/0 25 / 52 Air 43 / 90 0/0 220747 220555 220754 220554 220553 220552 220340 Metric Select Gases Set Preflow Set Cutflow Material Thickness mm 0.060 0.8 1 1.4 Initial Pierce Height mm 2.0 0.OPERATION Mild steel O2 Plasma / O2 Shield 50 A Cutting Note: Air must be connected to use this process.12 0.

1 0.0 15 5.3 0.080 15 0.7 0.8 factor % 150 Pierce Delay Time seconds 0.160 200 0.3 0.5 3.250 250 0.105 0.9 Plasma Shield Plasma Shield Plasma Shield 30 O2 Air 50 30 72 0.10 0.0 6.8 0.9 Plasma Shield Plasma Shield Plasma Shield 30 O2 Air 50 30 72 2.200 0.8 0.100 ipm 400 290 180 155 110 75 50 37 25 Initial Pierce Height in 0.5 mm/m 9810 7980 6145 4300 3045 1810 1410 1030 545 Initial Pierce Height mm 3.5 0.2 0.5 3 4 6 10 12 15 20 Arc Torch-to-Work Cutting Voltage Distance Speed Volts 112 115 117 120 123 127 130 133 135 mm 2.150 factor % 150 Pierce Delay Time seconds 0.2 4.OPERATION Mild steel O2 Plasma / Air Shield 80 A Cutting Flow rates – lpm/scfh O2 Preflow Cutflow 0/0 23 / 48 Air 76 / 161 41 / 87 220747 220189 220756 220188 220179 220187 220340 Metric Select Gases Set Preflow Set Cutflow Material Thickness mm 2 2.1 0.3 250 2.5 0.5 English Select Gases Set Preflow Set Cutflow Material Thickness in 0.0 200 0.0 in 0.7 0.100 Marking Select Gases N2 Ar N2 Air Set Preflow 10 50 10 10 Set Cutflow 10 50 10 10 Amperage Amps 15 15 Torch-to-Work Distance mm 2.075 0.12 Marking Speed mm/min 6350 2540 ipm 250 100 Arc Voltage Volts 130 78 4-22 HPR130XD Manual Gas Instruction Manual .135 3/16 1/4 3/8 1/2 5/8 3/4 Arc Torch-to-Work Cutting Voltage Distance Speed Volts 112 115 117 120 123 127 130 133 135 in 0.

1 0.6 mm/m 9810 7980 6145 4300 3045 1810 1410 1030 545 Initial Pierce Height mm 3.5 3 4 6 10 12 15 20 mm 2.150 factor % 150 Pierce Delay Time seconds 0.135 3/16 1/4 3/8 1/2 5/8 3/4 in 0.1 – 0.3 0.10 0.160 200 0.5 3.105 0.OPERATION Mild steel bevel cutting O2 Plasma / Air Shield 80 A Cutting Flow rates – lpm/scfh O2 Preflow Cutflow 0/0 23 / 48 Air 47 / 100 47 / 100 220637 220742 220845 220806 220179 220802 220700 Metric Select Gases Set Preflow Set Cutflow Equivalent Minimum Torch-to-Work Cutting Material Clearance Distance Speed Thickness mm mm 2 2.8 factor % 150 Pierce Delay Time seconds 0.0 in 0.5 0.0 200 0.75 0.08 – 0.5 0.0 6.6 24 5.5 – 8.7 0.34 24 0.1 0.0 2.2 4.34 ipm 400 290 180 155 110 75 50 37 25 Initial Pierce Height in 0.2 0.34 Marking Select Gases N2 Ar N2 Air Set Preflow 10 50 10 10 Set Cutflow 10 50 10 10 Amperage Amps 15 15 Torch-to-Work Distance mm 2.8 0.3 0.6 English Select Gases Set Preflow Set Cutflow Equivalent Minimum Torch-to-Work Cutting Material Clearance Distance Speed Thickness in in 0.5 – 8.12 Marking Speed mm/min 6350 2540 ipm 250 100 Arc Voltage Volts 130 78 HPR130XD Manual Gas Instruction Manual 4-23 .9 Plasma Shield Plasma Shield Plasma Shield 48 O2 Air 50 48 72 2.200 0.8 0.1 – 0.250 250 0.7 0.9 Plasma Shield Plasma Shield Plasma Shield 48 O2 Air 50 48 72 0.0 – 8.3 250 2.08 0.

6 6.7 1.5 mm/m 6505 5550 4035 2680 2200 1665 1050 550 375 255 7.220 0.120 0.2 0.5 0.6 200 factor % Pierce Delay Time seconds 0.8 Plasma Shield Plasma Shield Plasma Shield 35 40 O2 Air 35 80 28 65 Marking Select Gases N2 Ar N2 Air Set Preflow 10 50 10 10 Set Cutflow 10 50 10 10 Amperage Amps 15 15 Torch-to-Work Distance mm 2.200 0.110 0.0 4.0 in 0.0 1.3 0.0 1.300 190 Edge start 200 factor % Pierce Delay Time seconds 0.2 0.7 1.1 0.0 3.1 0.5 3.260 0.150 0.6 190 Edge start Initial Pierce Height mm 5.0 6.160 0.5 0.130 0.5 2.3 3.100 0.8 Plasma Shield Plasma Shield Plasma Shield English Select Gases Set Preflow Set Cutflow Material Thickness in 0.8 4.180 ipm 240 190 150 110 80 60 45 20 15 10 Initial Pierce Height in 0.0 5.3 0.10 0.8 3.240 0.135 3/16 1/4 3/8 1/2 5/8 3/4 1 1-1/4 1-1/2 Arc Torch-to-Work Cutting Voltage Distance Speed Volts 124 126 127 130 132 135 138 141 160 167 in 0.12 Marking Speed mm/min 6350 2540 ipm 250 100 Arc Voltage Volts 130 75 4-24 HPR130XD Manual Gas Instruction Manual .OPERATION Mild steel O2 Plasma / Air Shield 130 A Cutting Flow rates – lpm/scfh O2 Preflow Cutflow 0/0 33 / 70 Air 102 / 215 45 / 96 220747 220183 220756 220182 220179 220181 220340 Metric Select Gases Set Preflow Set Cutflow Material Thickness mm 3 35 40 O2 Air 35 80 28 65 4 6 10 12 15 20 25 32 38 Arc Torch-to-Work Cutting Voltage Distance Speed Volts 124 126 127 130 132 135 138 141 160 167 mm 2.

3 – 8.200 0.8 4.6 3.180 – 0.0 5.OPERATION Mild steel bevel cutting O2 Plasma / Air Shield 130 A Flow rates – lpm/scfh O2 Preflow Cutflow 0/0 33 / 70 Air 64 / 135 45 / 96 220637 Note: 220742 220740 220646 220179 220649 220700 Bevel angle range is 0° to 45° Equivalent Torch-to-Work Cutting Material Distance Speed Thickness mm 3 30 4 6 33 10 80 23 2.6 2.5 – 8.6 190 220 Edge start Metric Select Gases Set Preflow Set Cutflow Minimum Clearance mm Initial Pierce Height mm 5.130 – 0.3 0.340 0.5 – 8. 3.0 in 0.5 3.135 3/16 1/4 3/8 1/2 5/8 3/4 1 1-1/4* 1-1/2 in 0.0 Plasma Shield Plasma Shield Plasma Shield 30 33 O2 Air 15 80 23 0.260 0.8 4.8 – 8.12 Marking Speed mm/min 6350 2540 ipm 250 100 Arc Voltage Volts 130 75 * Suggestions for piercing 32 mm (1-1/4 in) mild steel: 1.5 0. Use pierce complete when piercing HPR130XD Manual Gas Instruction Manual 4-25 .0 1.0 1.340 0.0 – 8.160 – 0.0 6.240 0.7 1.2 0.4 190 220 Edge start 200 factor % Pierce Delay Time seconds 0.1 0.10 0.340 0. Turn preflow on during IHS.6 200 factor % Pierce Delay Time seconds 0.220 0.3 0.6 4.0 Plasma Shield Plasma Shield Plasma Shield O2 Air 15 English Select Gases Set Preflow Set Cutflow Minimum Clearance in Equivalent Torch-to-Work Cutting Material Distance Speed Thickness in 0.5 0.150 – 0.340 0. 2.340 ipm 240 190 150 110 80 60 45 20 15 10 Initial Pierce Height in 0.110 – 0.1 0.2 7.080 49 Marking Select Gases N2 Ar N2 Air Set Preflow 10 50 10 10 Set Cutflow 10 50 10 10 Amperage Amps 15 15 Torch-to-Work Distance mm 2.6 3.8 – 8.7 1.120 – 0.0 – 8.300 0.6 6. Use ohmic contact during IHS.0 12 15 20 25 49 32* 38 mm 2.6 mm/m 6505 5550 4035 2680 2200 1665 1050 550 375 255 10.6 3.100 – 0.340 0.340 0.6 4.2 0.

048 0.1 0.036 0.1 Plasma Shield Plasma Shield Plasma Shield N2 N2 35 5 55 60 2. F5/N2 stainless steel process.150 150 0.OPERATION Stainless steel N2 Plasma / N2 Shield 45 A Cutting Flow rates – lpm/scfh N2 Preflow Cutflow 24 / 51 75 / 159 220747 220202 220755 220201 220180 220308 220340 Metric Select Gases Set Preflow Set Cutflow Material Thickness mm 0.100 in ipm 240 210 180 160 120 75 Initial Pierce Height in factor % Pierce Delay Time seconds 0.2 1.10 0.135 Arc Torch-to-Work Cutting Voltage Distance Speed Volts 94 95 97 101 103 0.5 3 4 Arc Torch-to-Work Cutting Voltage Distance Speed Volts 94 95 97 101 103 mm mm/m 6380 5880 5380 4630 3935 3270 2550 1580 Initial Pierce Height mm factor % Pierce Delay Time seconds 0.8 1 1.060 0.2 0.5 2.8 150 0.3 English Select Gases Set Preflow Set Cutflow Material Thickness in 0.5 3. 4-26 HPR130XD Manual Gas Instruction Manual .0 0.0 0.3 Plasma Shield Plasma Shield Plasma Shield N2 N2 35 5 55 60 Marking Select Gases N2 Ar N2 Air Set Preflow 10 90 10 10 Set Cutflow 10 90 10 10 Amperage Amps 15 12 Torch-to-Work Distance mm 2.5 in 0.2 0.075 0.105 0.10 Marking Speed mm/min 6350 2540 ipm 250 100 Arc Voltage Volts 85 65 Note: This process produces a darker cut edge than the 45 A.5 2 2.

4 0.5 3 4 6 Arc Torch-to-Work Cutting Voltage Distance Speed Volts mm mm/m 6570 5740 4905 3890 3175 2510 2010 1435 845 Initial Pierce Height mm factor % Pierce Delay Time seconds Plasma Shield Plasma Shield Plasma Shield 99 2.5 Marking Select Gases N2 Ar N2 Air Set Preflow 10 90 10 10 Set Cutflow 10 90 10 10 Amperage Amps 15 12 Torch-to-Work Distance mm 2.060 0.8 150 F5 N2 35 25 55 60 15 101 102 103 104 110 0.8 1 1.3 190 0.2 1.10 Marking Speed mm/min 6350 2540 ipm 250 100 Arc Voltage Volts 85 65 Note: This process produces a shinier cut edge than the 45 A. N2/N2 stainless steel process.036 0.135 3/16 1/4 99 100 102 104 108 110 0.3 0.5 2 2.5 in 0.2 Initial Pierce Height in factor % Pierce Delay Time seconds Plasma Shield Plasma Shield Plasma Shield 60 F5 N2 35 25 55 150 0.150 15 0.5 0.0 English Select Gases Set Preflow Set Cutflow Material Thickness in 0.075 0.2 3.5 2.080 190 0.105 0.OPERATION Stainless steel F5 Plasma / N2 Shield 45 A Cutting Flow rates – lpm/scfh Preflow Cutflow F5 0/0 8 / 17 N2 43 / 91 65 / 138 220747 220202 220755 220201 220180 220308 220340 Metric Select Gases Set Preflow Set Cutflow Material Thickness mm 0.10 0. HPR130XD Manual Gas Instruction Manual 4-27 .048 0.100 Arc Torch-to-Work Cutting Voltage Distance Speed Volts in ipm 240 190 150 130 90 65 45 30 0.5 2.

170 0.120 ipm 105 60 45 25 Initial Pierce Height in 0.5 3.5 3.3 0.150 0.135 3/16 1/4 3/8 Arc Torch-to-Work Cutting Voltage Distance Speed Volts 108 110 112 120 in 0.120 0.110 0.OPERATION Stainless steel F5 Plasma / N2 Shield 80 A Cutting Flow rates – lpm/scfh Preflow Cutflow F5 0/0 31 / 65 N2 67 / 142 55 / 116 220747 220338 220755 220337 220179 220339 220340 Metric Select Gases Set Preflow Set Cutflow Material Thickness mm 4 6 10 Arc Torch-to-Work Cutting Voltage Distance Speed Volts 108 112 120 mm 3.2 150 0.180 factor % Pierce Delay Time seconds 0.5 Plasma Shield Plasma Shield Plasma Shield F5 N2 35 30 60 75 Marking Select Gases N2 Ar N2 Air Set Preflow 10 50 10 10 Set Cutflow 10 50 10 10 Amperage Amps 15 12 Torch-to-Work Distance mm 2.180 0.5 factor % 150 Pierce Delay Time seconds 0.12 Marking Speed mm/min 6350 2540 ipm 250 100 Arc Voltage Volts 95 60 4-28 HPR130XD Manual Gas Instruction Manual .8 4.5 3.2 0.10 0.5 Plasma Shield Plasma Shield Plasma Shield F5 N2 35 30 60 75 English Select Gases Set Preflow Set Cutflow Material Thickness in 0.0 2.0 in 0.3 0.100 0.0 mm/m 2180 1225 560 Initial Pierce Height mm 4.

5 0. HPR130XD Manual Gas Instruction Manual 4-29 .5 0.12 Marking Speed mm/min 6350 2540 ipm 250 100 Arc Voltage Volts 140 75 Note: This process produces a rougher.280 Edge start factor % 200 Pierce Delay Time seconds 0. and the cut edges are closer to perpendicular than the 130 A.140 0.3 0.0 in 0.170 ipm 75 55 30 25 15 Initial Pierce Height in 0.8 Plasma Shield Plasma Shield Plasma Shield N2 N2 20 65 70 30 English Select Gases Set Preflow Set Cutflow Material Thickness in 1/4 3/8 1/2 5/8 3/4 Arc Torch-to-Work Cutting Voltage Distance Speed Volts 153 156 162 167 176 in 0.150 0.240 0. darker cut edge with more dross.0 3.8 4.120 0. H35/N2 process.8 Plasma Shield Plasma Shield Plasma Shield N2 N2 20 65 70 30 Marking Select Gases N2 Ar N2 Air Set Preflow 10 50 10 10 Set Cutflow 10 50 10 10 Amperage Amps 18 15 Torch-to-Work Distance mm 2.3 mm/m 1960 1300 900 670 305 Initial Pierce Height mm 6.0 Edge start factor % 200 Pierce Delay Time seconds 0.5 3.OPERATION Stainless steel N2 Plasma / N2 Shield 130 A Cutting Flow rates – lpm/scfh N2 Preflow Cutflow 97 / 205 79 / 168 220747 220198 220756 220197 220179 220307 220340 Metric Select Gases Set Preflow Set Cutflow Material Thickness mm 6 10 12 15 20 Arc Torch-to-Work Cutting Voltage Distance Speed Volts 153 156 162 167 176 mm 3.0 7.10 0.5 3.3 0.

5 0.0 in 0.3 Plasma Shield Plasma Shield Plasma Shield 4.3 Plasma Shield Plasma Shield Plasma Shield 0.3 0. N2/N2 process. shinier cut edge with less dross.8 1.5 7.310 170 Edge start Marking Select Gases N2 Ar N2 Air Set Preflow 10 50 10 10 Set Cutflow 10 50 10 10 Amperage Amps 18 15 Torch-to-Work Distance mm 2.5 3. and the cut edges are less perpendicular than the 130 A.7 170 Edge start English Select Gases Set Preflow Set Cutflow 60 45 H35 N2 20 40 70 30 20 Material Thickness in 3/8 1/2 5/8 3/4 1 Arc Torch-to-Work Cutting Voltage Distance Speed Volts 154 158 162 165 172 in ipm 40 30 20 15 10 Initial Pierce Height in factor % Pierce Delay Time seconds 0.3 0. 4-30 HPR130XD Manual Gas Instruction Manual .180 0.12 Marking Speed mm/min 6350 2540 ipm 250 100 Arc Voltage Volts 130 75 Note: This process produces a smoother.5 0.8 1.10 0.OPERATION Stainless steel H35 Plasma / N2 Shield 130 A Cutting Flow rates – lpm/scfh Preflow Cutflow H35 0/0 26 / 54 N2 76 / 160 68 / 144 220747 220198 220755 220197 220179 220307 220340 Metric Select Gases Set Preflow Set Cutflow 60 45 H35 N2 20 40 70 30 20 Material Thickness mm 10 12 15 20 25 Arc Torch-to-Work Cutting Voltage Distance Speed Volts 154 158 162 165 172 mm mm/m 980 820 580 360 260 Initial Pierce Height mm factor % Pierce Delay Time seconds 0.

0 3.8 Plasma Shield Plasma Shield Plasma Shield N2 N2 20 65 70 80 2.5 – 10.0 Edge start factor % 200 Pierce Delay Time seconds 0.400 0.280 Edge start factor % 200 Pierce Delay Time seconds 0.400 0.0 English Select Gases Set Preflow Set Cutflow Minimum Clearance in Equivalent Torch-to-Work Cutting Material Distance Speed Thickness in 1/4 3/8 1/2 5/8 3/4 in 0.10 0.5 3.0 in 0.170 – 0.0 3.12 Marking Speed mm/min 6350 2540 ipm 250 100 Arc Voltage Volts 140 75 HPR130XD Manual Gas Instruction Manual 4-31 .8 – 10.5 0.080 Marking Select Gases N2 Ar N2 Air Set Preflow 10 50 10 10 Set Cutflow 10 50 10 10 Amperage Amps 18 15 Torch-to-Work Distance mm 2.OPERATION Stainless steel bevel cutting N2 Plasma / N2 Shield 130 A Flow rates – lpm/scfh N2 Preflow Cutflow 97 / 205 125 / 260 220637 Note: 220738 220739 220656 220179 220606 220571 Bevel angle range is 0° to 45° Metric Select Gases Set Preflow Set Cutflow Minimum Clearance mm Equivalent Torch-to-Work Cutting Material Distance Speed Thickness mm 6 10 12 15 20 mm 3.140 – 0.3 – 10.3 0.0 – 10.3 0.240 0.400 0.150 – 0.8 Plasma Shield Plasma Shield Plasma Shield N2 N2 20 65 70 80 0.0 mm/m 1960 1300 900 670 305 Initial Pierce Height mm 6.0 7.120 – 0.5 0.400 ipm 75 55 30 25 15 Initial Pierce Height in 0.0 4.

3 0.080 0.12 Marking Speed mm/min 6350 2540 ipm 250 100 Arc Voltage Volts 130 75 4-32 HPR130XD Manual Gas Instruction Manual .400 0.0 7.310 170 Edge start Marking Select Gases N2 Ar N2 Air Set Preflow 10 50 10 10 Set Cutflow 10 50 10 10 Amperage Amps 18 15 Torch-to-Work Distance mm 2.3 0.5 0.7 170 Edge start English Select Gases Set Preflow Set Cutflow Minimum Clearance in Equivalent Torch-to-Work Cutting Material Distance Speed Thickness in 3/8 1/2 5/8 3/4 1 in ipm 40 30 20 15 10 Initial Pierce Height in factor % Pierce Delay Time seconds 0.3 Plasma Shield Plasma Shield Plasma Shield H35 N2 20 40 70 80 2.5 0.10 0.8 1.0 4.OPERATION Stainless steel bevel cutting H35 Plasma / N2 Shield 130 A Flow rates – lpm/scfh Preflow Cutflow H35 0/0 26 / 54 N2 90 / 190 114 / 240 220637 Note: 220738 220739 220656 220179 220606 220571 Bevel angle range is 0° to 45° Equivalent Torch-to-Work Cutting Material Distance Speed Thickness mm 10 12 15 20 25 mm mm/m 980 820 580 360 260 Metric Select Gases Set Preflow Set Cutflow Minimum Clearance mm Initial Pierce Height mm factor % Pierce Delay Time seconds 0.180 – 0.5 3.5 – 10.0 in 0.3 Plasma Shield Plasma Shield Plasma Shield H35 N2 20 40 70 80 0.8 1.

10 Marking Speed mm/min 6350 2540 ipm 250 100 Arc Voltage Volts 85 75 HPR130XD Manual Gas Instruction Manual 4-33 .0 0.120 0.8 3.4 0.5 2.5 0.064 0.7 4.8 150 2.OPERATION Aluminum Air Plasma / Air Shield 45 A Cutting Flow rates – lpm/scfh Preflow Cutflow Air 45 / 95 78 / 165 220747 220202 220756 220201 220180 220308 220340 Metric Select Gases Set Preflow Set Cutflow Material Thickness mm 1.2 0.5 in 0.125 3/16 1/4 Arc Torch-to-Work Cutting Voltage Distance Speed Volts 130 115 113 110 102 114 117 in ipm 220 170 160 140 110 90 60 Initial Pierce Height in factor % Pierce Delay Time seconds Plasma Shield Plasma Shield Plasma Shield 60 Air Air 35 25 55 40 0.110 0.10 0.070 0.6 Marking Select Gases N2 Ar N2 Air Set Preflow 10 90 10 10 Set Cutflow 10 90 10 10 Amperage Amps 15 12 Torch-to-Work Distance mm 2.051 0.5 2 2.180 0.3 0.102 0.2 40 1.100 0.2 1.5 3 4 6 Arc Torch-to-Work Cutting Voltage Distance Speed Volts 130 115 113 110 107 102 117 mm mm/m 4750 4160 3865 3675 2850 2660 1695 Initial Pierce Height mm factor % Pierce Delay Time seconds Plasma Shield Plasma Shield Plasma Shield 60 Air Air 35 25 55 2.150 150 0.6 English Select Gases Set Preflow Set Cutflow Material Thickness in 0.5 3.3 0.040 0.

140 0.5 4.130 0.10 0.5 3.3 Plasma Shield Plasma Shield Plasma Shield Air Air 20 40 70 30 English Select Gases Set Preflow Set Cutflow Material Thickness in 1/4 3/8 1/2 5/8 3/4 1 Arc Torch-to-Work Cutting Voltage Distance Speed Volts 153 154 156 158 162 172 in 0.0 in 0.6 6. H35/N2 process.2 0.0 mm/m 2370 1465 1225 1050 725 525 Initial Pierce Height mm 5.3 3.110 0.OPERATION Aluminum Air Plasma / Air Shield 130 A Cutting Flow rates – lpm/scfh Preflow Cutflow Air 73 / 154 78 / 165 220747 220198 220756 220197 220179 220181 220340 Metric Select Gases Set Preflow Set Cutflow Material Thickness mm 6 10 12 15 20 25 Arc Torch-to-Work Cutting Voltage Distance Speed Volts 153 154 156 158 162 172 mm 2.0 6.120 0.3 0.8 3.8 1. 4-34 HPR130XD Manual Gas Instruction Manual .6 7.12 Marking Speed mm/min 6350 2540 ipm 250 100 Arc Voltage Volts 120 82 Note: This process produces a rougher cut edge that is less perpendicular than the 130 A.260 0.8 1.5 0.240 0.3 0.0 N/A 200 factor % Pierce Delay Time seconds 0.220 0.5 0.2 0.280 N/A 200 factor % Pierce Delay Time seconds 0.160 ipm 90 60 45 40 30 20 Initial Pierce Height in 0.3 Plasma Shield Plasma Shield Plasma Shield Air Air 20 40 70 30 Marking Select Gases N2 Ar N2 Air Set Preflow 10 50 10 10 Set Cutflow 10 50 10 10 Amperage Amps 18 15 Torch-to-Work Distance mm 2.0 3.

3 Plasma Shield Plasma Shield Plasma Shield English Select Gases Set Preflow Set Cutflow 60 45 H35 N2 20 40 70 30 20 Material Thickness in 3/8 1/2 5/8 3/4 1 Arc Torch-to-Work Cutting Voltage Distance Speed Volts 158 156 157 176 0.200 ipm 65 55 50 40 20 Initial Pierce Height in 0.5 3.310 factor % 130 170 Edge start Pierce Delay Time seconds 0.0 mm/m 1615 1455 1305 940 540 Initial Pierce Height mm 6.10 0.OPERATION Aluminum H35 Plasma / N2 Shield 130 A Cutting Flow rates – lpm/scfh Preflow Cutflow H35 0/0 26 / 54 N2 76 / 160 68 / 144 220747 220198 220755 220197 220179 220307 220340 Metric Select Gases Set Preflow Set Cutflow 60 45 H35 N2 20 40 70 30 20 Material Thickness mm 10 12 15 20 25 Arc Torch-to-Work Cutting Voltage Distance Speed Volts 158 156 157 176 4.12 Marking Speed mm/min 6350 2540 ipm 250 100 Arc Voltage Volts 130 75 Note: This process produces a smoother cut edge that is more perpendicular than the 130 A. HPR130XD Manual Gas Instruction Manual 4-35 .3 0.260 0.0 in 0.5 7.180 in 0.3 Plasma Shield Plasma Shield Plasma Shield Marking Select Gases N2 Ar N2 Air Set Preflow 10 50 10 10 Set Cutflow 10 50 10 10 Amperage Amps 18 15 Torch-to-Work Distance mm 2.5 0.8 1.3 0.5 mm 5.5 0.7 factor % 130 170 Edge start Pierce Delay Time seconds 0.8 1. Air/Air process.

.........................................................................................................................................................................................................................................................................................................................................................................................................................................................5-8 PCB block diagram ....................................................................................................................................................................................................................................................................Section 5 MAINTENANCE In this section: Introduction ..............5-24 Error code troubleshooting – Error codes 159 to 160..................................................5-27 Plasma system operation with pump timeout ................................................................5-12 Error code troubleshooting – Error codes 030 to 042...................................................................5-31 Air filter element replacement......................................................................................................................................................................................................5-34 Filter replacement ....................................................................5-26 Power supply states ..................................................................................................................................5-33 Coolant system filter and strainer...............................................................................................................................................................................5-10 Error code troubleshooting – Error codes 000 to 020..............................5-4 Sequence of operation ...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5-30 Power measurement........................................................................................................................5-16 Error code troubleshooting – Error codes 062 to 067 ...................................................................................................................5-29 Initial checks ................5-33 Draining the coolant system.............................................................................................................................................................5-32 Power supply coolant system servicing ..................................................................................................... ......5-11 Error code troubleshooting – Error codes 021 to 028...........................5-23 Error code troubleshooting – Error codes 155 to 158........................................................................................................................................................................5-28 CNC operation with pump timeout.....................................................5-3 System description...........................................................5-14 Error code troubleshooting – Error codes 047 to 053.......................................................................................................................................................................5-25 Error code troubleshooting – Error codes 180 to 181........................................................................................................................5-21 Error code troubleshooting – Error codes 138 to 143......5-9 Error codes...................5-35 HPR130XD Manual Gas Instruction Manual 5-1 .......................................................................................5-18 Error code troubleshooting – Error codes 093 to 105 ...............................................................................................................................................................................5-34 Coolant flow troubleshooting chart......................................................................5-17 Error code troubleshooting – Error codes 071 to 076 ..........................5-4 Control and signal cables................................................................................................................................................................................................................................................................................................................................................5-3 Routine maintenance ................................................................................................................................................................................................................................................................................................................................................................................................5-34 Pump strainer cleaning.......................................................................................................................................................................................................................................................5-6 Marking process .........................................................................................................................................................................................................................................................................................5-15 Error code troubleshooting – Error codes 054 to 061.............................................................................................................................................................................................................................................................................................5-6 Gas system valve usage.........................5-20 Error code troubleshooting – Error codes 124 to 134......................................................5-5 Gas system purge cycle.........................................5-13 Error code troubleshooting – Error codes 044 to 046 .................5-19 Error code troubleshooting – Error codes 106 to 123 ................................................................................................5-22 Error code troubleshooting – Error codes 144 to 154.............................................................

................................................................................................................................5-51 Chopper tests ........................................................................................................................................................................................................................5-36 Before testing .............................................................................................................5-40 Pump and motor troubleshooting...........................................5-44 Power supply power distribution board PCB2 .....................5-52 Phase-loss detection test.......................................................................................................................................................................................................................MAINTENANCE Coolant flow tests .......................................................................................................................................................................................................................5-54 Torch lead test....................................................................................................................................................................................................................................5-41 Testing the flow sensor.............................................................................................................................................................................................5-39 Test 6 – bucket test at the pump .........................................................................5-38 Test 3 – change the torch ...........................................................................................................................................................................................................................................................................................................................................................................................5-36 Manual pump operation..............................................................................................................................................................................................................................................................................................................................................................................................................5-56 5-2 HPR130XD Manual Gas Instruction Manual ..................................................................................5-36 Using the Hypertherm flow meter (128933).................. AC valve-driver board PCB3................................................................................................................................................................................................................5-42 Gas leak tests ................................................................................5-37 Test 1 – return line ........................................................................................................................................................5-46 Operation......................................................5-45 Start circuit PCB1 ...................5-43 Power supply control board PCB3.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................5-48 Gas console control board PCB2 ...........................................................................................................................................................................................................................................................................................................................................................................................................................................................5-50 Gas console.5-40 Test 7 – bypass the check valve.....................................................5-55 Preventive maintenance............................................................................5-39 Test 4 – supply line to the torch receptacle ......................................................5-46 Pilot arc current levels ............................................................................5-38 Test 2 – supply line at ignition console......5-46 Start circuit functional schematic..........................................................................................5-49 Gas console power distribution board PCB1......................................................................5-39 Test 5 – return line from the torch receptacle ..........................................................................................................5-46 Start circuit troubleshooting................................................

MAINTENANCE Introduction Hypertherm assumes that the service personnel performing the troubleshooting testing are high-level electronic service technicians who have worked with high-voltage electro-mechanical systems. on the chopper and the heatsinks. SHOCK HAZARD Use extreme care when working near the chopper modules. In addition to being technically qualified. Refer to the Safety section for operating precautions and warning formats. property damage or personal injury. WARNING Routine maintenance For a complete list of routine maintenance recommendations. HPR130XD Manual Gas Instruction Manual 5-3 . Wait at least 5 minutes after turning the power supply off before touching the chopper or the capacitors. located at the end of this section. Even if the power is off. Contact the Technical Services department listed at the front of this manual with any questions regarding the maintenance schedule or procedures. The large blue capacitors store high voltage. maintenance personnel must perform all testing with safety in mind. see the Preventive Maintenance Schedule. Knowledge of final isolation troubleshooting techniques is also assumed. Discharging any capacitor with a screwdriver or other implement may result in an explosion. dangerous voltages exist at the capacitor terminals.

5-4 HPR130XD Manual Gas Instruction Manual . Signal cable: Provides process and status signals between the power supply and the gas console. Power cable: Provides 120 VAC to the ignition console and control power to the off-valve assembly. Control cable: Provides 120 VAC control power to the solenoid valves.MAINTENANCE System description Control and signal cables Power cable: Provides 120 VAC to the gas console.

Auto Off – 10 second postflow Main contactors off Choppers off HPR130XD Manual Gas Instruction Manual 5-5 .MAINTENANCE Sequence of operation 1. Power-up – The system verifies that all of these signals are off at power-up Coolant flow off Chopper current off Transfer off Phase Loss off Chopper 1 over-temp off Magnetics over-temp off Coolant over-temp off Plasma start off 2. main contactor and pilot arc relay are on High frequency present Chopper current sensor = pilot arc current 6. Purge – Air or N2 gas flows through torch for 20 seconds Coolant flow on Contactor closes and the chopper performs a chopper test and a current sensor test Plasma start off Contactor opens when the purge cycle ends 3. Idle Gas pressure ok Coolant flow on Chopper current off Line voltage ok 4. Preflow – 2 second flow of gas 5. Steady State – normal operating parameters Coolant flow on Gas pressure ok Phase loss on Chopper 1 over-temp off Magnetics over-temp off Coolant over-temp off 9. Transfer – Pilot arc current sensed on the worklead 7. Ramp-down – Current and gas flow decreases after plasma start has been removed Cutflow gas off 10. Ramp-up – Chopper current increases to set point and gas switches to cutflow Coolant flow on Gas pressure ok Phase loss on Line voltage ok 8. Pilot Arc – Current flow between electrode and nozzle Chopper.

or 12 seconds with a manual gas console. The preflow and cutflow purges will follow the nitrogen purge.MAINTENANCE Gas system purge cycle When the system is turned on. O2/O2 process Valve location LED number Preflow Cutflow Gas console AC valve driver board – LEDs Gas console 1 2 3 4 SV4 SV4 Off-valve 10 SV10 SV10 SV14 SV16 5 6 7 SV7 SV7 8 9 11 12 13 14 15 16 17 18 19 20 SV1 SV2 SV1 SV2 SV17 SV18 SV19 O2/Air process Valve location LED number Preflow Cutflow Gas console AC valve driver board – LEDs Gas console 1 2 3 4 5 SV5 SV5 Off-valve 10 SV10 SV10 SV14 SV16 6 7 SV7 SV7 8 9 11 12 13 14 15 16 17 18 19 20 SV1 SV2 SV1 SV2 SV17 SV18 SV19 5-6 HPR130XD Manual Gas Instruction Manual . Gas system valve usage The following tables show which valves are active for each cutting process. Exception 2 – no purge process will occur if the operator changes from any process to a nitrogen marking process. it will be replaced by error code 139 (purge time-out error). for 12 seconds. The cutflow purge gas is turned on for 8 seconds with an auto gas console. Exception 1 – if the operator changes from a non-fuel gas process (O2/Air. There are 2 exceptions to the process described above. or N2/Air) to a fuel gas process (H35/N2. The preflow purge gas is turned on for 8 seconds with an auto gas console. or 12 seconds with a manual gas console. Nitrogen will purge the gas system first. if nitrogen is not connected to the gas system. there will be 3 stages to the purge process. Air/Air. or F5/N2) or the reverse. The purge process has 2 stages. a preflow purge and a cutflow purge. If error code 42 is not resolved in 3 minutes. or the operator changes from one process to another. Note: Error code 42 (low nitrogen gas pressure) will be displayed. the system automatically goes through a purge process.

MAINTENANCE N2/N2 process Valve location LED number Preflow Cutflow Gas console AC valve driver board – LEDs Gas console 1 2 3 4 5 6 SV6 SV6 Off-valve 10 11 SV11 SV11 SV14 SV16 7 8 SV8 SV8 9 12 13 14 15 16 17 18 19 20 SV17 SV18 SV19 F5/N2 process Valve location LED number Preflow Cutflow Gas console AC valve driver board – LEDs Gas console 1 2 3 SV3 SV3 Off-valve 10 11 12 SV12 SV12 SV14 SV16 4 5 6 SV6 SV6 7 8 SV8 SV8 9 13 14 15 16 17 18 19 20 SV17 SV18 SV19 H35/N2 process Valve location LED number Preflow Cutflow Gas console AC valve driver board – LEDs Gas console 1 2 3 SV3 SV3 Off-valve 10 11 12 SV12 SV12 SV14 SV16 4 5 6 SV6 SV6 7 8 SV8 SV8 9 13 14 15 16 17 18 19 20 SV17 SV18 SV19 N2/Air process Valve location LED number Preflow Cutflow Gas console AC valve driver board – LEDs Gas console 1 SV1 SV1 Off-valve 10 11 SV11 SV11 SV14 SV16 2 3 4 5 SV5 SV5 6 7 8 SV8 SV8 9 12 13 14 15 16 17 18 19 20 SV17 SV18 SV19 Air/Air process Valve location LED number Preflow Cutflow Gas console AC valve driver board – LEDs Gas console 1 SV1 SV1 Off-valve 10 11 12 13 14 15 16 17 18 19 20 2 3 4 5 SV5 SV5 6 7 SV7 SV7 8 9 SV9 SV9 SV17 SV18 SV14 SV16 SV19 HPR130XD Manual Gas Instruction Manual 5-7 .

The active valves in the gas console will differ. depending on what process was used before marking. Valves active when changing from a process that does not use a fuel gas N2/N2 process Valve location LED number Preflow Cutflow Gas console AC valve driver board – LEDs Gas console 1 2 3 4 5 6 SV6 SV6 Off-valve 10 11 SV11 SV11 SV14 SV16 7 8 SV8 SV8 9 12 13 14 15 16 17 18 19 20 SV17 SV18 SV19 Valves active when changing from a process that does use a fuel gas N2/N2 process Valve location LED number Preflow Cutflow Ar/Ar process Valve location LED number Preflow Cutflow Ar/Air 25 to 35 amps LED number Preflow Cutflow Ar/Air < 25 or > 35 amps LED number Preflow Cutflow 1 SV1 SV1 Gas console AC valve driver board – LEDs Gas console 1 2 3 4 5 6 SV6 SV6 Off-valve 10 11 SV11 SV11 SV14 SV16 7 8 SV8 SV8 9 12 13 14 15 16 17 18 19 20 SV17 SV18 SV19 Gas console AC valve driver board – LEDs Gas console 1 2 3 4 5 6 SV6 SV6 Off-valve 10 11 SV11 SV11 SV14 SV16 7 8 SV8 SV8 9 12 13 14 15 16 17 18 19 20 SV17 SV18 SV19 Gas console AC valve driver board – LEDs Gas console 1 SV1 SV1 Off-valve 10 11 SV11 SV11 SV14 SV16 2 3 4 5 SV5 SV5 6 7 SV7 SV7 8 9 12 13 14 15 16 17 18 19 20 SV17 SV18 SV19 Gas console AC valve driver board – LEDs Gas console 2 3 4 5 SV5 SV5 Off-valve 10 11 SV11 SV11 SV14 SV16 6 7 8 SV8 SV8 9 12 13 14 15 16 17 18 19 20 SV17 SV18 SV19 5-8 HPR130XD Manual Gas Instruction Manual .MAINTENANCE Marking process The valves that are active when marking are represented by the tables below.

Power supply PCB block diagram CommandTHC control module PCB (optional) Plasma interface cable Plasma interface PCB (optional) Machine interface cable Arc voltage CNC interface cable Control board Chopper Duty cycle – Chopper current sensor HPR130XD Manual Gas Instruction Manual CAN communication DC power in Total current Chopper temp + sensor AC power Cutting table controller Start circuit PA enable AC power Control signals to outputs Power distribution board Gas console Gas control board DC power in AC power in Power distribution board Control signals to valve drivers Valve driver board AC power in MAINTENANCE 5-9 .

5-10 HPR130XD Manual Gas Instruction Manual .MAINTENANCE Error codes HyPerformance plasma system error codes Error codes are displayed in the 3-digit LED display on the gas console.

Test in progress One of the gas test modes Wait for the test to finish. 012 013 Test passed The test was successful. 018 1. 7. Perform gas flow test (see Maintenance section). 017 Inspect the holes in the shield for obstructions. Verify that there are no restrictions in the coolant system. Perform torch lead test (see Maintenance section). The gas pressure in channel 2 is decreasing. Plasma pressure did not decrease in the time allowed. 6. Verify that coolant filters are in good condition. 2. Perform gas leak tests (see Maintenance section).5 bar (225 psi). 9. Look for leaks and loose connections between the selection console and the metering console. Replace the shield if the holes are blocked. HPR130XD Manual Gas Instruction Manual 5-11 . which indicates a leak. Verify proper preflow and cut-flow settings. 8. which indicates a leak. 3. 009 The flow switch is tested when the pump restarts after a pump timeout Flow switch (30 minutes without a start Wait 10 seconds for the flow rate to stabilize.MAINTENANCE Error code troubleshooting – error codes 000 to 020 Error code number 000 Name No error Description System is ready to run. No action required. Perform start circuit test (see Maintenance section). Pump output has exceeded 15. 2. 1. 4. 5. Verify spark across spark gap. The test ensures that the coolant flow is correct before firing the torch. 016 Verify that there is no obstruction in the plasma vent hose. 020 No current detected from No pilot arc chopper at ignition and before 1-second timeout. 014 Cut gas channel 1 fail Cut gas channel 2 fail Plasma rampdown fail Shield rampdown fail Pump over pressure HPR260 only The gas pressure in channel 1 is decreasing. test signal). Verify that the consumable parts are in good condition. is running. Inspect CON1 and pilot arc relay for excessive wear. 015 Look for leaks and loose connections between the selection console and the metering console. Shield pressure did not decrease in the time allowed. Corrective action None needed. Perform chopper test (see Maintenance section).

Only 5. contactor. remove cover on contactor and inspect contacts for excessive wear. Verify pierce delay time. Verify that the consumable parts are in good condition. scrap cutting. Verify arc did not lose contact with plate while cutting (hole Only cutting. Verify proper cut-flow gas settings. 028 1. Verify proper preflow and cut-flow settings. etc). Lost current 2. 2. Inspect phase loss fuses on Power Distribution board. Try connecting work lead directly to the plate. 4. etc). (hole cutting. Inspect work lead for damage or loose connections. work lead 500 milli-seconds 2. Chopper 3 Lost the current signal from 3. Perform chopper test (see Maintenance section). 4. HPR260 Chopper 2 after transfer.MAINTENANCE Error code troubleshooting – error codes 021 to 028 Error code number Name Description Corrective action 021 No arc transfer No current detected on 1. Verify pierce delay time. Perform chopper test (see Maintenance section). Verify pierce delay time. 5. Chopper 1 Chopper 1 after transfer. 1. Verify pierce delay time. Disconnect power to power supply. scrap cutting. Verify arc did not lose contact with plate while cutting (hole cutting. HPR400 Chopper 3 after transfer. 4. Verify proper cut-flow gas settings. 3. Inspect power cord. Verify arc did not lose contact with plate while cutting (hole HPR400 cutting. Verify that the consumable parts are in good condition. and input to chopper for loose connections. Lost current Lost the current signal from 3. Verify proper cut-flow gas settings. 2. Verify that the consumable parts are in good condition. 1. 024 1. 6. scrap cutting. etc). Verify that the consumable parts are in good condition. Verify phase-to-phase voltage to power supply. Lost the transfer signal after 4. Replace board if fuses are blown. Chopper 2 Lost the current signal from 3. established. scrap cutting. Perform chopper test (see Maintenance section). 5. 1. Verify proper cut-flow gas settings. 5-12 HPR130XD Manual Gas Instruction Manual . 5. Verify proper pierce height. 5. Perform phase loss test (see Maintenance section). 025 026 027 Phase imbalance to Lost phase chopper after contactor engaged or while cutting. 4. Verify arc did not loose contact with plate while cutting Lost transfer transfer completed. 2. after pilot arc current was 3. Lost current 2. 7. etc). Inspect work lead for damage or loose connections. 3. Perform chopper test (see Maintenance section).

If interface cable is good and a relay is not driving the start input. Replace the relay.34 bar (5 psi) – marking (N2) gas During N2 purge. 3. 2. See pressure changing between a fuel Setting the supply regulators (Installation section). 5. then PCB2 or PCB3 has failed. Only 031 Start lost 1. If a mechanical relay is being used to provide the HPR with a start signal. If CNC interface cable is good and it is a 1-torch system. 1.07 bar (30 psi) – cutting 1. Use the CAN tester to verify which board needs to be replaced. These LEDs indicate power to PCB2. Start signal was received 2.Verify that the nitrogen supply is turned on and inspect gas Low nitrogen supply pressure and volume of gas remaining in supply tanks. Verify that cable number 6 (power supply-to-gas console power cable) is not damaged and is properly connected inside the power supply and to the rear of the gas console. or poor and then lost before an arc electrical connections. Verify arc did not lose contact with plate while cutting (hole cutting. gas process and an oxidizer process. the CNC is dropping the start signal before a steady state arc has been established. was established. The CNC is maintaining this input. Inspect interface cable for damage.MAINTENANCE Error code troubleshooting – error codes 030 to 042 Error code number Name Description Corrective action 1. Perform chopper test (see Maintenance section). 3. Verify proper cut-flow gas settings. HPR130XD Manual Gas Instruction Manual 5-13 . 4. The hold wires may be short-circuiting inside. Verify that D1 (+5 VDC) and D2 (+3. Verify that the consumable parts are in good condition. 032 Hold timeout Hold signal was active for longer than 60 seconds. when 2. Only 042 Nitrogen gas pressure under lower limit of 2. 4. Verify that cable number 5 (power supply-to-gas console control cable) is not damaged and is properly connected to PCB3 and to the rear of the gas console. 3. or low inlet-gas pressure.27 bar (120 psi). able to charge the lines to Verify that there are no restrictions in the plasma and shield the correct value. 030 Gas system error A failure has occurred in Auto Gas the gas system. etc). If power is present at PCB2 and PCB3 and both gas console cables are good.3 VDC) are illuminated on PCB2 inside the gas console. 1. this relay is either bouncing when activated or the contacts are faulty. change PCB3. Verify that the gas regulator is set to 8. Verify pierce delay time. it could be waiting for an IHS complete input from another torch. 033 Precharge time-out Auto Gas Only Selection console was not This is a warning for a possible gas restriction in the leads. scrap cutting. 0. hoses. 2. 034 Lost current Lost the current signal Chopper 4 from Chopper 4 after HPR400 transfer. Check the interface cable for damage. faulty crimps. 2. 3.

is greater than 102 VAC (120 VAC -15%).38 VDC. 6.34 bar (5 psi) – cutflow (marking) 1. is greater than 108 VAC and the DC voltage between TP23 and TP2 on PCB1 in the cooler is also greater than 0. Perform gas leak tests (Maintenance section).4. verify the CAN link between PCB3 in the power supply and PCB1 in the cooler.415 VDC between TP23 and Line voltage is close to or TP2 on PCB1.38 VDC. pins 3 and 4. verify minimum 108 VAC operation is voltage on plug J4. 3.MAINTENANCE Error code troubleshooting – error codes 044 to 046 Error code number Name Description Corrective action 044 Plasma gas pressure under lower limit of 0. Verify the gas regulator settings on gas console with the parameters in the cut charts. See Setting the supply regulators (Installation section).4. 3.65 bar (140 psi) – auto If pressures decrease a valve is not functioning or no power to the valve. 108 VAC and DC voltage between TP23 and TP2 on The normal lower limit for PCB1 is less than 0. Verify gas supply pressure settings. High plasma upper limit of: 4. J2. pins 3 and 4 on PCB2 in the power supply. If AC voltage on PCB2. Voltage needs to be within 10% of nominal (120 VAC). If the voltage on plug J4 is greater than 108 VAC. 2. replace PCB1. 045 1.4. less than the lower limit of 5. Solenoid at off-valve is not opening. pins 3 and 4. gas pressure 7. 9. It should be about 0. 5-14 HPR130XD Manual Gas Instruction Manual . If the AC voltage on PCB2 in the power supply at J2. 4. Verify power to valves. 4. between PCB2 in the power supply and J4 on PCB1. pins 1 and 2 on PCB1.58 bar (110 psi) – manual disconnect plasma and shield hoses exiting off-valve. Verify gas regulator settings on gas console with cut chart. Plasma gas pressure over 3.45 bar (50 psi) – cutflow gas pressure (cutting) 0. 2. 2.34 bar (5 psi) – preflow Low plasma 3.38. but the DC voltage on TP23 and TP2 is less than 0. Inspect gas supply pressure and volume of gas remaining in supply tanks. Verify 120 VAC voltage on plug J2. 046 Low line voltage 1. Verify the voltage on PCB1 in the cooler with a DC volt meter. Verify input-line voltage at PCB2 in the power supply and PCB1 in the cooler. Verify the wiring 108 VAC (120 VAC -10%). See Setting the supply regulators (Installation section). Verify fuses on PCB2 in the power supply.

4. power to PCB2. J2. 053 HPR130XD Manual Gas Instruction Manual 5-15 . verify the CAN link between PCB3 in the power supply and PCB1 in the cooler.14 bar gas pressure (2 psi). The plasma start signal to the plasma was not dropped after the last cut. 2. 4. 4. Stop or clear the cutting program. If circuit is open. 3.44 VDC. is less than 132 VAC and the DC voltage between TP23 and TP2 on PCB1 in the cooler is also less than 0. is less than (120 VAC +15%).44. Verify that the CNC interface cable is not damaged. Verify wiring between (120 VAC +10%). 5. These LEDs indicate and the gas console. 4. Remove CNC interface cable from PCB3 and look for an is on at active during power-up of open circuit between pins 15 and 34. Verify that cable number 5 (power supply-to-gas console control cable) is not damaged and is properly connected to PCB3 and to the rear of the gas console. power-up power supply. PCB2 in the power supply and J4 on PCB1. Use the CAN tester to verify which board needs to be replaced.3 VDC) are illuminated between the power supply on PCB2 inside the gas console.44 VDC. but the DC voltage on TP23 and TP2 is greater than 0.415 VDC between TP23 and greater than the upper limit TP2 on PCB1. Verify that cable number 6 (power supply-to-gas console power cable) is not damaged and is properly connected An error occurred with the inside the power supply and to the rear of the gas console. If the circuit is closed either the CNC is issuing a plasma start or the CNC interface cable is damaged. of 138 VAC 5. 3. See Setting the supply regulators (Installation section). 048 CAN error 050 1. Verify fuses on PCB2 in the power supply.4. If AC voltage on PCB2. Shield pressure is below Low shield lower limit of 0. 1. CAN communications 3. Verify 120 VAC voltage on plug J2. If power is present at PCB2 and PCB3 and both gas console cables are good. pins 3 and 4 on PCB2 in the power supply. Perform gas leak tests (Maintenance section). 1. If the voltage on plug J4 is less than 132 VAC. Start signal Plasma start signal input is 3. replace PCB1. then PCB2 or PCB3 has failed. and LEDN300J is illuminated with CNC Interface cable removed from PCB3. 4. 6. 2. pins 3 and 4. It Should be about 0.4. 2. verify maximum 132 VAC voltage operation is 132 VAC on plug J4. Voltage needs to be within 10% of nominal (120 VAC). If the AC voltage on PCB2 in the power supply on plug J2. replace PCB3. Verify input-line voltage at PCB2 in the power supply and PCB1 in the cooler. 132 VAC and DC voltage between TP23 and TP2 on PCB1 The normal upper limit for is greater than 0. pins 1 and 2 on PCB1. Verify gas supply pressure and that a sufficient volume of gas remains in your supply. Verify that D1 (+5 VDC) and D2 (+3. pins 3 and 4. 2. Verify gas regulator settings on gas console with cut chart. Verify the voltage on PCB1 in the cooler with a DC volt Line voltage is close to or meter.MAINTENANCE Error code troubleshooting – error codes 047 to 053 Error code number Name Description Corrective action 047 High line voltage 1.

058 060 061 1. Increase or decrease the (50 psi) or greater than inlet gas pressure to correct the problem.65 bar (140 psi). Increase or decrease the Auto Gas 9. See Setting the supply regulators (Installation section). If the problem still exists. 5-16 HPR130XD Manual Gas Instruction Manual . upper limit of: gas 3. or 1.65 bar (140 psi).65 bar (140 psi) for nonmixing and mixing. Shield gas pressure is over High shield 2. Increase or decrease the (50 psi) or greater than inlet gas pressure to correct the problem. Only 9.the selector knob (2) may be set between not receiving signals from positions. Verify that gas pressure transducer P3 is between 3. Perform the coolant flow test procedure in the Maintenance section of the manual.65 bar (140 psi) – auto pressures decrease.65 bar (140 psi).65 bar (140 psi).45 bar (50 psi) and 9. proper working condition. Verify that the correct consumables are properly installed. Only selection console. 2. No plasma the gas selector knob.65 bar (140 psi).6 gpm).45 bar (50 psi) and 9. Verify that gas pressure transducer P2 is between 3. Reset the knob. Solenoid at off-valve is not opening.45 bar is less than 3.3 lpm coolant flow (0. 055 056 057 Cut gas 1 outlet pressure is Cut gas 1 less than 3. Increase or decrease the Auto Gas when mixing or greater than inlet gas pressure to correct the problem. console is not receiving the verify that the fuse on the power distribution PCB is in plasma gas type signal. Verify gas supply regulator settings. 3. Manual gas . Verify pressure settings on gas console with cut chart.The selection console (manual) is illuminated.45 bar 1. 9. Verify power to valves.45 bar Cut gas 2 (50 psi) for non-mixing.45 bar is less than 3.45 bar pressure (50 psi) or greater than (50 psi) and 9.The gas viewed on the CNC screen. replace the control board.65 bar (140 psi) in the inlet gas pressure to correct the problem.65 bar (140 psi).the process parameters may not have been downloaded.38 bar (20 psi) (50 psi) and 9. 4. Verify that the process information can be Manual gas . MV1 inlet pressure Auto Gas Only MV2 inlet pressure Auto Gas Only Motor valve 1 inlet pressure 1. Verify that there is power to the console by looking to see if gas type any LED on any board in the selection console (auto) or gas Auto gas .MAINTENANCE Error code troubleshooting – error codes 054 to 061 Error code number Name Description Corrective action 054 1. Verify that gas pressure transducer P4 is between 3. If 9. 1. a valve is not functioning or no power to the valve.45 bar pressure less than 1. Verify that gas pressure transducer P1 is between 3. console control board is 2. Auto gas . Motor valve 2 inlet pressure 1. If no LED is illuminated.58 bar (110 psi) – manual pressure disconnect plasma and shield hoses exiting off-valve. 7. 9. Coolant flow is less than Low the required 2. Cut gas 2 outlet pressure is less than 3.

on PCB3. Verify that the voltage on rear side of J3. 2. 2. Verify that all chopper fans are operating properly. 3. 3.202 pins 13 and 14. Replacement kit part number is 228309.MAINTENANCE Error code troubleshooting – error codes 062 to 067 Error code number Name Description Corrective action 062 1. on PCB3. 4. Spinning fan blades should be difficult to see. 3. HPR130XD Manual Gas Instruction Manual 5-17 .the process parameters may not have been downloaded.202 pins 1 and 2. Verify that all the large fans are operating properly. 1. 5. Auto gas . Blow dust out of system especially from fans and large power transformer.202. 5. is less than or equal to 2.9 VDC. the transformer has overheated. pins 5 and 6 Chopper 2 has overheated. 1. replace the chopper. verify correct wiring between chopper temperature sensor and J3. 4. 065 Chopper 1 overtemp 066 Chopper 2 overtemp HPR260 HPR400 Only 067 Magnetics overtemp Power transformer has overheated. 1. verify correct wiring between chopper temperature sensor and J3.the selector knob (2) may be set between not receiving signals from positions. Allow the power supply to idle with the fans running for a minimum of 30 minutes to cool the large power transformer. is equal to or less than 3. Manual gas . Verify that all chopper fans are operating properly. 6.The selection gas console (manual) is illuminated.202. Verify that there is power to the console by looking to see if type any LED on any board in the selection console (auto) or Auto gas . inspect wiring between the transformer's temperature sensor and J3.9 VDC. 4. Spinning fan blades should be difficult to see. 4. Blow dust out of system. If the voltage is low. Blow dust out of system. console control board is 2. If the problem still exists. 3.202 pins 14 and 15. If wiring is good and overtemp error does not clear after 30 minutes of the power supply idling with the fans running. PCB is in proper working condition. 2. Replace the transformer's temperature sensor if it is open or shorted.202 pins 4 and 5. Verify that the process information can be Manual gas .The gas viewed on the CNC screen. If no LEDs are console is not receiving the illuminated. especially from fans and heat sink of chopper. especially from fans and heat sink of chopper. No shield gas the gas selector knob.2 VDC. If wiring is good and overtemp error does not clear after 30 minutes of the power supply idling with the fans running. replace the control board. is less than or equal to 2. If the voltage is low. Verify that the voltage on the rear side of J3. replace the chopper. verify that the fuse on the power distribution shield gas type signal. If wiring is good. Reset the knob. 5. Look for shorts between wires or to ground. pins 2 and 3 Chopper 1 has overheated. Verify that the voltage on rear side of J3. If voltage is low or near 0 VDC. Spinning fan blades should be difficult to see.

A current less than 10 amps has been detected by current sensor 3. is less than or equal to 2.5. 074 Chopper 4 overtemp HPR400 Only 075 Low current on CS3 HPR400 Only Low current on CS4 HPR400 Only See the chopper test later in this section. Blow dust out of system.9 VDC.MAINTENANCE Error code troubleshooting – error codes 071 to 076 Error code number Name Description Corrective action 1. replace the chopper. for shorts to wires or ground. 072 Auto gas. 4. If the voltage is low. 2. Verify that the voltage on rear side of J3. 5. 2. pins 5 and 6.202. 4. Blow dust out of the cooler.5 pins 6 and 8. If wiring is good and overtemp error does not clear after 30 minutes of the power supply idling with the fans running. 6. Replace the coolant temperature sensor if it is open or shorted. 3. verify correct wiring between chopper temperature sensor and J3.202 pins 10 and 11. Verify that all chopper fans are operating properly. 12 on PCB3. replace the chopper. 5-18 HPR130XD Manual Gas Instruction Manual . control board Control board has overtemp exceeded 90° C (194° F).202 pins 7 and 8. Blow dust out of system. 3. If wiring is good. 4. especially from fans and heat sink of chopper. on PCB3. inspect wiring between coolant temperature sensor and J1. If voltage is low. 5. 1. pins 8 and 9 Chopper 3 has overheated. If the voltage is low. especially from the heat exchanger. 2. Verify that the large fan in the cooler is running. Spinning fan blades should be difficult to see.9 VDC. Verify that the voltage on the rear side of J1. 071 Coolant overtemp Torch coolant has overheated. Spinning fan blades should be difficult to see. Verify that the airflow to the gas console is not restricted. Verify that all chopper fans are operating properly. A current less than 10 amps has been detected by current sensor 4. Verify that the voltage on rear side of J3. is less than or equal to 2. 073 Chopper 3 overtemp HPR400 Only 1.8 VDC. let system idle with the fans running for 30 minutes to cool. Sensor part number is 229224. the coolant has overheated. 5. Auto Gas Only 1. verify correct wiring between chopper temperature sensor and J3. If wiring is good and overtemp error does not clear after 30 minutes of the power supply idling with the fans running. 3. 076 See the chopper test later in this section. is equal to or lower than 2. especially from fans and heat sink of chopper. pins 11 and Chopper 4 has overheated.202.

No coolant Coolant flow signal was 3. Verify that the CNC drives the plasma start signal for at least 10 seconds to allow the timed-out pump to turn on again. Verify that the coolant filter is in good condition. 2. replace the original CS1. If no jumper is present. Swap CS1 with CS2. See the chopper test later in this section. See the chopper test later in this section. 095 See the chopper test later in this section. If this is a new system. Verify that the transformer temperature sensor has not been bypassed or the wires to the temperature sensor are not shorted out in the harness. 2. the chopper is overheated and needs time to cool to 83° C (181. 2. Verify that the wiring between CS1 and PCB3 is correct and not damaged. 104 See the chopper test later in this section. follow start procedure. If no jumper is present. 3. 4. or that the sensor is open. High current on CS4 HPR400 Only A current greater than 35 amps has been detected by current sensor 4. 105 A current less than Low current 10 amps has been on CS1 detected by current sensor 1. the chopper is overheated and HPR400 needs time to cool to 83° C (181. flow lost or never was satisfied. 102 Chopper 1 Chopper 1 current signal current at is active at power-up power-up 1. 2. overtemp at power-up. High current on CS2 HPR260 HPR400 Only A current greater than 35 amps has been detected by current sensor 2. Only 1. Verify that the temperature sensor for the chopper has not Chopper 1 been bypassed or that the wires to the temperature switch Chopper 1 is indicating an overtemp at are shorted out in the harness. Verify that the sensor is not open or shorted. Verify that the temperature sensor for the chopper has not overtemp at been bypassed or that the wires to the temperature switch power-up Chopper 2 is indicating an are shorted out in the harness. if it is not open or shorted. power-up 2. See wiring diagrams in section 7 100 101 Magnetics Main transformer is overtemp at indicating an overtemp at power-up power-up.4° F). Chopper 2 1. 103 A current greater than High current 35 amps has been on CS1 detected by current sensor 1. Perform coolant flow tests (Maintenance section). 099 1.MAINTENANCE Error code troubleshooting – error codes 093 to 105 Error code number Name Description Corrective action 093 1. Verify that the voltage at CS1 is correct. If the error code changes to 156. HPR260 overtemp at power-up. or that the sensor is open. the main transformer is overheated and needs time to cool to 150° C (302° F).4° F). HPR130XD Manual Gas Instruction Manual 5-19 .

4. 108 Transfer at power-up The system has detected current on the work lead during power-up. Verify that cable number 6 (power supply-to-gas console power cable) is not damaged and is properly connected inside the power supply and to the rear of the gas console. Coolant Coolant is indicating an overtemp at overtemp at power-up. or closing at power-up. then PCB2 or PCB3 has failed. Verify that the main contactor (CON1) is not welded closed. replace the motor valve. (Manual gas console) Verify that D1 (+5 VDC) and D2 (+3. 2.MAINTENANCE Error code troubleshooting – error codes 106 to 123 Error code number Name Low current on CS2 HPR260 HPR400 Only High current on CS3 HPR400 Only Description A current less than 10 amps has been detected by current sensor 2. Verify that the coolant temperature sensor has not been bypassed or the wires to the sensor are not shorted out in the harness. Verify that cable number 5 (power supply-to-gas console control cable) is not damaged and is properly connected to PCB3 and the rear of the gas console. Motor valve 1 did not move into position within 60 seconds. Verify that the electrical connections to current sensors CS1 And CS3 are correct and not damaged. 5. 1.3 VDC) are illuminated on PCB2 inside the gas An error occurred with the console. These LEDs indicate power to PCB2. 2. power-up 111 116 Watchdog interlock 1. If they do not illuminate. Replace PCB 3 if connections are correct and not damaged.3 VDC) are illuminated on PCB2 inside the gas console. Verify that the gas console control PCB and power distribution PCBs are securely mounted to the chassis at all four corners. These LEDs indicate power to PCB2. 3. 107 See the chopper test later in this section. the coolant temperature is over the set point and needs time to cool to 70° C (158° F). replace PCB3. Verify that there is power at the sensor. 2. Verify that all the connectors have good connections. 1. If either illuminates. 123 MV1 error Auto Gas Only 5-20 HPR130XD Manual Gas Instruction Manual . If power is present at PCB2 and PCB3 and both gas console cables are good. (+3. A current greater than 35 amps has been detected by current sensor 3. (Auto gas console) Verify that D17 (+5 VDC) and D18 system. 3a. 109 “Coolant flow OK” signal Coolant flow is active during power-up at power-up and before pump motor is activated. Verify that LED D17 or D18 illuminates on the AC valve driver PCB in the selection console. If not. CAN communication 3b. Either the coolant flow sensor was bypassed or it is faulty. 1. 1. Corrective action 106 See the chopper test later in this section. Use the CAN tester to verify which board needs to be replaced. 2.

133 1. Verify that the wiring between CS1 and PCB3 is correct and not damaged. If the chopper still goes into overcurrent. 2. replace the current sensor. Verify that D1 (+5 VDC) and D2 (+3. take a voltage reading on current sensor while trying to cut. b) If the chopper does not go into overcurrent. console type installed or has not 4. Verify that the part numbers of PCB2 and PCB3 are correct. Remove connector JA. Measure voltage across current sensor. a) Red to black = +15 VDC. then PCB2 or PCB3 has failed. Ratio is 4 VDC = 100 amps. Use the CAN tester to verify which board needs to be replaced. illuminated on PCB2 inside the gas console.3 VDC) are received a CAN message.1 from the chopper and verify that LED1 is extinguished. a) If LED1 is extinguished with the connector removed. 134 Chopper 1 overcurrent Chopper 1 current feedback has exceeded 160 amps.1 and try to fire the torch.MAINTENANCE Error code troubleshooting – error codes 124 to 134 Error code number Name Description Corrective action 1. Green to black = -15 VDC. 3. replace the motor valve. 5. The power supply control 3. If either illuminates. HPR130XD Manual Gas Instruction Manual 5-21 . Verify that cable number 5 (power supply-to-gas console control cable) is not damaged and is properly connected to PCB3 and the rear of the gas console. Verify that LED D19 or D20 is illuminating on the AC valve driver PCB in the selection console. then reconnect JA. 1. c) If the current sensor voltage is approximately 6. Verify that cable number 6 (power supply-to-gas console board does not recognize power cable) is not damaged and is properly connected Unknown gas the gas console that is inside the power supply and to the rear of the gas console. replace PCB3. replace PCB3. 2. white to black = 0 VDC at idle and varies with current output (4 VDC = 100 amps).4 VDC or greater at idle. 124 MV2 error Auto Gas Only Motor valve 2 did not move into position within 60 seconds. These LEDs indicate power to PCB2. replace the chopper. b) If possible. If they do not illuminate. If power is present at PCB2 and PCB3 and both gas console cables are good.

2. 138 Chopper 2 overcurrent HPR260 HPR400 Only Chopper 2 current feedback has exceeded 160 amps. 5-22 HPR130XD Manual Gas Instruction Manual . Replace if necessary. white to black = 0 VDC at idle and varies with current output (4 VDC = 100 amps). Remove connector JB. Replace if necessary. Verify that the control boards in the metering and selection consoles are working properly. 2. If the chopper still goes into overcurrent. 3. b) If the chopper does not go into overcurrent. Replace if necessary. Verify that the inlet gas pressures are set to the proper levels. 3. 142 Faulty transducer or control board in the metering console or the selection console. c) If the current sensor voltage is approximately 6. 1. Replace if necessary. 3.MAINTENANCE Error code troubleshooting – error codes 138 to 143 Error code number Name Description Corrective action 1. Verify that the control boards in the metering and selection consoles are working properly. Verify that the wiring between CS2 and PCB3 is correct and not damaged. 143 Faulty transducer or control board in the metering console or the selection console. 2. 3. Replace if necessary. b) If possible. Verify that transducer P6 in the metering console is working properly. 139 This is a warning for a possible gas restriction in the leads. Verify that transducer P3 in the selection console is working properly. Pressure transducer 1or 8 error Auto Gas Only Pressure transducer 2 or 7 error Auto Gas Only Pressure transducer 3 or 5 error Auto Gas Only Pressure transducer 4 or 6 error Auto Gas Only Faulty transducer or control board in the metering console or the selection console. 2. Replace if necessary. Verify that transducer P2 in the selection console is working properly. 3. Replace if necessary. Verify that transducer P5 in the metering console is working properly. replace the chopper. time-out error complete within 3 minutes. 1. Verify that transducer P4 in the selection console is working properly. replace the current sensor. take a voltage reading on current sensor while trying to cut. 1. Replace if necessary. a) Red to black = +15 VDC. Replace if necessary. Verify that transducer P1 in the selection console is working properly.1 from the chopper and verify that LED1 is extinguished. Verify that transducer P7 in the metering console is working properly. Replace if necessary. 2.1 and try to fire the torch. Replace if necessary. Verify that there are no restrictions in the plasma and shield Purge The purge cycle did not hoses. Ratio is 4 VDC = 100 amps. Measure voltage across current sensor. Verify that transducer P8 in the metering console is working properly. Verify that the control boards in the metering and selection consoles are working properly. then reconnect JB. Green to black = -15 VDC. 2. a) If LED1 is extinguished with the connector removed. replace PCB3. 1.4 VDC or greater at idle. Verify that the control boards in the metering and selection consoles are working properly. Replace if necessary. 140 141 Faulty transducer or control board in the metering console or the selection console. 1.

MAINTENANCE Error code troubleshooting – error codes 144 to 154 Error code number 144 Name Internal flash error Manual Gas Only Internal flash error Auto Gas Only Chopper 3 overtemp at power-up HPR400 Only Chopper 4 overtemp at power-up HPR400 Only Description Communication problem to the flash chip on the gas console control board. Communication problem Internal flash to the flash chip on error the power supply control board.4° F). b) If the chopper does not go into overcurrent. Communication problem to the flash chip on the selection console control board. 152 1. then reconnect JC. Corrective action 1. Replace the control board. Replace the control board. overtemp at power-up. Verify that the wiring between CS3 and PCB3 is correct and not damaged. Green to black = -15 VDC. the chopper is overheated and needs time to cool to 83° C (181. 3. 146 1. Ratio is 4 VDC = 100 amps. 153 1.4 VDC or greater at idle. If the chopper still goes into overcurrent. HPR130XD Manual Gas Instruction Manual 5-23 .4° F). If no jumper is present.1 and try to fire the torch. b) If possible. 2. a) If LED1 is extinguished with the connector removed. 145 1. Verify that the temperature sensor for the chopper has not been bypassed or that the wires to the temperature switch Chopper 4 is indicating an are shorted out in the harness. replace the chopper. a) Red to black = +15 VDC. Replace power supply control board. 1. Replace the control board. the chopper is overheated and needs time to cool to 83° C (181. white to black = 0 VDC at idle and varies with current output (4 VDC = 100 amps). condition. 2. Verify that the temperature sensor for the chopper has not been bypassed or that the wires to the temperature switch Chopper 3 is indicating an are shorted out in the harness. take a voltage reading on current sensor while trying to cut. Remove connector JC. replace PCB3. 1. replace the current sensor. 2.1 from the chopper and verify that LED1 is extinguished. c) If the current sensor voltage is approximately 6. If no jumper is present. 147 151 Software has detected an Software fail incorrect state or 1. overtemp at power-up. EEPROM memory on PS EEPROM power supply control error board not working. Replace the control board. or that the sensor is open. 154 Chopper 3 overcurrent HPR400 Only Chopper 3 current feedback has exceeded 160 amps. or that the sensor is open. Measure voltage across current sensor.

MAINTENANCE Error code troubleshooting – error codes 155 to 158
Error code number Name Description Corrective action 1. Verify that the wiring between CS4 and PCB3 is correct and not damaged. 2. Measure voltage across current sensor. a) Red to black = +15 VDC, Green to black = -15 VDC, white to black = 0 VDC at idle and varies with current output (4 VDC = 100 amps). b) If possible, take a voltage reading on current sensor while trying to cut. Ratio is 4 VDC = 100 amps. c) If the current sensor voltage is approximately 6.4 VDC or greater at idle, replace the current sensor. 3. Remove connector JD.1 from the chopper and verify that LED1 is extinguished. a) If LED1 is extinguished with the connector removed, then reconnect JD.1 and try to fire the torch. If the chopper still goes into overcurrent, replace the chopper. b) If the chopper does not go into overcurrent, replace PCB3. See wiring diagrams in section 7 Chopper 2 current signal is active at power-up 1. Verify that the voltage at CS2 is correct. 2. Verify that the wiring between CS2 and PCB3 is correct and not damaged. 3. Swap CS2 with CS3. If the error code changes to 157, replace the original CS2.

155

Chopper 4 overcurrent HPR400 Only

Chopper 4 current feedback has exceeded 160 amps.

156

Chopper 2 current at power-up HPR260 HPR400 Only

See wiring diagrams in section 7 Chopper 3 current at power-up HPR400 Only Chopper 3 current signal is active at power-up 1. Verify that the voltage at CS3 is correct. 2. Verify that the wiring between CS3 and PCB3 is correct and not damaged. 3. Swap CS3 with CS2. If the error code changes to 156, replace the original CS3.

157

See wiring diagrams in section 7 Chopper 4 current at power-up HPR400 Only Chopper 4 current signal is active at power-up 1. Verify that the voltage at CS4 is correct. 2. Verify that the wiring between CS4 and PCB3 is correct and not damaged. 3. Swap CS4 with CS2. If the error code changes to 156, replace the original CS4.

158

5-24

HPR130XD Manual Gas Instruction Manual

MAINTENANCE Error code troubleshooting – error codes 159 to 160
Error code number Name Description Corrective action

159

Motor-drive fault HPR400 Only

The pump-motor-drive board (PCB7) is indicating a drive fault.

1. Verify that the circuit breaker on PCB7 has not tripped. If it has tripped, reset the breaker by pressing the button until it is even with the top of the circuit breaker. If the circuit breaker is not tripped and there is no power to PCB7, verify that the fuse on PCB2 in the power supply is good. 2. If D32 illuminates, the solenoid valve and motor are drawing too much current. D32 will only illuminate for a short time, and extinguishes after the outputs from the pump-motordrive turn-off in response to the fault condition. Verify the wiring to the solenoid valve and the motor. Verify that the pump spins freely and is properly mounted to the motor. Look for obstructions in the torch, consumables, coolant lines, and in-line filter. Verify that the solenoid valve is operating. Any of these can cause the motor or solenoid valve to draw excessive current. Test for low coolant flow by using the coolant flow test on page 5-33. 3. If D32 illuminates immediately at power-up, and all the items above have been verified, replace PCB7. 4. If D30 illuminates, the IGBT drive has encountered an overcurrent condition. D30 will only illuminate for a short time, and extinguishes after the outputs from the pump motor-drive turn off. Follow the same steps for D32 above. 5. If D31 illuminates, the heatsink thermistor is indicating that the heatsink is too hot. Wait 10 minutes for it to cool. If the error remains, verify that the wires from heatsink on PCB7 are properly connected to the J6 connector on PCB7. If the error still remains, turn OFF all power to the system and measure the resistance on the J6 connector between pins 1 and 2. At 25° C (77° F) the resistance should be 10k.

160

Communication between the control board (PCB3 HPR cooler’s in the power supply) and CAN fault the cooler sensor board HPR400 (PCB1 in the cooler) was Only interrupted for more than 1 second.

1. Verify that the cable connections from the power supply to the cooler are good. 2. Verify that D1 (+ 5 VDC) and D2 (+3.3 VDC) are illuminated on PCB1 inside the cooler. 3. Verify that the CAN bus LEDs, D7 and D8 are blinking.

HPR130XD Manual Gas Instruction Manual

5-25

MAINTENANCE Error code troubleshooting – error codes 180 to 181
Error code number Name Description Corrective action

180

1. Verify that the power supply-to-selection console CONTROL and POWER cables are not damaged and are properly connected to PCB3, and the rear of the selection console. 2. Verify that D17 (+5 VDC) and D18 (+3.3 VDC) are illuminated on PCB2 inside the selection console. These Selection LEDs indicate power to PCB2. Also verify that D26 (CAN The power supply did not console CAN RX) and D27 (CAN - TX) are illuminated on PCB2 inside receive a CAN message timeout the selection console. These LEDs indicate communication from the selection console Auto Gas between the selection console and the power supply. within 1 second. Only 3. If power is present at PCB2 and PCB3 and both selection console cables are good, then PCB2 or PCB3 has failed. Use the CAN tester to verify which board needs to be replaced. 4. Verify that the gas console control PCB and power distribution PCBs are securely mounted to the chassis at all four corners.

181

1. Verify that the power supply-to-metering console CONTROL and POWER cables are not damaged and are properly connected to PCB3, and the rear of the metering console. 2. Verify that D17 (+5 VDC) and D18 (+3.3 VDC) are illuminated on PCB2 inside the metering console. These LEDs indicate power to PCB2. Also verify that D26 (CAN Metering The power supply did not RX) and D27 (CAN - TX) are illuminated on PCB2 inside console CAN receive a CAN message the metering console. These LEDs indicate communication timeout from the metering console between the metering console and the power supply. Auto Gas within 1 second. 3. If power is present at PCB2 and PCB3 and both metering Only console cables are good, then PCB2 or PCB3 has failed. Use the CAN tester to verify which board needs to be replaced. 4. Verify that the gas console control PCB and power distribution PCBs are securely mounted to the chassis at all four corners.

5-26

HPR130XD Manual Gas Instruction Manual

MAINTENANCE

Power supply states
Set switch 8 on the gas console to the status position to view ID numbers.

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

HPR130XD Manual Gas Instruction Manual

5-27

MAINTENANCE

Plasma system operation with pump timeout
HPR power supply power-up Purge cycle begins, NOT READY FOR START signal is active Error output on

Purge timer done

PLASMA START signal active

Yes

No

System is in IDLE state waiting for a START signal, NOT READY FOR START signal is inactive If 30 minutes has passed since the last start, turn OFF the pump START signal removed

START signal No

Fire the torch and begin cutting

Yes

Yes

If the pump has timed out, turn on the NOT READY FOR START signal and turn on the pump

Is the flow sensor satisfied?

No

5-28

HPR130XD Manual Gas Instruction Manual

MAINTENANCE CNC operation with pump timeout User presses START on CNC Assert the PLASMA START and HOLD signals to all plasma systems Remove the START and HOLD signals Yes Is the NOT READY FOR START signal active on any plasma system No Apply the START signal and remove the HOLD signal Complete the cut cycle HPR130XD Manual Gas Instruction Manual 5-29 .

4. and turn the main disconnect switch ON. 5-30 HPR130XD Manual Gas Instruction Manual . or other apparent damage. The voltage between any 2 of the 3 terminals should be equal to the supply voltage. Repair or replace any defective component. See figure on next page. Inspect interior of power supply for discoloration on PC boards. If no damage is apparent. Dangerous voltages exist within the power supply which could cause injury or death. power cable. If there is a problem at this point. Measure the voltage between the W. if required. transformers and power distribution board. 5. remove and replace it before doing any testing. Also refer to the wiring diagram in Section 7.MAINTENANCE Initial checks Before troubleshooting. and fuses at line disconnect switch. do a visual check and verify that proper voltages are present at the power source. If a component or module is obviously defective. V and U terminals of TB1 located on the right side of the power supply. Refer to the Parts List section to identify parts and part numbers. DANGER SHOCK HAZARD: Always use caution when servicing a power supply when plugged in and the covers are removed. 2. connect power to the power supply. 3. Remove the power supply’s top panel and two side panels. 1. disconnect main power and check connections. Disconnect line power by turning OFF the main disconnect switch.

MAINTENANCE

Power measurement

DANGER
There is line voltage at the contactor and the power distribution board (PCB2) when the line disconnect switch is on. Use extreme care when measuring primary power in these areas. Voltages present at the terminal block and contactors can cause injury or death.

Main power in

U V W

Note:

Check lines in the following order: U to V U to W V to W Check each line to ground. If one line is 10% or higher than the other 2, put that leg on U.

HPR130XD Manual Gas Instruction Manual

5-31

MAINTENANCE

Air filter element replacement
1. Turn OFF all electrical power and disconnect the air hose from the filter. 2. Remove the filter bowl by turning it counter clockwise until it releases. 3. Pull the clear filter housing down firmly to remove it. The filter housing has an o-ring around the top. Apply a thin film of silicone lubricant on the o-ring to extend it’s life. The o-ring should look shiny, but there should not be any excess or built-up grease.

Clear filter housing

Filter bowl

4. Use a screwdriver to remove the filter element from the filter housing. Then install the new filter element. Note: Do not allow the filter element to turn when loosening the screw.

5. Reinstall the clear filter housing and the filter bowl.

5-32

HPR130XD Manual Gas Instruction Manual

MAINTENANCE

Power supply coolant system servicing
Draining the coolant system

1. Turn OFF the power, and remove the return coolant hose (red tape) from the pump and put it in a 20 liter (5 gallon) container.

2. Press and hold the current selection knob (8) and turn ON the power switch. The pump will run continuously while (8) is pressed.

3. Run the pump until the coolant stops flowing and immediately release the current selection knob (8).

HPR130XD Manual Gas Instruction Manual

5-33

MAINTENANCE

Caution:

Coolant will flow from the filter when its housing is removed. Drain coolant before servicing the filter.

Coolant system filter and strainer
Filter replacement
1. Turn OFF all power to the system. 2. Remove housing. 3. Remove and discard filter element. 4. Install new filter element 027664. 5. Re-install housing. 6. Refill with new coolant.

2

3

4

5

Pump strainer cleaning
1. Turn OFF all power to the system. 2. Drain coolant. See Power supply coolant draining in this section. 3. Remove nut. 4. Remove and clean strainer with a mild soap and water solution. 5. Re-insert strainer. 6. Re-install nut. 7. Refill with new coolant.

Strainer Nut

5-34

HPR130XD Manual Gas Instruction Manual

HPR130XD Manual Gas Instruction Manual 5-35

Coolant flow troubleshooting chart
Replace the pump, and inspect the shaft for damage Flow rate from bucket test < 0.9 gpm Flow rate from bucket test < 0.9 gpm

Coolant error (093) or (060)

Go to “steps to take before testing” on the next page Flow rate from flow tube < 0.8 gpm

Go to “pump/motor troubleshooting”

No flow

Go to test 1

Go to test 2

Go to test 6

Flow rate from flow tube > 0.8 gpm Flow rate from CNC > 0.8 gpm

Flow rate from bucket test > 0.9 gpm

Flow rate from bucket test > 0.9 gpm

Go to test 7

Replace the torch If the flow shown On the CNC is > 0.9 gpm

Go to test 3

Order a replacement Check valve or your Coolant will drain out at Each consumable change

Flow rate from CNC < 0.8 gpm

Flow rate from CNC < 0.9 gpm

Check your power supply outlet hose for kinks. If there are no kinks, replace the bypass valve and the hose set between the power supply and the high frequency console.

Go to test 4 Replace the flow switch Flow rate from bucket test > 0.9 gpm Flow rate from bucket test > 0.9 gpm Flow rate from bucket test < 0.9 gpm Flow rate from bucket test < 0.9 gpm There is a kink or clog between the high frequency console and the power supply. If there is not a kink, replace the leads.

MAINTENANCE

There is a kink in the return hose to the power supply. If there is not a kink, replace the hose.

Go to test 5

There is a kink in the leads between the high frequency console and the torch. If there is not a kink, replace the leads.

The following “bucket” tests give a good idea of the flow rate. Square in both axis. Replace the filter on the rear of the power supply.2 1. 2. The coolant in the system will drain out as soon as the in-line filter is removed.8 .2 1. Clean the filter/strainer. when refilling the system after completing steps 1 and 2.MAINTENANCE Coolant flow tests If the LED display on the gas console shows a coolant flow error (093 or 060). Take your reading from the edge shown below.4 1.1 1. 1. 2. Before testing Note: Coolant must be drained from the system before the in-line filter is cleaned (step 1 below). but can not be used with all the tests described. Hold the flow meter upright.2 Flow direction 5-36 HPR130XD Manual Gas Instruction Manual . 3. turn OFF the system and then ON again to clear the error.0 Float .0 Read from this edge Example shown 1. Verify that the system has the correct level of coolant.8 1. Then perform the following tests to find the cause of the problem.4 . An in-line flow meter is the most accurate way to measure the flow rate.6 1. HPR130 pump filter/strainer Filter on the rear of the power supply Filter/Strainer Nut Using the Hypertherm flow meter (128933) Use the steps below to get an accurate reading from the flow meter. 2.0 1. 1.6 . An in-line flow meter (part number 128933) is available from Hypertherm.

3 lpm (0. the pump must be turned on manually within 12 seconds of turning on the power supply. and allow the coolant to flow for 60 seconds. 3. Release the current selection knob (8) and then turn OFF the power.MAINTENANCE Manual pump operation If the LED display on the gas console shows coolant flow error 093. sheet 15 of 19 HPR130XD Manual Gas Instruction Manual 5-37 . Press and hold the current selection knob (8) to turn on the pump manually.6 gpm) for the system to operate. Note: A flow diagram can be found on schematic 013375. Coolant flow must be greater than 2. 1. or the power will have to be turned off and then on again. Turn ON the power. The recorded flow rate will be used for comparison during some of the tests. 2. Write down the coolant flow rate shown on the gas console's LED display.

Torch-lead coolant hoses 1. Write down how long it takes to fill the container. Turn OFF the power. go to test 3. Measure the flow rate on the flow meter. go to test 2. If the container is full in 65 seconds or less.8 gpm or more. Remove the return coolant line (blue hose with red tape). 5-38 HPR130XD Manual Gas Instruction Manual . Turn ON the pump manually (see step 1 under “Manual pump operation”). Turn OFF the power. 3. Reconnect the coolant lines. Test 2 – supply line at ignition console Note: Remove the torch-lead coolant hoses to access the supply line. go to test 7. go to test 6. Turn ON the power. A Hypertherm coolant container works well. Remove the supply coolant line (blue hose with green tape) from the RHF/LHF console. 3. 1. and place it in a 3. Turn ON the power.MAINTENANCE Test 1 – return line Note: An in-line flow meter is required to complete this test. Measure how long it takes to fill the container.8 gpm. 2. If there is no flow. Write down the flow rate from the flow meter. If it takes more than 65 seconds to fill the container. If the flow rate is 0. Reconnect the return coolant line (blue hose with red tape). If the flow rate is less than 0. go to pump and motor troubleshooting. Turn ON the pump manually (see step 1 under “Manual pump operation”). 2.8 liter (1 gallon) container. and connect the flow meter to measure the flow rate.

Write down how long it takes to fill the container. If the flow rate is still less than 0. Replace the torch and consumables with a new torch and new consumables. If it takes more than 65 seconds to fill the container. Caution: Coolant will flow from the hose very quickly. and place it in a 3. there is an obstruction in the return coolant line (from the RHF/LHF console to the power supply). 2. Turn ON the pump manually (see step 1 under “Manual pump operation”). 3. If the container is full in 65 seconds or less. Turn ON the pump manually (see step 1 under “Manual pump operation”). Test 5 – return line from the torch receptacle (remove at the ignition console) 1. replace the torch leads. Remove the return coolant line (blue hose with red tape) from the RHF/LHF console. 2. replace the torch. look for an obstruction or kink in the coolant hose between the torch and the LHF/RHF console. Remove the coolant supply line from the torch receptacle.MAINTENANCE Test 3 – change the torch 1.8 liter (1 gallon) container. Turn OFF the power. and look at the flow rate on the LED display on the gas console. If there is no obstruction or kink. If the container is full in 65 seconds or less. Turn ON the pump manually (see step 1 under “Manual pump operation”). If the flow rate shown on the LED display is 0. 2. A Hypertherm coolant container works well. 3. go to test 4. Turn ON the power. If it takes more than 65 seconds to fill the container. Reconnect the return coolant line. there is an obstruction in the torch receptacle. Turn OFF the power. let it run for 60 seconds.9 gpm. Measure how long it takes to fill the container. Test 4 – supply line to the torch receptacle 1. Write down how long it takes to fill the container. Replace the torch receptacle. and place it in a 3. Turn ON the power. HPR130XD Manual Gas Instruction Manual 5-39 .9 gpm or more. A Hypertherm coolant container works well. Replace the return coolant line. go to test 5. Reconnect the coolant supply line to the torch receptacle. Measure how long it takes to fill the container.8 liter (1 gallon) container.

5-40 HPR130XD Manual Gas Instruction Manual .8 liter (1 gallon) container. Install the push-to-connect fitting and connect the hose. A Hypertherm coolant container works well. replace the pump and check the motor shaft for damage. 2. Turn ON the pump manually (see step 1 under “Manual pump operation”). Remove the push-to-connect fitting from the relief valve. If it takes less than 65 seconds to fill the container.MAINTENANCE Test 6 – bucket test at the pump 1. 4. Measure how long it takes to fill the container. Turn ON the power. If no kinks are found. Remove the pump outlet. If it takes more than 65 seconds to fill the container. 3. Turn OFF the power. Write down how long it takes to fill the container. 2. Remove the hose from the relief valve. coolant line. Test 7 – bypass the check valve 1. check the coolant supply line (from the power supply to the RHF/LHF console) for kinks. replace the hoses between the power supply and RHF/LHF console. Remove the relief valve. and place it in a 3. Turn OFF the power.

If the motor will not turn on. turn the pump on manually. as shown.8 gpm.MAINTENANCE Test 7 – continued 5. If the flow shown on the LED display is less than 0. but the pump is not running. and note the coolant flow rate shown on the LED display on the gas console.8 gpm. verify that the solenoid valve and check valve are working correctly. replace the flow switch. The arrow points up. Coolant will drain out of the torch during every consumable change if the check valve is bypassed. Check valve orientation Pump and motor troubleshooting Is the motor LED illuminated on the control board? Is the motor on? If the LED is illuminated. HPR130XD Manual Gas Instruction Manual 5-41 . Note: The check valve must be oriented correctly. verify that the fuse is OK. If the flow shown on the LED display is more than 0. Turn ON the power supply. and make sure there is power to the motor. If you are still not getting flow from the pump. replace the check valve.

0.67 VDC at the flow switch) equals 2.45 VDC (0. If the TP210 voltage reading is below 0. TP210 provides a filtered.3 lpm (0.45 VDC and the flow is equal to or above 3. Measure the VDC between TP210 and TP206. voltage from the flow switch. TP206 is common on PCB3. 2. replace the flow switch. TP 206 TP 210 041993 5-42 HPR130XD Manual Gas Instruction Manual .6 gpm).0 lpm (1 gpm). Turn ON the power.MAINTENANCE Testing the flow sensor 1. 67% scaled.

4. The pressure displays should remain at or close to zero while inlet pressures remain constant. 2. then one or more inlet valves in the gas console are not closing properly. Close gas supply valves. The leak test mode is activated by switching the shield gas selector switch (2) to the TEST position and then switching the RUN/SET switch (7) to either SET PREFLOW or SET CUTFLOW to begin the leak test. If a gas supply pressure gauge decreases then there is a leak in the supply hoses between the shut-off and the gas console. The inlet valves within the gas console will close and the off-valves will open to allow any trapped gas to escape. Close the gas supply valves. If a gas supply pressure gauge decreases but no pressure is displayed on gas console. Leak test 1 1. After performing leak test 1. 5. The inlet valves in gas console will remain closed. 3. 3. The pressures displayed should remain constant. After initial gas purge switch shield selector switch (2) to TEST. Monitor the pressure displays and the gas supply pressure gauges for 20 minutes. Leak Check Mode 2 – Switch 7 in the SET CUTFLOW position. This test is intended to identify a leak between the gas console and the off-valve. The inlet valves will open and pressurize the gas lines between the off-valve and the gas console. Monitor the pressure displays on the gas console and the gas supply pressure gauges for 20 minutes. HPR130XD Manual Gas Instruction Manual 5-43 . After 20 seconds all inlet valves are turned off. Turn ON power to the HPR130. This traps pressure between the gas console and the off-valve. If any pressure displays decrease. If any pressure display increases. and the pressure displays should read zero. The off-valve will close after 20 seconds. then there is a leak in the supply hoses between the shut-off and the gas console.MAINTENANCE Gas leak tests The system has two automatic leak test modes. At this point there should be no pressure between the gas console and offvalve. Leak test mode 1 – With switch 7 in the SET PREFLOW position. 6. 2. After 20 seconds all the off-valves will close. Pressure displays and gas supply gauges should remain constant. This test also checks for leaks in the supply lines. turn on gas supply valves again and move switch 7 to SET CUTFLOW. then there is a leak in a gas line between the gas console and the off-valve. Leak test 2 1. This test is intended to identify a problem with any inlet supply valve that does not close properly in the gas console. in which case pressure will build at the off-valve and be displayed on the gas console. The inlet valves in the gas console will open for 20 seconds and then close. 4. The off-valve opens and exhausts gas between the gas console and torch. while the off-valve remains closed. Select SET PREFLOW on switch 7. 5. 8. 7.

MAINTENANCE Power supply control board PCB3 Control PCB LED list LED D100 D101 D113 D114 D117 D118 041993 Control PCB3 firmware list Item U104 U105 Part number 081169 EVEN 081169 ODD Signal name +5 VDC +3.3 VDC CAN TX CAN RX RS-422 TX RS-422 RX Notes Constant blinking Constant blinking = HPR130 = HPR260 Note: See wiring diagrams for other dipswitch settings LED D321 D322 D323 D324 D325 D326 D327 D328 D329 D330 Control PCB LED list Output Input Machine motion Error Rampdown error Not ready Spare Pilot arc enable Hold Pierce Corner current Plasma start Notes LED D331 D332 D333 D334 D335 D336 D337 Control PCB LED list Output Input HV transformer Pump motor enable Contactor Pilot arc relay Spare Surge select Phase loss Notes Not used 5-44 HPR130XD Manual Gas Instruction Manual .

MAINTENANCE Power supply power distribution board PCB2 D1 D2 D5 D7 D25 D33 D3 D35 D12 Power distribution PC board LED list LED D1 D2 D3 D5 D7 D12 D23 D25 D26 D31 D32 D33 D35 Output Contactor Pilot arc relay 120 VAC (switched) HF ignition Surge select 24 VAC (switched) 240 VAC (switched) + 24 VDC Pump motor + 5 VDC – 15 VDC + 15 VDC 24 VAC Color Red Red Green Red Red Green Green Red Green Red Red Red Green HPR130XD Manual Gas Instruction Manual D23 D26 D31 D32 5-45 .

It allows the initial pilot arc current to flow through the pilot arc lead quickly.MAINTENANCE Start-circuit PCB1 Operation The start circuit is a high-speed switch that quickly transfers the pilot arc current from the pilot arc lead to the work lead. the start circuit introduces impedance to the pilot arc lead to aid in transferring the arc to the workpiece. The start circuit performs 2 functions: 1. Dangerous voltages exist within the power supply which could cause injury or death. After initial pilot arc current is established. with little impedance. Start circuit functional schematic Plasma power supply Chopper Choke Power resistor Control logic IGBT ALEL Caps Cutting arc Diode Pilot arc Start circuit Start circuit troubleshooting DANGER SHOCK HAZARD: Always use caution when servicing a power supply when plugged in and the covers are removed. 5-46 HPR130XD Manual Gas Instruction Manual . See schematic below. 2.

• Verify a resistance of about (≈) 1 Ω across the R1 resistor. the board may need to be replaced. the board may need to be replaced or the board may not be receiving power. replace the board. If arc transfer is immediate. the LED will not illuminate. Verify a resistance of about (≈) 15 kΩ between snubber and H8. but a pilot arc is established. D1 illuminates as soon as the torch fires and will extinguish as soon as the arc transfers to the workpiece. Note: Resistance value may slowly increase to the correct value due to the capacitance in the circuit. The work lead connection to the cutting table should be clean and have good contact to the table. If there is no arc at the torch or if the arc will not transfer: 1. • Verify that LED-D2 is illuminated. Verify a resistance of about (≈) 5. If it is not illuminated. Verify a resistance of 1Ω or less. 4.MAINTENANCE D2 should always be illuminated. • Fire the torch in the air and verify that D1 is illuminated. Turn OFF all power to the system. If the resistance value is not correct. 2. D1 D2 15kΩ or H8 WORK + – H9 NOZZLE 5. Remove wires from H8 (WORK) and H9 (NOZZLE) studs on the board. 3.5 kΩ between H8 and D50 (–).5kΩ R1 1Ω HPR130XD Manual Gas Instruction Manual 5-47 . If it is not illuminated. • The work lead should not have any cuts or breaks.

See table below.MAINTENANCE Pilot arc current levels The pilot arc current level will change depending on the chosen process and arc current level. Pilot arc current Plasma gas O2 N2 H35 F5 Air 30-amps 25 25 25 25 25 45-amps 30 30 30 30 30 50-amps 30 30 30 30 30 80-amps 30 30 30 30 30 130-amps 30 35 35 35 35 Transfer current Plasma gas O2 N2 H35 F5 Air 30-amps 10 10 10 10 10 45-amps 10 10 10 10 10 50-amps 10 10 10 10 10 80-amps 10 10 10 10 10 130-amps 15 15 15 15 15 5-48 HPR130XD Manual Gas Instruction Manual .

left digit Plasma preflow. right digit Current. right digit Plasma cutflow.3 VDC Coolant error Pressure error CAN– TX CAN– RX Voltage error Temperature error Green Green Yellow Yellow Green Green Yellow Yellow HPR130XD Manual Gas Instruction Manual 5-49 . left digit Shield cutflow.MAINTENANCE Gas console control board PCB2 Control PCB2 firmware list Item U17 U18 Part number 081109 EVEN 081109 ODD LEDN LEDN1 LEDN2 LEDN3 LEDN4 LEDN5 LEDN6 LEDN7 LEDN8 LEDN9 LEDN10 LEDN11 Gas console control board LEDN list Signal name Plasma preflow. left digit Plasma cutflow. center digit Current. right digit Shield cutflow. right digit Color Red Red Red Red Red Red Red Red Red Red Red Gas console control board LED list LED Signal name Color D1 D2 D4 D6 D8 D9 D10 D11 + 5 VDC + 3. left digit Shield preflow. right digit Shield preflow. left digit Current.

MAINTENANCE

Gas console power distribution board PCB1

Gas console control board LED list LED Signal name Color D1 D7 D9 120 VAC (switched) + 5 VDC + 24 VDC Green Red Red

5-50

HPR130XD Manual Gas Instruction Manual

MAINTENANCE

Gas console, AC valve-driver board PCB3
P1 P2 P3 P4

LED D1 D2 D3 D4 D5 D6 D7 D8 D9 D10

Signal name SV1 SV2 SV3 SV4 SV5 SV6 SV7 SV8 SV9 SV10

Color Red Red Red Red Red Red Red Red Red Red
SV14 SV13

LED D11 D12 D13 D14 D15 D16 D17 D18 D19 D20

Signal name SV11 SV12 SV13 SV14 SV15 SV16 SV17 SV18 SV19 SV20

Color Red Red Red Red Red Red Red Red Red Red

SV12 SV10 SV4

SV3 SV19 SV18 SV20

SV16 SV17

SV6 SV2 SV11 SV9 SV8 SV7

Off-valve

SV5 SV1

HPR130XD Manual Gas Instruction Manual

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MAINTENANCE

Chopper tests
WARNING
SHOCK HAZARD: Use extreme care when working near the chopper modules. Each large electrolytic capacitor (blue-cased cylinder) stores large amounts of energy in the form of electric voltage. Even if the power is off, dangerous voltages exist at the capacitor terminals, on the chopper, and the diode heatsinks. Never discharge any capacitor with a screwdriver or other implement… explosion, property damage and/or personal injury will result.
LED display

Automatic chopper and current sensor tests during power-up
Turn ON the system. When the preflow starts, the contactor will close and the system will automatically test the chopper and current sensors. The system closes the contactor and turns on the chopper at 90% duty cycle. The chopper will charge the surge capacitor on the I/O board (PCB 6). The current that charges the capacitor should be between 10 amps and 35 amps. Error code 105 will show in the LED display on the gas console, if the current is < 10 amps or there is no feedback on current sensor 1 (CS1). Error code 103 will show in the LED display if the current is > 35 amps. Place the toggle switch in the STATUS position if the system completes the power up sequence. If the system shows error code 003 the test passed. The chopper and current sensors are OK. If error code number 103 or 105 is displayed, continue with the tests below.
Toggle switch

Troubleshooting low-current error code 105 1. Verify that the current sensors (CS1 and CS3) and cables are not damaged. 2. Exchange CS1 and CS3. Replace the faulty sensor if the error code is not displayed again. 3. Measure the resistance between wire 38 and wire 39 on PCB6 with a meter. The value should be increasing as the capacitor charges. Replace PCB6 if a constant value is seen. 4. Check for loose wires or shorts from the chopper to PCB6. 5. Check for 220 VAC to 1A, 1B, and 1C on the chopper when the contactor closes.

I/O board (PCB6)

CS3

CS1

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HPR130XD Manual Gas Instruction Manual

MAINTENANCE
Troubleshooting high-current error code 103 1. Verify that the current sensors (CS1 and CS3) and cables are not damaged. 2. Exchange CS1 and CS3. Replace the faulty sensor if the error the code is not displayed again. 3. Look at the surge capacitor to ensure that it is not short-circuited. Replace PCB6 if the surge capacitor is shorted. 4. Check for short circuits from the work terminal to the negative terminal on PCB6. Resistance should be about 100K ohm from the work terminal to the negative terminal. Resistance will vary if you have a voltage divider for a height control system.

HPR130XD Manual Gas Instruction Manual

5-53

MAINTENANCE

Phase-loss detection test
1. Turn OFF all power to the system and remove the cover from CON1.

2. Inspect the condition of the 3 contacts for excessive wear. If one or more of the contacts are worn excessively, replace CON1 and restart the system. If the error remains, perform the following steps.

OK

Excessive wear

3. Test the fuses F5, F6, and F7 on the power distribution board (PCB2). If any of the fuses are blown, replace PCB2.

D1

D2

D5

D7

D25

D33 D3 D35 D12

4. Remove J2.8 from PCB2 and place a jumper between pins 1 and 2 on the cable connector. a. Make a test cut. If the phase-loss error continues, verify wiring between J2.8 on PCB2 and J3.302 on PCB3 by verifying the continuity between – J2.8 pin1 to J3.302 pin14 – J2.8 pin2 to J3.302 pin15. b. If the wiring is ok replace PCB3. If any wiring is damaged repair or replace damaged wires. c. If the phase-loss error goes away while the jumper is on J2.8, make another cut and measure the phase-tophase voltage across the fuses, F5, F6, and F7. The voltage should be 220 VAC +/-15%. If one of the 3 voltage readings is less than 187 VAC, check the contacts to the contactor, and check for loose connections between the power cord – contactor – power transformer – and the chopper.

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HPR130XD Manual Gas Instruction Manual

D23

D26

D31

D32

2. 3. Verify that the pilot arc wire on the torch lead is not damaged. A measurement of greater than 3 ohms indicates a faulty connection between the torch and ignition console or between the ignition console and the power supply. 5. The reading should be less than 3 ohms. Dangerous voltages exist within the power supply which could cause injury or death. If it is not damaged replace the torch head. D1 D2 H8 WORK H8 WORK + – H9 NOZZLE H9 NOZZLE 4. Have a second person close the contact. Torch lead test 1. Locate the start circuit assembly. HPR130XD Manual Gas Instruction Manual 5-55 . Measure the ohm value between the nozzle and the plate. If it is damaged replace the lead. Locate the pilot arc relay (CR1) and remove the dust cover.MAINTENANCE DANGER SHOCK HAZARD: Always use caution when servicing a power supply when plugged in and the covers are removed. Install a temporary jumper wire between H8 (work) and H9 (nozzle) on the start circuit PCB1. Turn OFF all power to the system. 6.

and the work of cutting must stop more often to change consumables. Since labor and overhead can account for 80% of the cost of cutting. Reduced parts life increases operating costs in two ways: The operator must use more electrodes and nozzles to cut the same amount of metal. and you would like confirmation of your decision. If you see any discoloration that might indicate overheating. Inspect the main contactor for excessive pitting on the contacts. If this condition exists. In the U. improved productivity can reduce cutting costs dramatically. Preventive maintenance protocol The following protocol covers the basic elements of all Hypertherm HyPerformance plasma systems. please contact Hypertherm's Technical Service department. 5-56 HPR130XD Manual Gas Instruction Manual . 3. 2. 4. damage or loose connections. 1. Use compressed air to blow out any accumulation of dust and particulates. If inspection suggests that a component is worn and might require replacement.MAINTENANCE Preventive maintenance Introduction Deteriorating consumable parts life is one of the first indications that something is wrong with a plasma system. With power to the power supply turned off. Replace if necessary. Inspect the pilot arc relay (CR1) for excessive pitting on the contacts. The power supply DANGER ELECTRIC SHOCK CAN KILL Turn off all electrical power before removing the power supply cover and set the line disconnect switch to OFF. In other countries. Inspect wiring harnesses and connections for wear. rough surface on any of the contacts. remove all side panels.. characterized by a blackened. contact Hypertherm Technical Service. Proper maintenance often eliminates the problems that shorten the life of consumable parts.S. replacement is recommended. characterized by a roughened. black surface. use a “lock-out and tag-out” procedure until the service or maintenance is complete. follow appropriate local and national safety procedures.

At the ignition console. dry. 9. Check that the retaining or shield cap is tightened securely to the torch main body. Too much lubricant may obstruct gas flows. but do not overtighten. pipe cleaner or clean cloth. 12. 14. Verify that proper Hypertherm coolant is being used. 6. If the filter is a brownish color. oil-free surface. Damage to the threads usually results from not cleaning the torch and retaining cap threads properly. there may be a 0. 10. check the coolant tank for dirt and particulates. so that dirt and particulates accumulate in the threads. Primary locations to inspect are these: A. If the gas supply line is a hose. C.5 bar (5 to 7 psi) drop due to hose-stretch. Make sure that the correct amount of lubricant – a thin film – is applied to these o-rings. Torch main body 7. Clean all threads on the front end of the torch head with hydrogen peroxide and a cotton swab. Pressurize the gas line to 8. Check that all connections between the torch and torch leads are tight. Consult the Parts List in this manual for part numbers. Inspect the torch insulator for cracks. Gas flows 15. If no pitting is observed. Proper Hypertherm coolant (028872) is a red liquid. When removing consumables. 11. Pitting on the current ring generally indicates improper maintenance (i. Do not use alcohol. lack of regular cleaning). 13. Inspect the current ring inside the torch main body. Repeat for each line from a gas supply source. Inspect the coolant-circulating system’s filter element at the rear of the power supply. then check for coolant leaks.3 to 0. and C.e. replace it. The back of the power supply. The current ring should be smooth and not pitted. B. always place them on a clean. Damage to the fitting threads may indicate that overtightening has occurred. See torque specs in the Installation section of this manual. Replace the torch if you find cracks. clean the current ring with a clean cotton swab and hydrogen peroxide. Remove and plug the inlet gas fitting at the gas console. B. Also. Do not use alcohol. Verify that the water tube is straight and has no pitting on the end.3 bar (120 psi). D. Close the gas supply valve at the source. Watch for a pressure drop. 8.MAINTENANCE Cooling system 5. Inspect all o-rings on the torch body and consumables. Inspect all hose fittings at the rear of the torch for wear. Perform a coolant flow test as described in this manual. as follows: A. find the leak within the system. HPR130XD Manual Gas Instruction Manual 5-57 . At the torch main body. If any pressure continues to drop. since dirty consumables may cause the torch to malfunction. Check each gas line from the gas supply.

Check for hose restrictions. If the outside insulation has been cut or otherwise damaged. System grounding 22. 17. Inspect the torch leads. Verify that all components of the system are individually grounded to a driven earth ground. If moisture is present. Check that the console doors close properly. B. A. Cable connections 18. as follows: A. particularly where the work lead (+) connects to the cutting table. 20. dry the inside of the console with a cloth and try to identify the source of the moisture. All cables should be checked for chafing or unusual wear. such as the power supply. ignition console and gas console. Open the cover and use compressed air to blow out any accumulation of dust and particulates. should be connected individually to a ground point. Ensure that the wiring connections to the spark gap assembly are secure. replace the cable. If the gas line pressures hold steady. or equivalent-size wire. Complete the Preventive Maintenance worksheet on the next page. check the position of the leads in the power track to ensure the leads do not twist or kink. perform a system gas leak test as specified in this manual.MAINTENANCE 16. If the cutting table uses a power track system to support leads from the power supply to the gas console or torch. clean connection because a poor connection may cause arc-transfer problems. Ensure that they are fastened tightly to the outside of the ignition console. Check the work lead (+) connection. 23. 5-58 HPR130XD Manual Gas Instruction Manual . All metal enclosures. These connections should be made with 10 mm2 (#8 AWG) wire (USA). causing a possible restriction. Check all hoses to verify that they have no kinks or sharp bends. 21. This must be a good. as described in the Installation and Grounding sections of this manual. which can restrict gas flow. 24. for future reference. Inspect the spark gap assembly. Ignition console 19.

• Verify proper coolant level. HPR130XD Manual Gas Instruction Manual 5-59 . – Mandatory at every consumable change. Annually: Year • Replace service parts per the Service Part Replacement Schedule. • Verify proper gas flow settings. or a vacuum cleaner. • Inspect torch and replace consumables as needed. oil free compressed air. • Clean torch threads and current ring. Jan Feb March April May June July Aug Sept Oct Nov Dec Semi-Annually: Year 1st service 2nd service • Replace service parts per the Service Part Replacement Schedule.MAINTENANCE Preventive Maintenance Master Schedule Daily: • Verify proper inlet gas pressure. • Verify cooling fans are working properly. Weekly: Week 1 2 3 4 5 • Clean power supply with dry.

Inspect hose fittings 14. Motor valve hoses P NP B. Inspect plumbing from gas supply NP A. Coolant flow checked at _________ gallons per minute ( _________ l/min) 16. Oxygen NP B. Off-valve to torch body P NP D. Inspect connection from cutting table to workpiece (+) lead General comments and recommendations: Preventive maintenance performed by: 5-60 Date: HPR130XD Manual Gas Instruction Manual . Perform coolant flow test A. Inspect spark gap subassembly 21. Verify proper fit of retaining or shield cap 13. Inspect for particulates and blow out 2. Inspect torch leads System grounding P P NP NP 22. Clean threads on torch front end 10. Inspect main contactor 4. Inspect wiring harnesses 3. Nitrogen or argon NP C. CommandTHC NP B. Nitrogen-Hydrogen (F5) NP E. From ignition console and gas console to power supply Ignition console P P NP NP NP Gas flows P NP P P P P P P 15. Inspect cables NP A. Air NP D. Inspect pilot arc relay Coolant system P P NP NP P 5. Inspect for hose restrictions P NP A. Hoses in power track NP Torch main body P P P P P P P P NP NP NP NP NP NP NP NP Cable connections P NP P P P 7. Inspect current ring 9. Inspect torch-to-torch-lead connections 18. Inspect Vespel torch insulator 11. Control cable from off-valve to gas console NP C. Inspect filter element 6. Inspect torch and consumable o-rings 12. Oxygen pressure drop at ____________ psi in 10 minutes ( ____________ bar) B. Inspect water tube 8. Nitrogen pressure drop at ____________ psi in 10 minutes ( ____________ bar) NP 17. Argon-Hydrogen (H35) NP F. Inspect for proper system component grounding 23. dust and particulates 20. Inspect compressed air filter system P 19. Perform gas leak test A. Inspect for moisture. Gas console to motor valve P NP C.Preventive Maintenance Protocol Checklist Customer: Location: Contact: Date: Hypertherm system: System serial #: System arc hours: (if equipped with an hour meter) P – Performed NP – Not present on system Comments Power supply P P P P NP NP NP NP Gas flows – continued P 1.

5 Years or 2100 arc hours HPR130XD Manual Gas Instruction Manual 5-61 .MAINTENANCE Service parts replacement schedule – 1 of 2 228015 – annual preventive maintenance parts kit This kit includes all the parts in the shaded boxes below Timeline Component Coolant filter element Coolant solution 70/30 Torch kit Quick-disconnect kit Air filter element Coolant filter element Coolant solution 70/30 Main contactor Torch main body Pilot arc relay Air filter element Coolant filter element Coolant solution 70/30 Torch kit Quick-disconnect kit Air filter element Coolant filter element Coolant solution 70/30 Main contactor Torch main body Pilot arc relay Coolant pump kit Torch leads Air filter element Coolant filter element Coolant solution 70/30 Torch kit Quick-disconnect kit Air filter element Coolant filter element Coolant solution 70/30 Main contactor Torch main body Pilot arc relay Cooling fan 6" Cooling fan 10" Air filter element Coolant filter element Coolant solution 70/30 Torch kit Quick-disconnect kit Air filter element Part number 027664 028872 128879 128880 011110 027664 028872 003139 220162 003149 011110 027664 028872 128879 128880 011110 027664 028872 003139 220162 003149 228170 System dependant 011110 027664 028872 128879 128880 011110 027664 028872 003139 220162 003149 127039 027079 011110 027664 028872 128879 128880 011110 Qty. 1 4 1 1 1 1 4 1 1 1 1 1 4 1 1 1 1 4 1 1 1 1 1 1 1 4 1 1 1 1 4 1 1 1 4 3 1 1 4 1 1 1 6 months or 300 arc hours 1 Year or 600 arc hours 1.5 Years or 1500 arc hours 3 Years or 1800 arc hours 3.5 Years or 900 arc hours+ 2 Years or 1200 arc hours 2.

5 Years or 3300 arc hours 6 Years or 3600 arc hours 6. 1 4 1 1 1 1 1 1 1 1 4 1 1 1 1 4 1 1 1 1 1 1 1 1 1 1 4 1 1 1 1 4 1 1 1 1 1 4 3 1 4 Years or 2400 arc hours 4.5 Years or 2700 arc hours 5 Years or 3000 arc hours 5.MAINTENANCE Service parts replacement schedule – 2 of 2 Timeline Component Coolant filter element Coolant solution 70/30 Main contactor Torch main body Pilot arc relay Coolant pump kit Torch leads Coolant pump motor kit Air filter element Coolant filter element Coolant solution 70/30 Torch kit Quick-disconnect kit Air filter element Coolant filter element Coolant solution 70/30 Main contactor Torch main body Pilot arc relay High voltage transformer Power distribution board Metering console Pilot arc lead Gas leads Air filter element Coolant filter element Coolant solution 70/30 Torch kit Quick-disconnect kit Air filter element Coolant filter element Coolant solution 70/30 Main contactor Torch main body Pilot arc relay Coolant pump kit Torch leads Cooling fan 6" Cooling fan 10" Air filter element Part number 027664 028872 003139 220162 003149 228170 System dependant 228538 011110 027664 028872 128879 128880 011110 027664 028872 003139 220162 003149 129854 041802 078535 System dependant System dependant 011110 027664 028872 128879 128880 011110 027664 028872 003139 220162 003149 228170 System dependant 127039 027079 011110 Qty.5 Years or 3900 arc hours Repeat schedule starting at 6 months or 300 arc hours 5-62 HPR130XD Manual Gas Instruction Manual .

..........6-10 Torch assembly ........................................................................................................................................................................................................................................................................................................................................6-8 Gas console – 2 of 2 .................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6-2 Ignition console.......................................6-9 HyPerformance torch .......................................................6-12 Consumables for mirror-image cutting...................................................................................................................................6-11 Ohmic contact wire .......................................................................Section 6 PARTS LIST In this section: Power supply .............................................6-13 Recommended spare parts........................6-14 HPR130XD Manual Gas Instruction Manual 6-1 .............................................6-10 Torch leads ......................................................................................................6-9 Off-valve..................................................................................................................................................................................6-11 Consumable parts kits .....................................................................................................................................................................................................6-7 Gas console – 1 of 2 ...........................

with label Panel: Front. 2 3 4 5 6 1 1 1 1 1 6-2 HPR130XD Manual Gas Instruction Manual .PARTS LIST Power supply 2 1 3 6 4 5 Item 1 Part Number 078538 078539 078540 078541 078542 078543 078544 078545 228328 075241 228532 228531 129633 Description HyPerformance Plasma power supply: 200/208 volt HyPerformance Plasma power supply: 220 volt HyPerformance Plasma power supply: 240 volt HyPerformance Plasma power supply: 380 volt HyPerformance Plasma power supply: 400 volt HyPerformance Plasma power supply: 440 volt HyPerformance Plasma power supply: 480 volt HyPerformance Plasma power supply: 600 volt Panel: Top. with label Sheet metal screws Panel: Right or left side. with label Green power lamp assembly Designator Qty.

50 HZ 220 volt main transformer: 19. 60 HZ 600 volt main transformer: 19. 60 HZ Kit: Thermistor replacement for main transformer Designator Qty. 120 VAC 50-60 HZ 200 volt main transformer: 19.5 KW. 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 CH1 T2 HPR130XD Manual Gas Instruction Manual 6-3 .5 KW.5 KW. 50-60HZ 240 volt main transformer: 19. 3 ph. 3 ph. 60 HZ 380 volt main transformer: 19. 3 ph. 115 VAC 50-60 HZ 10" fan: 450-550 CFM. 3 ph.5 KW. 50 HZ 440 volt main transformer: 19. 50-60 HZ 480 volt main transformer: 19.5 KW.PARTS LIST Power supply 2 3 4 1 5 6 Item 1 2 3 4 5 6 Part Number 027634 027664 127014 129792 127039 027079 014283 014284 014282 014303 014283 014284 014282 014281 228309 Description Filter housing Filter element Cap: Coolant reservoir Chopper assembly 6" fan: 230 CFM.5 KW.5 KW.5 KW. 3 ph. 3 ph. 3 ph. 50 HZ 400 volt main transformer: 19. 3 ph.

1 1 1 1 1 1 1 1 * 400 volt power supply only 6-4 HPR130XD Manual Gas Instruction Manual . 440 VAC 3PH Start circuit assembly Current sensor: Hall 100 amp. 4 volt Current sensor: Hall 100 amp. 120 VAC PCB: I/O Contactor EMI filter: 60 amp. 4 volt Inductor: 4MH Designator CR1 PCB6 CON1 PCB1 CS3 CS1 Qty.PARTS LIST Power supply 4 3 5 6a 6b 2 1 7 Item 1 2 3 4 5 6a 6b 7 Part Number 003149 041837 003139 109036* 229238 109004 109004 014280 Description Relay: Pilot arc.

5 amp. 440. 240 volt Kit: Motor with clamp Designator F1. 2 2 1 1 1 1 1 2 1 1 1 1 CLT SOL * 380. 480 and 600 volt power supplies ** 200/208 and 240 volt power supplies HPR130XD Manual Gas Instruction Manual 6-5 . F2 PCB3 PCB2 T2 FLS Qty. 500 volt Control PCB Power distribution PCB Temperature sensor Flow switch assembly Heat exchanger assembly 4" fan Check valve: 1/4" FPT Kit: Pump with clamp Solenoid valve assembly: 3/8". F2 F1.PARTS LIST Power supply 4 5 3 2 6 1 7 8 10 9 Item 1 2 3 4 5 6 7 8 9 10 Part Number 008551* 008709** 228548 041802 109393 229206 027978 027185 006075 228170 006046 228538 Description Fuse: 7. 400. 600 volt Fuse: 20 amp.

1 1 1 1 1 1 1 1 6-6 HPR130XD Manual Gas Instruction Manual . 50-60 HZ Control transformer: 440 volt. 50-60 HZ Control transformer: 480 volt. 50 HZ Control transformer: 400 volt. 50-60 HZ Control transformer: 240 volt.PARTS LIST Power supply 1 Item 1 Part Number 129786 229117 129966 229094 129787 229013 129967 129989 Description Control transformer: 200/208 volt. 50-60 HZ Control transformer: 220 volt. 60 HZ Control transformer: 380 volt. 50-60 HZ Designator T2 Qty. 50-60 HZ Control transformer: 600 volt.

1 1 1 HPR130XD Manual Gas Instruction Manual 6-7 .PARTS LIST Ignition console 1 2 3 4 Item 1 2 3 4 Part Number 078172 129831 041817 129854 Description Ignition Console Coil assembly HFHV Ignition PCB Transformer Designator T2 PCB IGN T1 Qty.

PARTS LIST Gas console 1 2 3 4 5 7 Part Number 078532 041805 041822 005263 006109 006112 006136 005262 6 Item 1 2 3 4 5 6 7 Description Gas Console Power distribution PCB Valve driver PCB Pressure sensor Solenoid valve Replacement solenoid coil Solenoid valve Illuminated power switch Designator PCB1 PCB3 PT1-PT4 SV2. SV6. SV5. SV8-SV14 SV1. SV7 SW1 Qty. 1 1 4 11 3 1 6-8 HPR130XD Manual Gas Instruction Manual . SV3. SV4.

PR4 PR2 Qty. PR3. 1 5 5 1 1 2 HPR130XD Manual Gas Instruction Manual 6-9 . 1 3 1 1 1 Off-valve Item 1 2 Part Number 078534 006109 006112 123748 Description Off valve assembly Solenoid valve Replacement solenoid coil Off-valve cable Designator V16-V20 Qty.PARTS LIST Gas console 2 3 4 1 Item 1 2 3 4 Part Number 041912 229128 229129 228147 011109 011110 Description Control PCB Regulator assembly with elbow fitting Regulator assembly with elbow and tee fitting Kit: Regulator upgrade (replaces all 4 regulators) Filter assembly Filter element Designator PCB2 PR1.

75 in) 2" spanner wrench Torch kit: o-rings. water tube and seal Quick disconnect kit: o-ring and connector 6 6-10 HPR130XD Manual Gas Instruction Manual . 248 mm (9. 181 mm (7 in) Torch mounting sleeve assembly: Short.PARTS LIST HyPerformance torch Torch assembly 1 2 3 4 5 6 Part Number 228520 220706 220571 220705 220789 220788 220790 104269 128879 128880 Item 1 2 3 4 5 Description HPR130XD machine torch assembly Quick-disconnect torch Water tube Quick-disconnect receptacle Torch mounting sleeve assembly: Standard.5 in) Torch mounting sleeve assembly: Long. 114 mm (4.

5 m (15 ft) 6 m (20 ft) 7. 123983 123984 123985 123986 123987 123988 123989 123990 123991 Length 3 m (10 ft) 6 m (20 ft) 7.5 m (25 ft) 9 m (30 ft) 12 m (40 ft) 15 m (50 ft) 23 m (75 ft) 30 m (100 ft) 45 m (150 ft) HPR130XD Manual Gas Instruction Manual 6-11 .5 m (25 ft) 10 m (35 ft) 15 m (50 ft) 20 m (65 ft) Ohmic contact wire (Not part of the HPR130XD system. Shown for reference only) Part no. 228291 228292 228293 228294 228295 228296 228297 228547 Length 2 m (6 ft) 3 m (10 ft) 4.PARTS LIST Torch leads Part no.

208" X 0.364" X 0.208" X 0.070" Lubricant: Silicone 1/4-oz tube O-ring: 1.364" X 0. 5 1 2 1 1 1 1 3 4 2 2 2 1 2 2 1 1 2 1 2 1 1 1 1 1 Stainless steel and Aluminum consumable starter kit – 228421 Part Number 026009 027055 044028 104119 104269 220179 220180 220197 220198 220201 220202 220307 220308 220337 220338 220339 220340 220755 Description O-ring: 0.070" Lubricant: Silicone 1/4-oz tube O-ring: 1.070" Tool: Consumable removal / replacement Wrench: Spanner Swirl ring Swirl ring Nozzle Shield Nozzle Shield Electrode Electrode Nozzle Shield Electrode Water tube Nozzle retaining cap Qty. 5 1 2 1 1 1 1 2 1 2 1 2 2 2 1 2 1 1 6-12 HPR130XD Manual Gas Instruction Manual .PARTS LIST Consumable parts kits Note: See Consumable selection or Cut charts for specific applications Mild steel consumable starter kit – 228420 Part Number 026009 027055 044028 104119 104269 220179 220180 220181 220182 220183 220187 220188 220189 220192 220193 220194 220340 220552 220553 220554 220555 220665 220747 220754 220756 Description O-ring: 0.070" Tool: Consumable removal / replacement Wrench: Spanner Swirl ring Swirl ring Electrode Nozzle Shield Electrode Nozzle Shield Electrode Nozzle Shield Water tube with o-ring Electrode Swirl ring Nozzle Shield SilverPlus electrode Shield cap Nozzle retaining cap Nozzle retaining cap Qty.

PARTS LIST Consumables for mirror-image cutting Mild steel Shield cap Shield Nozzle retaining cap Nozzle Swirl ring Electrode Water tube 30 A 220194 220810 220193 220306 220192 50 A 220555 220810 220554 220549 220552 220340 220747 80 A 220189 220755 220188 220305 220187 130 A 220183 220755 220182 220305 220181 HPR130XD Manual Gas Instruction Manual 6-13 .

70 gpm. 50-60 HZ Designator Qty. 600 volt Control PCB Power distribution PCB Flow switch assembly Heat exchanger fan: 4" Check valve: 1/4" FPT Solenoid valve assembly Kit: Pump. 115 VAC 50-60 HZ 10" fan: 450-550 CFM.PARTS LIST Recommended spare parts Power supply Part Number 129633 027634 027664 129792 127039 027079 003149 041837 003139 109004 229238 008551* 228548 041802 229206 027185 006075 229229 228170 228538 Description Green power lamp assembly Filter housing Filter element Chopper assembly 6" fan: 230 CFM. 240 volt. 120 VAC 50-60 HZ Relay: Pilot arc. 1 1 1 2 1 Off-valve Part Number 006109 Description Solenoid valve Designator V16-V19 Qty. 120 VAC PCB: I/O Contactor Current sensor: Hall 100 amp. F2 PCB3 PCB2 FLS CLT SOL * 400. 4 volt Start circuit assembly Fuse: 7. 480 and 600 volt power supplies Ignition console Part Number 041817 129854 Description HFHV Ignition PCB Transformer Designator T1 Qty. 1 6-14 HPR130XD Manual Gas Instruction Manual . 200 psi Kit: Motor. 1/3 HP. 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 CH1 CR1 CON1 PCB1 F1. 1 1 Gas console Part Number 041805 041822 005263 006109 005262 Description Power distribution PCB Valve driver PCB Pressure sensor Solenoid valve Illuminated power switch Designator PCB1 PCB3 PT1-PT3 SV1-SV14 SW1 Qty.5 amp.

HPR130XD Manual Gas Instruction Manual 7-1 . When tracing a signal path or referencing with the Parts List or Troubleshooting sections.Section 7 WIRING DIAGRAMS Introduction This section contains the wiring diagrams for the system. please be aware of the following format to assist you in understanding the wiring diagrams' organization: • • Sheet numbers are located in the lower right-hand corner. Page-to-page referencing is done in the following manner: C SHEET 4-D3 Source Connection Source Reference Block Destination Sheet # Destination Coordinates SHEET 4-D3 C Source Sheet # Source Coordinates Source Reference Block Destination Coordinates Destination and Source Coordinates refer to letters A-D on the Y-axis of each sheet and numbers 1-4 on the X-axis of each sheet. Wiring Diagram Symbols Wiring diagram symbols and their identification precede the system wiring diagrams in this section. Lining up the coordinates will bring you to the source or destination blocks (similar to a road map).

Solid State. Earth IGBT Inductor LED Lamp MOV Pin Socket Plug PNP Transistor Potentiometer Relay. DC Relay. AC . Normally Open Relay. non-polarized Cap. Dry Resistor SCR Shield Shunt Spark Gap Receptacle Push Button. Coil Relay. polarized WIRING DIAGRAMS Cap. Normally Closed Relay. Solid State. AC Relay. Normally Closed Battery Cap.7-2 Fuse Ground Clamp Ground. Solid State. Normally Open Push Button. feed-thru Circuit breaker Coax shield Current Sensor Current sensor DC supply Diode Door interlock Fan Feedthru LC HPR130XD Manual Gas Instruction Manual Filter. Chassis Ground.

Normally Closed Time Delay Closed. 2 Throw Switch. Center Off Switch. Flow Time Delay Open. Normally Open Terminal Block Time Delay Closed. Temperature. NC/On Torch Symbols Switch. Solenoid Torch. 1 Pole. Pressure. NO/Off Electrode Transformer Switch. HyDefinition™ Voltage Source Zener Diode Switch. Level. Temperature. 1 Pole. 1 Throw Switch. Normally Open Transformer.Switch. Normally Closed Switch. Normally Closed Switch. Pressure. 1 Throw. 1 Pole. Air Core Nozzle HPR130XD Manual Gas Instruction Manual Transformer Coil Shield Triac Torch VAC Source Valve. NC/Off WIRING DIAGRAMS Time Delay Open. NO/Off 7-3 .

WIRING DIAGRAMS 7-4 HPR130XD Manual Gas Instruction Manual .

Discrete output functionality HPR130XD Manual Gas Instruction Manual 7-5 .

WIRING DIAGRAMS 7-6 HPR130XD Manual Gas Instruction Manual .

Cable Unit N Operator Pendant (Optional Unit) B Unit 5 1X4 Plasma Interface Cable THC (Optional Unit) Lifter I/O Interface Cable Motor Drive Cable A A ELEC SCH:HPR130XD PWR SPLY 013375 SHEET 1 OF 19 4 3 2 1 A 7-7 .4 3 2 1 3 Phase Power w/ Ground D D Negative Lead HF/PS Cable Atm Vent Plasma Preflow Shield Preflow Plasma Cutflow Shield Cutflow 3X3 Torch Lead Assembly 1X3 2X1 Pilot Arc Lead Cooling Supply Lead Cooling Return Lead Unit 2 Ignition Console Oxygen N2/Ar Air H35/F5 Unit 3 Gas Console 3X1 3X2 Unit 4 Off Valve Assy 4X1 72" Plasma Shield Unit M Torch Lifter (Optional Unit) C Gas Power Cable Gas Control Cable Work Lead 128782 Off Valve Cable C 1X1 1X2 Torch Workpiece Unit 1 Power Supply 1X5 1X6 CNC Interface Cable CNC Interface Cable CNC Interface Cable B Unit 6 CNC Interface (Customer Supplied) Pendant Ext.

6 J6 CH1 + – 39 CS1 39 R9 R8 R1 10K 10K 10K C1 350UF K1 V W A4 B4 C4 CON1 C RED RED/BLK TB1 1 W 2 V 3 U 4 PE 3 2 1 YEL/BLK YEL D INPUT POWER FROM FACILITY SHEET AA 3-A4 PE L1 L2 L3 U SHEET 3-B4 AF SHEET 8-A4 D J11 1 2 J1 BLU (–)NEGATIVE L1 L2 L3 L1 L2 L3 L1 38 K1 A1 A2 K2 I/O SURGE INJECTION 041837 R5 100K C3 .1 J1 AJ SHEET 13-C2 CABLE: 123662 RED/BLK 20 19 RED J9.4 3 2 1 RED RED/BLK C SHEET 4-D4 D SHEET 4-C1 WHT BLU T SHEET 3-B4 A SHEET 4-C1 RED/BLK RED BLK RED SHLD WHT E SHEET 3-C1 J4.1 1 2 3 4 5 6 A4 A3 0 A2 A1 0 B4 B3 0 B2 B1 0 C4 C30 C2 C10 T1 1A 1B 1C 1 2 3 1A 1B 1C J1 CHOPPER SA 129792 F J9.22UF C 1 2 3 4 1A 1B 1C J12 B SHEET 3-D4 RED GRN WHT BLK R2 10 R3 100R4 10 J3 (++)POSITIVE BLK L2 BLK L3 T1 SHOWN WIRED FOR 480V SEE PAGES 6 AND 7 FOR OTHER CONFIGURATIONS F2 .22UF 1 2 3 4 H9 J10 RED GRN WHT BLK SHIELD CR1 21 H9 BLK 39 22 40 BLK C2 R7 10K J2 C4 R6 10K F1 (+)POSITIVE B BLK BLK B H8 YEL 24VAC RED 120VAC ORN 240VAC T2 CONTROL TRANSFORMER J SHEET 4-B1 F SHEET 3-D4 BLU WHT SHEET H 4-C4 A H9 H8 J1.1 1 RED 1 2 2 ENABLE 3 RED/BLK 3 PCB1 4 PILOT ARC CONTROLLER 229238 I SHEET 3-C1 A ELEC SCH:HPR130XD PWR SPLY 013375 SHEET 2 OF 19 4 3 2 1 A 7-8 .4 J4 J1 J1.022UF CS3 G SHEET 4-C1 + .

B J4 2-A4 J2.13 1 2 J2 J2.5 J5 1 2 3 4 5 6 7 8 9 10 11 12 D3 120VAC D12 24VAC D26 Pump motor signal D25 +24V D23 240VAC D31 +5V D32 -15V D33 +15V AC1 AC2 K2 F3 120VAC HOT FAN 1 FAN 2 CHP CHP 5 6 7 FAN 8 9 FAN 2 CLT 10 FAN 1 CLT CHOPPER POWER E SHEET 2-D2 I SHEET 2-A1 K1 F1 C K3 + CONTACTOR D1 CONTACTOR + PILOT ARC RELAY D2 PILOT ARC RELAY + HV XFMR D5 HV XFMR + SURGE SELECT D7 SURGE SELECT – 120VAC RTN START CIRCUIT POWER AC PWR LT B J9 6 RED 1 2 3 4 5 6 WHT RED 7 RED/BLK SHEET Y 4-D1 FLS POWER – + J12 J2.2 1 2 BLU WHT J7 J2.A 1 1 YEL 24VAC 24VAC YEL 24VAC 2 2 HARNESS: 229329 3 3 FOR ARCGLIDE THC ONLY RED 120VAC RED 120VAC 120VAC 4 4 5 5 ORN 240VAC ORN 240VAC 240VAC 6 6 BLK SHEET M 5-D4 J2.15 J15 1A 1 2 1B BLK 3 4 BLK 1C 5 SHEET BC 6 9-D4 RED/BLK SHEET A RED J2.8 1 2 BLU WHT O SHEET 4-B4 J5 1 2 1 2 CLT SOL D F2 F4 240VAC HOT 240VAC RTN +24V +24V COM J11 J2.11 BLK 1 2 3 4 WHT 5 6 J1 J2.12 1 2 J13 J2.3 SHEET T 2-D4 SHEET U 2-D1 RED/BLK RED RED/BLK RED RED/BLK RED RED RED/BLK SHEET AA 2-A1 RED RED/BLK 1 2 3 4 5 6 7 8 9 10 1112 COM 24VAC J2.1 RED/BLK 1 RED/BLK 2 RED/BLK 3 RED 4 RED 5 RED 6 RED/BLK 7 RED/BLK 8 RED/BLK 9 RED 10 RED 11 RED 12 RED/BLK 13 RED/BLK 14 15 RED 16 RED 17 18 J13 1 2 BLK WHT D DC POWER OUTPUTS +5V +5V COM +15V +/-15V COM -15V C SHEET L 4-B4 + LINE VOLTAGE OUTPUT PUMP MOTOR CNTRL REMOTE ON/OFF 120VAC RTN PUMP MOTOR 240VAC HOT CON PAR HF SS 240VAC COM SIGNAL COM 24VAC HOT 24VAC RTN BLU WHT BLU WHT BLU WHT BLU WHT B J3 J2.4 J2.14 J14 BLU 1 WHT 2 3 BLU 4 WHT 5 RED 6 BLK 7 YEL 8 SHEET B 2-C3 F5 F6 F7 3 2 1 PHASE LOSS INPUT PCB2 POWER DISTRIBUTION 041802 U5 PHASE LOSS OUTPUT + – J8 J2.7 1 2 BLK WHT BLU WHT MANUAL GAS CONSOLE POWER J8 1 2 1 2 SHEET BD 9-B4 Q SHEET 4-C1 P SHEET 4-C4 HARNESS: 229329 FOR ARCGLIDE THC ONLY TB2 RED/BLK 1 1 2 2 3 3 4 4 5 5 6 6 7 7 REMOTE ON/OFF 7 6 5 4 3 2 1 WHT RED RED RED RED/BLK 1X1 CABLE: 123674 AH SHEET 10-A4 A 4 3 2 1 1X3 GRN WHT BLK HF A ELEC SCH:HPR130XD PWR SPLY CABLE: 123670 AI SHEET 13-D3 013375 SHEET 3 OF 19 3 2 1 A 7-9 4 .4 J2.

302 J302 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 +24V HF PUMP CONTACTOR PILOT ARC RELAY SPARE SURGE PHASE LOSS PWR GND TP200 1 2 TP201 1 2 TP207 1 2 +15V –15V CHOPPER SENSOR A COM CHOPPER SENSOR B B BLU WHT CORNER CURRENT– CORNER CURRENT+ PIERCE– PIERCE+ HOLD– HOLD+ START– START+ SHEET L 3-C4 SHEET O 3-D1 WORK LEAD SENSOR MOTION-E MOTION-C ERROR-E ERROR-C RDERR-E RDERR-C NOT READY-E NOT READY-C MOTION2-E MOTION2-C MOTION3-E MOTION3-C MOTION4-E MOTION4-C CNC J200 J3.4 3 2 1 J8.201 TP210 2 3 TP206 +24V COM COOLANT FLOW SENSOR A+3.1 RED RED/BLK J1 J3 NO COM 3 2 1 120VAC RTN 120VAC HOT SHEET Y 3-B1 D J3.107 1 2 J106 J3.106 1 2 J108 1 2 3 4 5 6 7 8 9 1 20 2 21 3 22 4 23 5 24 6 25 7 26 8 27 9 2810 291130123113 32 1433 1534 16351736 183719 J300B J304 1 2 A +24V t 0 A ELEC SCH:HPR130XD PWR SPLY 013375 SHEET 4 OF 19 4 3 2 1 A 7-10 .3V COOLANT TEMP SENSOR XFMR TEMP SENSOR CHOPPER TEMP SENSOR A CHOPPER TEMP SENSOR B LINE VOLTAGE INPUT 1 2 3 4 5 6 7 8 9 10 11 12 13 14 BLK RED SHIELD BLU WHT BLU WHT BLU WHT J8.4 J4 2 1 FLS COM FLOW J6 D SHEET C 2-D3 RED BLK SHIELD 1 2 1 2 T2 A SHEET 2-D3 D SHEET 2-D2 Q SHEET 3-A2 C START CIRCUIT ENABLE SHEET H 2-A2 BLU WHT C SHEET P 3-A2 BLU WHT BLU WHT BLU WHT BLU WHT BLU WHT J3.301 J301 RED BLK SHIELD 1 2 3 4 5 6 7 8 9 10 11 12 13 14 ARC BREAKOVER COM +5V PWM DRV A PWM DRV B SS-C SS-E PA-C PA-E PCB3 POWER SUPPLY CONTROL 041993 J201 J3.200 RED 1 GRN 2 WHT 3 BLK 4 SHIELD 5 6 7 8 9 10 RED 11 GRN 12 WHT 13 BLK 14 15 16 G SHEET 2-B2 J SHEET 2-B1 B TX– RX– TX+ 422 GND CNC +24V PWR GND RX37– RX37+ TX37– TX37+ 422 GND RX+ S101 121 121 J107 J3.

101 CANA SHIELD CANB BLK RED BLK CABLE: 123691 SHEET AG 11-B4 A RED A ELEC SCH:HPR130XD PWR SPLY 013375 SHEET 5 OF 19 4 3 2 1 A 7-11 .105 J105 1 2 3 4 5 6 7 8 D PCB3 POWER SUPPLY CONTROL 041993 0 BLU WHT BLU WHT RED BLK YEL +24V PWR GND +5V GND +15V COM –15V C J110 1 2 3 4 5 6 7 8 9 10 11 12 13 14 C TMS TRST\ TDI COM +5V TDO TCK JTAG B EMU0 EMU1 121 CANH CANL CAN +24V CAN GND B J101 1 2 J102 1 6 2 7 3 8 4 9 5 J103 1 6 2 7 3 8 4 9 5 J3.4 3 2 1 D SHEET M 3-D4 J3.

4 INPUT POWER FROM FACILITY 3 2 INPUT POWER FROM FACILITY 1 PE L1 L2 L3 WIRED FOR 480V 60HZ PE L1 L2 L3 WIRED FOR 240V 60HZ D TB1 1 W 2 V 3 U 4 PE L1 L2 L3 V W A4 B4 C4 CON1 F1 F2 A4 A3 0 A2 A1 0 B4 B3 0 B2 B1 0 C4 C30 C2 C10 T1 1A 1B 1C 014282 TB1 1 W 2 V 3 U 4 PE L1 L2 L3 V W A4 B4 C4 CON1 F1 T1 F2 A4 A3 0 A2 A1 0 B4 B3 0 B2 B1 0 C4 C30 C2 C10 T1 1A 1B 1C 014282 D GRY WHT BLK WHT T1 C T2 T2 C INPUT POWER FROM FACILITY PE L1 L2 L3 TB1 1 W 2 V 3 U 4 PE L1 EMI FILTER L2 L3 L1 L2 L3 CON1 F1 F2 WIRED FOR 400V 50-60HZ INPUT POWER FROM FACILITY PE L1 L2 L3 WIRED FOR 200-208V 50-60HZ B V W A4 B4 C4 BLU WHT T1 BLK WHT A4 A30 A2 A10 B4 B30 B2 B10 C4 C30 C2 C10 T1 1A 1B 1C 014283 TB1 1 W 2 V 3 U 4 PE L1 L2 L3 V W A4 B4 C4 CON1 F1 F2 A4 A3 0 A2 A1 0 B4 B30 B2 B10 C4 C30 C2 C10 T1 1A 1B 1C B 014283 T1 T2 T2 A A ELEC SCH:HPR130XD PWR SPLY 013375 SHEET 6 OF 19 4 3 2 1 A 7-12 .

4 3 2 1 INPUT POWER FROM FACILITY D TB1 1 W 2 V 3 U 4 PE L1 L2 L3 PE L1 L2 L3 INPUT POWER FROM FACILITY WIRED FOR 440V 50-60HZ PE L1 L2 L3 WIRED FOR 220V 50-60HZ D V W A4 B4 C4 CON1 A4 A3 0 A2 A1 0 B4 B3 0 B2 B1 0 C4 C30 C2 C10 T1 1A 1B 1C 014284 TB1 1 W 2 V 3 U 4 PE L1 L2 L3 V W A4 B4 C4 CON1 F1 F2 F1 T1 F2 A4 A3 0 A2 A1 0 B4 B3 0 B2 B1 0 C4 C30 C2 C10 T1 1A 1B 1C 014284 BLK WHT T2 INPUT POWER FROM FACILITY INPUT POWER FROM FACILITY BRN WHT C T1 C T2 PE L1 L2 L3 WIRED FOR 380V 50HZ TB1 1 W 2 V 3 U 4 PE L1 L2 L3 PE L1 L2 L3 WIRED FOR 600V 60HZ V W A4 B4 C4 CON1 A1 0 B1 0 C1 0 T1 1A TB1 1 W 2 V 3 U 4 PE L1 L2 L3 V W A4 B4 C4 CON1 A1 0 B1 0 C1 0 T1 1A B 1B 1B B 1C T1 014303 F1 GRY WHT F1 BLK WHT F2 1C T1 014281 F2 T2 T2 A A ELEC SCH:HPR130XD PWR SPLY 013375 SHEET 7 OF 19 4 3 2 1 A 7-13 .

303A J12.4 3 2 1 D J2A 1 20 2 21 3 22 4 23 5 24 6 25 7 26 8 27 9 28 10 29 11 30 12 31 13 32 14 33 15 34 16 35 17 36 18 37 19 THC OPTION COMMAND PLASMA INTERFACE 041842 RX– RX+ TX– TX+ CABLE: 123760 PCB3 POWER SUPPLY CONTROL 041993 RX37– RX37+ TX37– TX37+ 422 GND MOTION 1-E MOTION 1-C ERROR-E ERROR-C RDERR-E RDERR-C NOT READY-E NOT READY-C MOTION 2-E MOTION 2-C MOTION 3-E MOTION 3-C MOTION 4-E MOTION 4-C CORNER– CORNER+ PIERCE– PIERCE+ HOLD– HOLD+ START– START+ J300A J2B 1 20 2 21 3 22 4 23 5 24 6 25 7 26 8 27 9 28 10 29 11 30 12 31 13 32 14 33 15 34 16 35 17 36 18 37 19 D J3.2B C TO POWER SUPPLY TO COMMAND CONTROL MODULE SPARE OUT 1– SPARE OUT 1+ PIERCE COMPLETE OUT– PIERCE COMPLETE OUT+ HOLE IGNITION OUT– HOLD IGNITION OUT+ PLASMA START OUT– PLASMA START OUT+ B ELECTRODE GND SHIELD WORK +24VDC EMI GND 1 20 2 21 3 22 4 23 5 24 6 25 7 26 8 27 9 28 10 29 11 30 12 31 13 32 14 33 15 34 16 35 17 36 18 37 19 J301 1 2 t 0 C B PWR GND CNC +24V J5 1 2 YEL/BLK 2 3 3 4 5 +24V A SHEET AF 2-D1 YEL A ELEC SCH:HPR130XD PWR SPLY 013375 SHEET 8 OF 19 4 3 2 1 A 7-14 .

303B PCB3 POWER SUPPLY CONTROL 041993 J5 J13.5 J13.4 3 2 1 SHEET BC 3-D4 D THC OPTION ARCGLIDE ETHERNET INTERFACE 141131 RX– RX+ TX– TX+ MOTION IN +5V ERROR IN +5V RAMPDOWN ERROR IN +5V NOT READY IN +5V CABLE: 123760 J303B D J3.6 RED/BLK RED 1 2 ON/OFF OUT+ ON/OFF OUT- CORNER OUT– CORNER OUT+ PIERCE COMPLETE OUT– PIERCE COMPLETE OUT+ HOLE IGNITION OUT– HOLD IGNITION OUT+ PLASMA START OUT– PLASMA START OUT+ B ELECTRODE SHEET BD 3-A2 WORK 1 20 2 21 3 22 4 23 5 24 6 25 7 26 8 27 9 28 10 29 11 30 12 31 13 32 14 33 15 34 16 35 17 36 18 37 19 1 20 2 21 3 22 4 23 5 24 6 25 7 26 8 27 9 28 10 29 11 30 12 31 13 32 14 33 15 34 16 35 17 36 18 37 19 J301 RX37– RX37+ TX37– TX37+ 422 GND YEL/BLK 2 A SHEET AF 2-D1 YEL 1 4 J7 J1 J6 MOTION 1-E MOTION 1-C ERROR-E ERROR-C RDERR-E RDERR-C NOT READY-E NOT READY-C MOTION 2-E MOTION 2-C MOTION 3-E MOTION 3-C MOTION 4-E MOTION 4-C CORNER– CORNER+ PIERCE– PIERCE+ HOLD– HOLD+ START– START+ C B PWR GND CNC +24V J4 2 1 1 2 t 0 +24V A ELEC SCH:HPR130XD PWR SPLY 013375 SHEET 9 OF 19 3 2 1 A 7-15 .7 RED/BLK RED 1 2 24VAC RTN 24VAC C 1 2 3 4 5 6 7 8 TO ARCGLIDE MODULE(S) TO POWER SUPPLY J13.

4 3 2 1 D SHEET AB 10-B4 J1.6 RED/BLK RED AC VALVE DRIVER POWER AE SHEET 12-D3 C C 120VAC RTN SHEET AB 10-D4 B 1A RED 2A RED/BLK SW1 1 2 RED B WHT REMOTE ON/OFF GAS CLS PWR RED RED/BLK 3X1 SHIELD RED BLK CABLE: 123674 SHEET AH 3-A1 WHT BLK A 7 6 5 4 3 2 1 WHT RED A ELEC SCH:HPR130XD PWR SPLY 013375 SHEET 10 OF 19 A 7-16 3 2 1 4 .1 J1 1 2 3 4 5 6 7 8 +24V +24V COM +5V +5V COM GAS CONSOLE DC POWER 120VAC HOT D1 120VAC D7+5V D9 +24V J6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 J1.2 J2 RED 1 RED/BLK 2 3 F1 120V RTN 120V HOT D PCB1 GAS CONSOLE POWER DISTRIBUTION 041805 BLU WHT BLU WHT SHEET AC 11-D4 J1.

4 3 2 1 J7 BLU WHT J2.8 J8 1 2 CABLE: 123692 BLK BLK J2.4 J4 1 2 3 4 5 6 7 8 J2.9 J9 1 2 3 4 CAN A 5 6 7 8 9 +24V +24V COM +5V +5V COM PCB2 GAS CSL CONT 041912 RXD TXD 232 COM 1 2 3 4 5 6 7 8 9 D SHEET AC 10-C4 BLU WHT RS-232 D 3X2 CABLE: 123691 BLK BLK 1 2 3 4 5 6 7 8 9 CANL CAN GND C RED RED SHIELD RED RED SHIELD CANH CAN +24V TMS TRST\ TDI +5V COM +5V JTAG TDO TCK CANH CAN +24V o C J3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 SHEET AG 6-A4 CAN B J10 1 2 3 4 5 6 7 8 9 J11 1 2 t CANL CAN GND EMU0 EMU1 +24V SIG COM SIG SIG J2.2 CABLE: 123703 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 J2 SIG B CAN PWR CAN +24V B A PT3-PP PT4-PC PT2-SP PT1-SC A ELEC SCH:HPR130XD PWR SPLY 013375 SHEET 11 OF 19 A 7-17 4 3 2 1 .

3 RED/BLK 1 RED/BLK 2 RED/BLK 3 RED/BLK 4 RED/BLK 5 RED 6 RED 7 RED 8 RED/BLK 9 RED 10 RED 11 RED 12 RED/BLK 13 RED 14 RED 15 RED 16 RED/BLK 17 RED 18 RED 19 RED 20 RED/BLK 21 RED 22 RED 23 24 RED/BLK 25 26 27 28 RED/BLK 29 30 31 32 RED/BLK 33 RED/BLK 34 RED/BLK 35 36 J3.1 1 2 3 J1 2 PCB3 AC VALVE DRIVER 041822 120V HOT SV4 120V RTN SV3 SV2 SV1 SV5 120V RTN 120V RTN 120V RTN SV6 120V RTN 120V RTN 120V RTN SV7 120V RTN 120V RTN 120V RTN SV8 D20 120V RTN D19 120V RTN D18 120V RTN D17 SV9 D16 120V RTN D15 120V RTN D14 120V RTN D13 SV10 D12 120V RTN D11 120V RTN D10 120V RTN D9 SV11 D8 120V HOT D7 120V HOT D6 120V HOT D5 SV12 D4 SV13 D3 SV14 D2 SPARE OUTPUT D1 J3 J3.6 J3.2 RED/BLK RED RED/BLK RED/BLK RED RED RED/BLK RED RED/BLK RED 1 RED/BLK RED RED/BLK RED SV1 RED/BLK RED SV3 RED/BLK RED SV5 RED/BLK RED SV7 RED/BLK RED SV9 RED/BLK RED SV11 RED/BLK RED SV13 RED/BLK RED SV2 D J6 NOT USED NOT USED NOT USED +5V +5V +5V SPARE 4 SPARE 3 SPARE 2 SPARE 1 SV20 SV19 SV18 SV17 SV16 SV15 SV14 SV13 SV12 SV11 SV10 SV9 SV8 SV7 SV6 SV5 SV4 SV3 SV2 SV1 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51 53 55 57 59 J2.4 3 SHEET AE 10-C1 PCB2 GAS CSL CONT 041912 J3.4 60 COND RIBBON C J4 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51 53 55 57 59 RED/BLK RED D SV4 RED/BLK RED SV6 RED/BLK RED SV8 RED/BLK RED SV10 RED/BLK RED C SV12 RED/BLK RED SV14 J2 CABLE: 123704 SV16 120V RTN SV17 120V RTN SV18 120V RTN SV19 120V RTN SV20 120V RTN 1 2 3 4 5 6 7 8 9 10 SV16 SV17 SV18 SV19 SV20 B B SV20 120V RTN SV19 120V RTN SV18 120V RTN SV16 120V RTN SV17 120V RTN 3X3 S C RED/BLK SV16 RED S P RED/BLK SV18 RED 1 2 12 3 4 13 5 6 14 7 8 11 9 10 1 2 12 3 4 13 5 6 14 7 8 11 9 10 RED/BLK SV17 RED A CABLE: 123678 4X1 P P A P C RED/BLK SV19 RED 129816 OFF VALVE MANIFOLD ELEC SCH:HPR130XD PWR SPLY 013375 SHEET 12 OF 19 1 RED/BLK RED V V RED/BLK RED P C RED/BLK RED P P RED/BLK RED S C RED/BLK RED S P V V RED/BLK SV20 RED A 7-18 4 3 2 .

22uF 1kVDC 009224 J1 SG1 109344 5kV SG2 109344 5kV PILOT ARC J5 B AJ SHEET 2-D1 CABLE: 123662 C C T1 129854 COIL SECONDARY IN J6 COIL PRIMARY 2 T2 009793 COIL PRIMARY 1 COIL SECONDARY OUT NOZZLE CONNECTION C3 1400pF 20kV 009975 C4 1400pF 20kV 009975 C5 1400pF 20kV 009975 J3 B J2 B A A ELEC SCH:HPR130XD PWR SPLY 013375 SHEET 13 OF 19 4 3 2 1 A 7-19 .4 3 2 1 D CABLE: 123670 RED/BLK RED GRN SHEET AI 3-A4 D 2X1 1 2 3 4 009045 FLTR CATHODE BLOCK HPR HFHV IGNITION 041817 TORCH C2 0.22uF 1kVDC J4 009224 C1 0.

4 3 2 1 O2 5 Micron Air Filter N2/Ar H35/F5 D V2 V1 V3 V12 D V4 V5 V6 V7 V8 V9 V10 V11 PR1 PR2 PR3 PR4 V14 V13 Gas Console P1 P2 P3 P4 C Shield Cutflow Shield Preflow Plasma Preflow C Plasma Cutflow V16 V17 V18 V19 V20 Off Valve Manifold B Vent B Shield Plasma Vent Torch HPR130XD Manual Gas Schematic A A ELEC SCH:HPR130XD PWR SPLY 013375 SHEET 14 OF 19 4 3 2 1 A 7-20 .

4 3 2 1 D D RESERVOIR HEAT EXCHANGER FLOW SENSOR CHECK VALVE MANIFOLD C C THERMISTOR FILTER PUMP SHUT OFF VALVE B RHF B TORCH A A ELEC SCH:HPR130XD PWR SPLY 013375 SHEET 15 OF 19 4 3 2 1 A 7-21 .

try removing the jumpers on J106 and J107 on the control board. Only remove the termination jumper on the serial isolation board that is connected to the HPR power supply.4 3 2 1 Optional Multi-System Interface D Unit 1 Unit 2 Unit 3 Unit 4 D HPR PAC Dry Cutting System HPR PAC Dry Cutting System HPR PAC Dry Cutting System HPR PAC Dry Cutting System C 041993 CONTROL BOARD ON S100 ON S101 J106 1 2 J303 J107 1 2 041993 CONTROL BOARD ON S100 ON S101 J106 1 2 J303 J107 1 2 041993 CONTROL BOARD ON S100 ON S101 J106 1 2 J303 J107 1 2 041993 CONTROL BOARD ON S100 ON C S101 J106 1 2 J303 1 2 3 4 1 2 3 4 J107 1 2 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 5 6 7 8 Serial ID Dipswitch J300A Machine Motion Jumper Block J300B 1 2 3 4 5 6 7 8 Serial ID Dipswitch J300A Machine Motion Jumper Block J300B 1 2 3 4 5 6 7 8 Serial ID Dipswitch J300A Machine Motion Jumper Block J300B 1 2 3 4 5 6 7 8 Serial ID Dipswitch J300A Machine Motion Jumper Block J300B B CNC Interface Cable CNC Interface Cable CNC Interface Cable B CNC Interface Cable Notes: 1) For single system installations set Serial ID (S100). and the termination jumper (J6 or J8) on the serial isolation board in the controler. See sheet 17 for more details. Dipswitch setting example: S100 ON ON 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 A CNC Interface (Customer Supplied) RX Termination 120 TX Termination 120 Switch 1 is in the On position Switches 2-8 are in the Off position A ELEC SCH:HPR130XD PWR SPLY 013375 SHEET 16 OF 19 A 7-22 1 4 3 2 . Jumpers J106 and J107 are left open on all systems except for the very last system where they are in the closed position. and Machine Motion (J303) as shown in Unit 1. and there are intermittent communication failures (PS Link Failure). 2) On multi-system installations refer to the illustration. jumpers J106 and J107 must be closed. 3) If a Hypertherm Automation Controller is being used. Termination resistors (120-ohm) or termination jumpers must be installed/set at the CNC for each of the RS-422 RX and TX signal pairs.

24Vac.5 Amp) C S101 ON J106 1 2 J107 1 2 RED/BLK RED 6 5 4 1 2 3 4 J303 1 2 3 4 1 2 3 4 WHT RED ON 1 2 3 4 5 6 7 8 4 5 6 J300A J300B 1X1 Serial ID Dipswitch Machine Motion Jumper Block WHT 1 1 76 RED Gas Power Cable * If a Hypertherm Automation controller is being used. set jumpers as shown on the multi-system interface page RED/BLK 21 RED 3) The CNC will need a dedicated I/O for each system using the Remote On/Off feature (contact should be rated for min. Only remove the termination jumper on the serial isolation board that is connected to the HPR power supply. and the termination jumper (J6 or J8) on the serial isolation board in the controler. try removing the jumnpers on J104 and J105 on the control board. See figure below for details. Relocate the white wire on TB2 from position #3 to position #2. TB2 7 7 2) For a multi-system installation set up as described above. Connect one terminal of the Remote On/Off cable to position #2 on TB2 and the other terminal to position #3. J1 SV 3 2 2 3 RIBBON CABLE B Remote On/Off Customer Supplied CNC Interface Cable 078170 Gas Console BMD J2 BHST J5 AHST J6 AMD J3 B BTR J7 RS-232 J9 J10 RS-232 ATR J8 Dipswitch setting example: S100 ON ON 1 2 7 8 A 1 2 3 4 5 6 7 8 3 4 5 6 CNC Interface (Customer Supplied) RS-422 RS-422 Serial isolation board in a Hypertherm Automation controller Switch 1 is in the On position Switches 2-8 are in the Off position A ELEC SCH:HPR130XD PWR SPLY 013375 SHEET 17 OF 19 A 7-23 4 3 2 1 . J106 & J107 as shown.4 3 2 1 Optional Remote On/Off D D HPR PAC Dry Cutting System Notes: 1) For single system installation set Serial ID (S100). Refer to page 3 of the wiring diagram C 041993 CONTROL BOARD S100 Depress the Gas Console Power switch to the closed position (on position). 0. Machine Motion (J303). and there are intermittent communication failures (PS Link Failure). Connect customer supplied Remote On/Off cable in series with the power supply and the gas console power switch.

See figure on Sheet 19 for details. ON CNC Interface (Customer Supplied) S100 Serial ID Dipswitch for second system S100 Serial ID Dipswitch for third system S100 Serial ID Dipswitch for fourth system Dipswitch setting example: S100 ON ON 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 1 2 3 4 5 6 7 8 ON Switch 1 is in the On position Switches 2-8 are in the Off position A 1 2 3 4 5 6 7 8 ON A ELEC SCH:HPR130XD PWR SPLY 013375 SHEET 18 OF 19 A 7-24 2 1 1 2 3 4 5 6 7 8 4 3 . 5) All machine interface cables (Pwr. try removing the jumpers on J106 and J107 on the control board. 3) For a three system installation set up as described above. set Serial ID as shown for the third system. Cable Serial ID Dipswitch J300B 1 2 3 4 5 6 7 8 Machine Motion Jumper Block J300A J2B Command THC (Optional Unit) Lifter I/O Interface Cable Motor Drive Cable CNC Interface Cable CNC Interface Cable Command I/O Cable-Second THC Command I/O Cable-Third THC Command I/O Cable-Fourth THC B CNC Interface Cable B Notes: 1) For a single system installation set Serial ID (S100). 2) For a two system installation duplicate a second power supply and Command THC as illustrated for a single system. set Serial ID as shown for the second system. J106 & J107 as shown above. 4) For a four system installation set up as described above. 7) If a Hypertherm Automation controller is being used.4 3 2 1 Optional Command THC Interface D HPR PAC Dry Cutting System Torch Lifter (Optional Unit) D 041993 CONTROL BOARD ON S101 J106 1 2 J107 1 2 041842 PLASMA INTERFACE BD Operator Pendant (Optional Unit) Torch Workpiece C S100 ON 1 2 3 4 J303 1 2 3 4 1 2 3 4 See Command THC Manual for internal Power Supply wiring J2A C CNC Interface Cable Pendant Ext. supply-CNC) used for serial communication between Pwr. set Serial ID as shown for the fourth system. 6) The CNC will need a dedicated I/O port for each Command THC. supply-CNC will have a common connection node with the CNC. and the termination jumper (J6 or J8) on the serial isolation board in the controler. Only remove the termination jumper on the serial isolation board that is connected to the HPR power supply. and there are intermittent communication failures (PS Link Failure). Machine Motion (J303).

set SW1 on the 141131 boards as shown in Units 1 through 4. and Machine Motion (J303) as shown.4 3 2 1 Optional ArcGlide/EdgePro Multi-System Interface D D Unit 1 Unit 2 Unit 3 Unit 4 HPR PAC Dry Cutting System 041993 CONTROL BOARD J106 1 2 J303 J107 1 2 S101 ON 1 2 3 4 J303 HPR PAC Dry Cutting System 041993 CONTROL BOARD J106 1 2 J107 1 2 S101 ON 1 2 3 4 J303 HPR PAC Dry Cutting System 041993 CONTROL BOARD J106 1 2 J107 1 2 S101 ON 1 2 3 4 J303 HPR PAC Dry Cutting System 041993 CONTROL BOARD J106 1 2 J107 1 2 S101 ON 1 2 3 4 C 1 2 3 4 1 2 3 4 141131 ETHERNET INTERFACE BOARD 0 4 1 2 3 4 1 2 3 4 141131 ETHERNET INTERFACE BOARD 0 4 1 2 3 4 1 2 3 4 141131 ETHERNET INTERFACE BOARD 0 4 1 2 3 4 1 2 3 4 141131 ETHERNET INTERFACE BOARD 0 4 C Machine Motion Jumper Block S100 ON 1 2 3 4 5 6 7 8 Serial ID Dipswitch J300A J300B Machine Motion Jumper Block S100 ON Machine Motion Jumper Block S100 ON Machine Motion Jumper Block S100 ON 5 67 5 67 5 67 5 67 1 23 UNIT ADDRESS J5 J1 1 23 1 23 1 23 SW1 1 2 3 4 5 6 7 8 Serial ID Dipswitch J300A J300B SW1 1 2 3 4 5 6 7 8 Serial ID Dipswitch J300A J300B SW1 1 2 3 4 5 6 7 8 Serial ID Dipswitch J300A J300B SW1 UNIT ADDRESS J5 J1 UNIT ADDRESS J5 J1 UNIT ADDRESS J5 J1 B CNC Interface Cable CNC Interface Cable ArcGlide Ethernet Cable ArcGlide Ethernet Cable CNC Interface Cable ArcGlide Ethernet Cable ArcGlide Ethernet Cable Dipswitch setting example: CNC Interface Cable B Notes: 1) For the 041993 control board. set SW1 on the 141131 boards as shown in Units 1 through 2. 2) For a single system installation. set SW1 on the 141131 board as shown in Unit 1. 3) For a two system installation. set SW1 on the 141131 boards as shown in Units 1 through 3. serial IDs are determined by the 141131 board setting. All 041993 DIPSWITCH and jumper settings are the same. 5) For a four system installation. S100 ON ON 1 2 1 2 3 4 5 6 7 8 3 4 5 6 7 8 Switch 1 is in the On position Switches 2-8 are in the Off position A ArcGlide THC and/or EdgePro Module(s) A ELEC SCH:HPR130XD PWR SPLY 013375 SHEET 19 OF 19 A 7-25 4 3 2 1 . set Serial ID (S100). Jumpers J106 and J107 should be installed. 4) For a three system installation.

............................................................................................Appendix A HYPERTHERM TORCH COOLANT SAFETY DATA In this section: Section 1 Chemical Product and Company Identification ....................................................................................................a-5 Section 15 Regulatory Information ..........a-2 Section 4 First Aid Measures .................................a-2 Section 3 Hazards Identification.a-3 Section 5 Fire Fighting Measures ............a-3 Section 7 Handling and Storage ......................a-3 Section 8 Exposure Controls / Personal Protection ...................................................................................................................................................................................................a-4 Section 12 Ecological Information...................................................................................................................................................................................................................................................................................................................a-2 Section 2 Information on Ingredients ...............................................a-5 Freezing Point of Propylene Glycol Solution.....................................................................................................................................................................................................................................................................................................................................................................................................a-5 Section 16 Other Information .....................................................a-4 Section 9 Physical and Chemical Properties ........................................................a-5 Section 13 Disposal Considerations ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................a-5 Section 14 Transport Information......................................................................................................................................................a-4 Section 10 Stability and Reactivity...............................................................................a-4 Section 11 Toxicological Information ............................................................................................................................................................................................................a-6 Hypertherm Plasma systems a-1 4/06/07 .........................................................................................................................................a-3 Section 6 Accidental Release Measures....................................................

.........../Kg.... Mists are harmful.. N. skin contact ........0 EXPOSURE LIMITS OSHA PEL ACGIH TLV R Phrases N...... Inc....................MATERIAL SAFETY DATA SHEET SECTION 1 – CHEMICAL PRODUCT AND COMPANY IDENTIFICATION PRODUCT NAME Latest Revision Date ISSUE DATE DISTRIBUTOR: Hypertherm Torch Coolant Nov............... 2008 Product Information: (603) 643-3441 Hypertherm................... a-2 11/7/2008 Hypertherm Plasma systems ..E...............36/37/38 R36/37/38 SECTION 3 – HAZARDS IDENTIFICATION Emergency Overview Causes eye irritation.. N...... eye contact ......H...........0 <50...... Inhalation ... 03755 SECTION 2 – COMPOSITION / INFORMATION ON INGREDIENTS Hazardous Component Benzotriazole Propylene Glycol CAS No.. N.. 7... May cause skin irritation Potential Health Effects Ingestion ........E.......E... 21 Great Hollow Road Hanover....... 2008 EMERGENCY TELEPHONE NUMBERS Nov.............. R22... May be harmful if swallowed. Causes eye irritation... N. Oral LD 50 (rat) as reported for 100% Benzotriazole is 560 mg... <1.. Can cause skin irritaion... 95-14-7 57-55-6 % by wt......E. 7....

Immediately flush eye with cool running water. Foam. Avoid breathing or creating airborne mists. Place in covered waste dissposal container. Flammable limits Not Established Product is an aqueous solution. Seek immediate medical attention. Get medical attention. Store in a cool dry place. Seek medical attention. Symptoms may not be immediately apparent. SECTION 5 – FIRE FIGHTING MEASURES Flash Point / Method Extinguishing media special fire fighting procedures Fire and explosion hazards None to boiling. DO NOT TAKE INTERNALLY. Use Carbon Dioxide. Keep containers tightly closed when not in use. and clothing. Full protective equipment including self-contained breathing apparatus should be used. Large spills: Dike or dam spill. Restore breathing. Keep warm and quiet. Avoid contact with skin eyes. Water base solution. Remove contact lenses if applicable. seek medical attention. Avoid inhalation of vapor or mists. Note to Physician Treatment based on judgment of the physician in response to reactions of the patient.MSDS Product Hypertherm Torch Coolant CODE Page 2 of 4 SECTION 4 – FIRST AID MEASURES Ingestion Seek immediate medical attention. Dry Chemical. remove from exposure. Inhalation Eye Contact Skin Contact If affected. If irritation develops or persists. SECTION 7 – HANDLING AND STORAGE Handling precautions Storage precautions Keep container in upright position. SECTION 6 – ACCIDENTAL RELEASE MEASURES Response to spills Small spills: Mop up residues and place in a covered waste disposal container. Pump to containers or soak up on inert absorbent. Continue flushing with water for at least 15 minutes. Hypertherm Plasma systems a-3 11/7/2008 . Clean up spills immediately. Keep from freezing. During emergency conditions overexposure to decomposition products may cause a health hazard. Wash with soap and water.

E. Neoprene or Nitrile acceptable SECTION 9 – PHYSICAL AND CHEMICAL PROPERTIES Appearance ODOR pH of Concentrate Specific gravity solubility in water Clear Pink/Red Liquid None 5. Carbon Monoxide Nitrogen Oxides Stable X Unstable Incompatibility Hazardous products of decomposition Polymerization Conditions to avoid Will not occur Not applicable X May occur SECTION 11 – TOXICOLOGICAL INFORMATION Carcinogenicity X THIS PRODUCT CONTAINS A KNOWN OR SUSPECTED CARCINOGEN THIS PRODUCT DOES NOT CONTAIN ANY KNOWN OR ANTICIPATED CARCINOGENS ACCORDING TO THE CRITERIA OF THE NTP ANNUAL REPORT ON CARCINOGENS AND OSHA 29 CFR 1910. Recommended Recommended.5-7. Eye wash station in immediate area of use.0 Complete Boiling point freezing point vapor pressure vapor density evaporation rate 100EC Not established Not applicable Not applicable Not determined SECTION 10 – STABILITY AND REACTIVITY Chemical Stability Conditions to avoid None None Known BY FIRE: Carbon Dioxide. PVC. Good general ventilation. Z Other effects Acute Chronic Not determined Not determined a-4 9/2/04 Hypertherm Plasma systems . U.S Nil.E.K HSE EH:40 Not listed If exposed to mists.MSDS Product Hypertherm Torch Coolant CODE Page 3 of 4 SECTION 8 – EXPOSURE CONTROLS / PERSONAL PROTECTION Hygienic practices Engineering controls Personal protective equipment X X X Respirator goggles / face shield APRON Gloves Boots Normal procedures for good hygiene. M./O.L.0 1.

2. no warranty. Non Hazardous Yes X CODE 2 – HDPE No SECTION 14 – TRANSPORT INFORMATION DOT Classification Hazardous Not Hazardous X Description Not applicable SECTION 15 – REGULATORY INFORMATION REGULATORY STATUS: Benzotriazole 1. 3. Since actual use and handling are beyond our control. 6. Labeling Information R Phrases S Phrases EI NECS No. 4. EC annex 1 Classification German WGK Irritant R 36/37/38.6mg/l Ecotoxicity SECTION 13 – DISPOSAL CONSIDERATIONS Waste disposal method RCRA Classification Recycle container Waste material must be disposed of in accordance with national/local legislative requirements. in connection with the use of this information. 26 Not listed Nil. — SECTION 16 – OTHER INFORMATION NFPA Classification 1 0 0 — BLUE RED YELLOW WHITE Health hazard Flammability reactivity Special hazard Information contained in this MSDS refers only to the specific material designated and does not relate to any process or use involving other materials. Trout (96 hr. and the Product is intended to be used in a manner that is customary and reasonably foreseeable. is made and no liability is assumed by Hypertherm. Tlm):28mg/l. LC 50): 39mg/l. Daphina magna (48 hr.. Algae(96hr.MSDS Product Hypertherm Torch Coolant CODE Page 4 of 4 SECTION 12 – ECOLOGICAL INFORMATION Biodegradability BOD / COD Value Considered biodegradable Not biodegradable Not established As reported for 100% Benzotriazole: Bluegill Sunfish (96 hr. Inc.4mg/l. 22 S 24/25. EC 50): 15. Hypertherm Plasma systems a-5 9/2/04 . Tlm):28mg/l. Minnow (96hr. express or implied. 5. LC 50): 141. This information is based on data believed to be reliable.

°C 4 -1 -7 -12 °F 40 30 20 10 0 -10 -20 -30 -40 -50 -60 -70 0 10 20 30 40 50 60 Temperature -18 -23 -29 -34 -40 -46 -51 -57 % of Propylene Glycol Freezing Point of Propylene Glycol Solution a-6 8/21/08 Hypertherm Plasma systems .

Check for error conditions every 10 milliseconds. Update the chopper control loop every 26 microseconds. take action. Full initialization of DSP hardware. Initialization a. perform a purge cycle. d. Main loop a. h. copy code in external flash to internal flash. If inlet gases change. – If valid message is received. • Chopper setpoints = 0. III. f. Check for CAN message. Check for serial messages from the internal UART. b.e.Appendix B FUNCTIONAL DESCRIPTION OF SOFTWARE III. b. b. parse the message and take action. If an error has occurred. Idle • Outputs are off. Jump to internal flash and start execution. k. parse the message and take action. parse the message and take action. update the data in the EEPROM. Calculate checksum on external flash and on DSP internal flash. e. HPR130XD Manual Gas Instruction Manual b-1 . Check for serial messages from the external UART. d. g. If current setpoint has changed. j.) 1. – If checksums don’t match. – If CAN message has arrived. c. Limited initialization of digital-signal processing (DSP) hardware. Descriptions of machine states (Numbers listed below do not correspond to actual state numbers. – If valid message is received. Processor boots in microprocessor mode and begins to execute code in external flash memory. Power-up a. • 6-second delay for other processors to initialize. pressures) every 250 milliseconds. III. i. Update analog inputs. Refresh data from gas console (i. c. Read EEPROM for previous current setpoint.

shut down the system. • Check for chopper over temperature (065). the gas console goes into Preflow state. 5. Error checking • If coolant flow rate is less than 1. • If the gas console or serial interface requests a state change. report error “UNKNOWN GAS CONSOLE” (133). • Check for over/under line voltage (047/046). • Pulse HF after 50-millisecond delay to allow pilot arc relay to close. 3. 4. turn off the contactor and soft-start controller. continue pumping coolant until flow is above 2. • Check for coolant flow at power-up (109).2 lpm (0. the contactor and the soft-start controller turn on. Error checking • Verify that Start signal is off (050). b-2 HPR130XD Manual Gas Instruction Manual . After preflow cycle is done. send a CAN reset message to the gas console and go to the Purge state. • After CAN watchdog messages have been received.6 gpm) (060). Purge • • • • • Turn on coolant pump or motor. wait for CAN watchdog message from the gas console. • Wait for preflow to finish (2 seconds if contactor timeout. • If no CAN watchdog message after 6-second delay. • If coolant flow rate is less than 2. Pilot Arc • Turn on pilot arc controller and pilot arc relay. Error checking • Check for coolant flow at power-up (093).6 gpm). with no start allowed at this time. Idle2 • If Start signal is active.5 seconds) and for the Hold signal to be removed.1 lpm (0. Error checking • Check for coolant flow at power-up (093). • Check for coolant over temperature (071). and system goes into Preflow state. • Verify that all temperatures are below the specified temperature limits. • Check for no chopper current (102). 2. take action. Gas console runs preflow gases for 12 seconds. Preflow_IHS • Chopper setpoint = pilot arc current.FUNCTIONAL DESCRIPTION OF SOFTWARE • After delay. • After more than 10 seconds since the last Start signal. Verify that the Plasma Start signal is off before going to Idle2 state. verify coolant flow. • Check for transformer over temperature (067). Gas console runs cutflow gases for 12 seconds. • Check for no chopper current (102).2 lpm (0. otherwise 0.3 gpm) (093).

• Once chopper current is = or > setpoint. • If start-signal input is off. • Check for transformer over temperature (067). Error checking • Check for coolant flow at power-up (093). • If no transfer after 500 milliseconds. Error checking • No error checking due to HF noise. show transfer lost error (026). then switch to cutflow gases. Ramp-down • Do current ramp-down according to tables. • If corner-current input is on. • Check for coolant over temperature (071). “No pilot arc. then switch to corner-current setpoint. • If no chopper current after 10 HF pulses. • Check for coolant flow at power-up (093). • If chopper current is < 1⁄2 of current setpoint. turn off HF and go to Transfer state. Ramp-up • If Pierce-complete input is off. “No arc transfer. • If work lead current < 1⁄2 of setpoint. go to Ramp-up state and turn off pilot arc controller and pilot arc relay. HPR130XD Manual Gas Instruction Manual b-3 . show current lost error (024).FUNCTIONAL DESCRIPTION OF SOFTWARE • If chopper current = 1⁄2 of pilot arc current. • Check for transformer over temperature (067). Transfer • If work lead current is > transfer reference current. • Check for over/under line voltage (047/046). Steady state • If Pierce-complete input is off. turn on HF. 9. go to final Ramp-down state. then go to Ramp-down state.” Error checking • No error checking due to HF noise. 6. • Check for over/under line voltage (047/046). then switch to cutflow gases. Error checking • Check for loss of phase (027). • Once current reaches end current. • Check for coolant over temperature (071). • Check for chopper over temperature (065). Error checking • Check for coolant flow at power-up (093). • Ramp-up current is based on tables. • Put gas console into Idle state or Ramp-down state according to tables. 7.” • If chopper current is < 1⁄2 of setpoint. go to Auto Off state with error code (021). • Check for chopper over temperature (065). 8. go to Auto Off state with error code (020). go to Steady state.

If Ramp-down error has occurred. Error checking • Check for coolant flow at power-up (093). Shut-down • • • • • Gas console goes to Shut-down state. 11. turn on CNC error output. • Check for no Start signal. pilot arc controller. • Go to Idle state. HF.FUNCTIONAL DESCRIPTION OF SOFTWARE 10. turn on CNC Ramp-down error output. Error checking • Check for coolant flow at power-up (093). • Wait for request to go to Idle state or Test Preflow state. Test cutflow • Gas console runs cutflow gases. If error has occurred. • Check for no Start signal. Preflow gases run for a 10-second postflow period. and machine motion outputs. • Initialize timers. Auto-off • • • • • • Turn off pilot arc relay. Postflow timer and contactor timer run for 10 seconds. • Wait for request to go to Idle state or Test Cutflow state. 14. CNC error output on. All outputs off. b-4 HPR130XD Manual Gas Instruction Manual . Reset • Reset CAN controller. Error checking • Check for coolant flow at power-up (093). 15. Test preflow • Gas console runs preflow gases. Wait for reset request. go to Idle2 state. If no Start signal. Final ramp-down • Chopper setpoints = 0 Error checking • Check for coolant flow at power-up (093). 13. Chopper setpoints = 0. 12.

.....................c-2 Leather overwrap ..........................................c-2 Torch leads ..................c-2 HPR130XD Manual Gas Instruction Manual c-1 .........................c-2 Rotational mounting sleeve (optional)..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................Appendix C ROBOTIC APPLICATIONS In this section: Components for robotic applications...........................................................c-2 Robotic teaching torch (laser pointer) ........................................................................................................

They are available with 2 m (6 ft). Note: Consumable life will be reduced if the 2. Extensions can be found in the table below Part number 223059 223060 223061 223062 223063 Length 1. Over all length 2 m (6 ft) 2.5 m (8 ft) gas leads.5 m (12 ft) 4.5 m (8 ft) gas leads are used.5 m (15 ft) 6 m (20 ft) 7. or bevel. applications.APPENDIX C – ROBOTIC APPLICATIONS Components for robotic applications Torch leads The torch leads listed below have been designed to withstand the added stresses found in robotic. or 2.5 m (75 ft) 30 m (100 ft) 45 m (150 ft) c-2 HPR130XD Manual Gas Instruction Manual .5 m (25 ft) 10 m (35 ft) 15 m (50 ft) 6 foot gas lead 228514 228515 228475 228476 228477 228478 228479 228480 228481 8 foot gas lead 228516 228517 228482 228483 228484 228485 228486 228487 228488 Ohmic contact extension A 2.5 m (15 ft) 6 m (20 ft) 9 m (30 ft) Part number 223064 223065 223066 223067 223068 Length 12 m (40 ft) 15 m (50 ft) 22.5 m (8 ft) 3 m (10 ft) 3.5 m (5 ft) 3 m (10 ft) 4.4 m (8 ft) Ohmic contact wire is part of the lead set.

and does not need to be used to use the torch leads listed above.5 mm (5. This adds protection in applications where molten metal will splash back on the leads. • Use for online programming/teaching and robotic alignment systems. HPR130XD Manual Gas Instruction Manual c-3 .25 in). and is designed to be installed over the leads from where they attach to the torch. The length of the rotational sleeve is 142. Leather overwrap – 024866 The leather overwrap is 3 m (10 ft) long.APPENDIX C – ROBOTIC APPLICATIONS Rotational mounting sleeve (optional) – 220864 The rotational sleeve is designed for use in applications where the torch leads are twisted repeatedly. Rotational mounting sleeve clamp (optional) – 220900 The rotational sleeve has a larger diameter than standard sleeves (57 mm/2.6 in). Robotic teaching torch (laser pointer) – 228394 • Mount the laser pointer in the torch sleeve to provide accurate positioning and alignment of the torch. It is an optional component.

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