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

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

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

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

It is your responsibility to dispose of any Hypertherm product or component part in an environmentally acceptable manner according to national and local codes. • In other countries. • In the United States. check the EU directives.hypertherm. Proper disposal of Hypertherm products Hypertherm plasma cutting systems. check all federal. For more information. 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. and local laws. In no event shall Hypertherm be liable for injury to persons or property damage by reason of any code violation or poor work practices. 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. may contain materials or components. state. Hypertherm v 4-08 . that cannot be discarded with ordinary waste. visit www.WARRANTY Insurance At all times you will have and maintain insurance in such quantities and types. like all electronic products. check national and local laws. • In the European Union. 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.com/weee. such as printed circuit boards. national.

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

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

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

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

...5-32 Power supply coolant system servicing ......5-17 Error code troubleshooting – Error codes 071 to 076 ...................................................................................5-38 Test 3 – change the torch .............................................................................................................................................................................................................................5-38 Test 2 – supply line at ignition console.............................................................................................................................................................................................................................................................5-31 Air filter element replacement...................................................................................................................................................5-24 Error code troubleshooting – Error codes 159 to 160..............................................................................................................................................................5-40 Pump and motor troubleshooting....................................................................................................................................................................................................................................5-14 Error code troubleshooting – Error codes 047 to 053.........................TABLE OF CONTENTS Error code troubleshooting – Error codes 021 to 028....................................................................5-36 Using the Hypertherm flow meter (128933)..............................5-13 Error code troubleshooting – Error codes 044 to 046 ...............................5-33 Coolant system filter and strainer.....................................................................................................................................................................................................5-39 Test 4 – supply line to the torch receptacle .........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5-34 Coolant flow troubleshooting chart.........................................5-21 Error code troubleshooting – Error codes 138 to 143..................................................................................................................................5-44 Power supply power distribution board PCB2 ...............................................................................................................................................................................................................................................................................................................................5-45 Start circuit PCB1 ............5-28 CNC operation with pump timeout...................................................................................................................................5-16 Error code troubleshooting – Error codes 062 to 067 ....................................................................................................................................5-46 Operation..............................................................................................................................................5-35 Coolant flow tests ..................................5-34 Filter replacement .................................................................................5-46 HPR130XD Manual Gas Instruction Manual xi .....5-39 Test 5 – return line from the torch receptacle .............................5-12 Error code troubleshooting – Error codes 030 to 042.........................................................................................................................................................5-19 Error code troubleshooting – Error codes 106 to 123 ..........5-34 Pump strainer cleaning............................................................................5-36 Manual pump operation......................5-30 Power measurement........................................5-26 Power supply states ...............5-22 Error code troubleshooting – Error codes 144 to 154....................5-27 Plasma system operation with pump timeout ................................................................................................................................................................................................................................................................................................................................................5-25 Error code troubleshooting – Error codes 180 to 181.................................................................................5-46 Start circuit functional schematic..................................................................................................................5-23 Error code troubleshooting – Error codes 155 to 158...................................................................................................................................................................................................................................................................................................................................................5-37 Test 1 – return line ...... .....................................................................................................................................................................................................................................................................5-40 Test 7 – bypass the check valve.......................................................................................................................................................................................................................5-41 Testing the flow sensor............................................................................................................................................................................5-18 Error code troubleshooting – Error codes 093 to 105 ................................................................................................5-42 Gas leak tests ...............................................................................................5-29 Initial checks ............................................................................................................................................................................................................................................................................................................5-36 Before testing ...........................................5-15 Error code troubleshooting – Error codes 054 to 061......................................................................................5-39 Test 6 – bucket test at the pump ............................................................5-43 Power supply control board PCB3.........................................................................................................................................................................................................................................................................................................5-33 Draining the coolant system.........................................5-20 Error code troubleshooting – Error codes 124 to 134..........................................................................................................................................................

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

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

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

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

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

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

• Remove any combustibles. such as a butane lighter or matches.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 . • Keep away from the torch tip. • Do not hold metal near the cutting path.SAFETY A PLASMA ARC CAN CAUSE INJURY AND BURNS Instant-on torches Plasma arc comes on immediately when the torch switch is activated.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. Cutting area Prepare the cutting area to reduce reflection and transmission of ultraviolet light: • Paint walls and other surfaces with dark colors to reduce reflection. • Use protective screens or barriers to protect others from flash and glare. and a welding helmet) with appropriate lens shading to protect your eyes from the arc’s ultraviolet and infrared rays. safety shoes and hat. 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. and hot metal. The plasma arc will cut quickly through gloves and skin. • Use eye protection in accordance with applicable national or local codes. • Gauntlet gloves. 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. sparks. from your pockets before cutting. • Warn others not to watch the arc. • Wear eye protection (safety glasses or goggles with side shields.1:2005) (ANSI Z49. Skin protection Wear protective clothing to protect against burns caused by ultraviolet light. • Cuffless trousers to prevent entry of sparks and slag. • Flame-retardant clothing to cover all exposed areas. Use placards or signs. • Never point the torch toward yourself or others.

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

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

SAFETY ADDITIONAL SAFETY INFORMATION 1. CSA mark Hypertherm products with a CSA mark meet the United States and Canadian regulations for product safety.2. Canadian Standards Association Standard Sales 178 Rexdale Boulevard. 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.2.1.S. Government Printing Office. AWS F5. NY 10018 4. American Welding Society. EMC filters needed to comply with the European EMC Directive are incorporated within versions of the product with a CE marking. Boston.C. Boston. not all marks are applied to every version of a product. NY 10018 3. Cutting and Welding Processes. tested. AWS Safety and Health Fact Sheets. Box 351020. ANSI Standard Z87. American National Standards Institute.O. Code for Safety in Welding and Cutting. Canada 8. ANSI Standard Z49. New York. AWS F4. FL 33135 5. P. MA 02210 10. FL 33135 6. CSA Standard W117. Due to differences and conflicts in national regulations. 20402 11. Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances. Fire Prevention in the Use of Cutting and Welding Processes. OSHA. Safe Practices for Occupation and Educational Eye and Face Protection. Rexdale. American Welding Society 550 LeJeune Road.1.O. FL 33135 www. 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.aws. 1-8 11/08 Hypertherm . Safe Handling of Compressed Gases in Cylinders. NFPA Standard 51B. D. Safety in Welding and Cutting. such as Underwriters Laboratories. Miami. 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. P.2. MA 02210 9. and certified by CSA-International. National Fire Protection Association. 470 Atlantic Avenue. VA 22202 7. National Fire Protection Association 470 Atlantic Avenue. 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. Miami. Box 351040. American Welding Society 550 LeJeune Road. Ontario M9W 1R3. 550 LeJeune Road P.org/technical/facts/ SYMBOLS AND MARKS Your Hypertherm product may have one or more of the following markings on or near the data plate. CE marking The CE marking signifies the manufacturer’s declaration of conformity to applicable European directives and standards. American National Standards Institute 1430 Broadway. The products were evaluated.1.O. Safety and Health Standards. 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. Box 351040. New York. Miami. 1430 Broadway. 29FR 1910 U.O. Miami. Washington. ANSI Standard Z49. Recommended Safe Practices for Plasma Arc Cutting. NFPA Standard 70–1978. P. Arlington. Compressed Gas Association 1235 Jefferson Davis Highway. National Electrical Code. Box 351040. 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. Incorporated (UL) or TÜV. American Welding Society 550 LeJeune Road. FL 33135 2. CGA Pamphlet P-1.

Utiliser exclusivement les torches indiquées dans le manual. Plasma fumes can be hazardous. 2.3 Wear complete body protection. 3. or worn (PN 110584 Rev C). Seul le personnel qualifié a le droit de faire fonctionner cet équipement. 4. 4. Protéger les oreilles contre le bruit. Read and follow these instructions. Arc rays can burn eyes and injure skin. “Safety in Welding. 2.org) and OSHA Safety and Health Standards. 4. 6. détruire ni couvrir cette étiquette. 5. 1. Become trained. éloigner la buse de soi. Boutonner le col de la chemise.1 Ne pas couper près des matières inflammables. 2. Ne pas toucher les pièces sous tension. Button shirt collar.gov). ears. point the nozzle away from yourself. eyes. 2. 2.2 Do not grip the workpiece near the cutting path. Les rayons d’arc peuvent brûler les yeux et blesser la peau. 4. Consult manual before operating. 3. Suivre une formation. 5. 3. 2. WARNING Plasma cutting can be injurious to operator and persons in the work area.1. 3. Cutting sparks can cause explosion or fire. 1. and body. Le non respect des ces instructions de sécurité peut entraîner la mort. and material safety data sheets.3 Do not operate in closed spaces. Plasma arc can injure and burn. 3.aws. Keep non-qualified personnel and children away. Do not remove.3 Couper l’alimentation avant l’entretien. Remplacer les gants quand ils sont humides ou endommagés.2 Un extincteur doit être à proximité et prêt à être utilisé. L’arc plasma peut blesser et brûler.SAFETY WARNING LABEL This warning label is affixed to some power supplies. hands. endommagée ou usée (PN 110584 Rev C). Consulter le manuel avant de faire fonctionner. 7.2 Have a fire extinguisher nearby and ready to use. 4. Risk of electric shock or burn.1 Couper l’alimentation avant de démonter la torche.3 Ne pas couper dans des espaces clos. or cover this label.1 Wear insulating gloves.1 Do not inhale fumes. 1. employer safety practices.3 Do not use a drum or other closed container as a cutting table. Le personnel non qualifié et les enfants doivent se tenir à l’écart. Remove fumes with ventilation. 3. les yeux.osha. 1. Protect ears from noise. 29 CFR 1910 (http://www. les oreilles. Do not touch live parts. It is important that the operator and maintenance technician understand the intent of these warning symbols as described. Replace gloves when wet or damaged. Tension dangereuse. damaged. Cutting and Allied Processes” from American Welding Society (http://www. Refer to ANS Z49. destroy. Les étincelles de coupage peuvent provoquer une explosion ou un incendie. Only qualified personnel should operate this equipment.2 Ne pas saisir la pièce à couper de la trajectoire de coupage.1 Wear correct and appropriate protective equipment to protect head. Failure to follow all these safety instructions can result in death. 2. Chasser les fumées par ventilation.2 Se protéger contre les chocs en s’isolant de la pièce et de la terre.2 Use forced ventilation or local exhaust to remove the fumes. 6. 4. les mains et le corps. AVERTISSEMENT Le coupage plasma peut être préjudiciable pour l’opérateur et les personnes qui se trouvent sur les lieux de travail. Arc starts instantly when triggered.1 Ne pas inhaler les fumées 4. 3.3 Disconnect power before servicing. Use torches specified in the manual. Use welding helmet with the correct shade of filter.3 Ne pas utiliser un fût ou un autre contenant fermé comme table de coupage. 7. 1. 5.1 Porter un bon équipement de protection pour se protéger la tête. Hypertherm 1-9 11/08 . 2.3 Se protéger entièrement le corps. Ne pas enlever.1 Turn off power before disassembling torch. Utiliser un masque de soudeur avec un filtre de nuance appropriée. 3. Il s’allume instantanément quand on l’amorce. Hazardous voltage.1 Do not cut near flammables. Les fumées plasma peuvent être dangereuses. Replace if it is missing.1 Porter des gants isolants. 1. 4. 1. 5. 1.2 Protect from shock by insulating yourself from work and ground.2 Utiliser une ventilation forcée ou un extracteur local pour dissiper les fumées. La remplacer si elle est absente. Risque de choc électrique ou de brûlure.

3 Wear complete body protection. 4. hands. Only qualified personnel should operate this equipment. 3. Arc starts instantly when triggered. or worn. Arc rays can burn eyes and injure skin. 6. 1.3 Do not operate in closed spaces. 4. 1.2 Have a fire extinguisher nearby and ready to use. Button shirt collar. Use welding helmet with the correct shade of filter. 3.1 Wear correct and appropriate protective equipment to protect head. 2.1 Wear insulating gloves. 7. and body. Plasma fumes can be hazardous. Do not remove. 3.3 Disconnect power before servicing. 4. 4. Use torches specified in the manual. 5. Protect ears from noise. 1.SAFETY WARNING LABEL This warning label is affixed to some power supplies.2 Use forced ventilation or local exhaust to remove the fumes. Keep non-qualified personnel and children away. Hazardous voltage. 2. point the nozzle away from yourself. Become trained.3 Do not use a drum or other closed container as a cutting table.2 Do not grip the workpiece near the cutting path. ears. Remove fumes with ventilation. 1. Cutting sparks can cause explosion or fire. 1-10 11/08 Hypertherm .1 Turn off power before disassembling torch.1 Do not cut near flammables. Risk of electric shock or burn. 3. Replace gloves when wet or damaged. Replace if it is missing. or cover this label. Plasma arc can injure and burn. 5. 2. eyes. destroy.1 Do not inhale fumes. The numbered text corresponds to the numbered boxes on the label. Do not touch live parts. damaged. 2. It is important that the operator and maintenance technician understand the intent of these warning symbols as described.2 Protect from shock by insulating yourself from work and ground.

the Kst value. National Fire Protection Association’s 2007 edition of NFPA standard 68. 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. maintenance. Hypertherm 1-11 11/08 . but it does apply these new requirements to all dry dust collection systems.SAFETY Dry dust collection information At some sites. 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.” provides requirements for the design. AHJ. by the publication of any Hypertherm manual. dry dust can represent a potential explosion hazard. 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. installation. and use of devices and systems to vent combustion gases and pressures after any deflagration event. state. deflagration index. Note 2 – Users of Hypertherm manuals should consult and comply with all applicable federal. and other terms. 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. The U. and local laws and regulations. “Explosion Protection by Deflagration Venting. and this manual may never be construed as doing so.S. intend to urge action that is not in compliance with all applicable regulations and standards. Hypertherm does not. location. NFPA 68 does not specifically identify plasma cutting or other thermal cutting processes as requiring deflagration venting systems. adopted by reference.

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

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

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

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

• Ne pas tenir de métal près de la trajectoire de coupe. chaussures et casque de sécurité. • Utiliser des écrans et autres dispositifs de protection afin de protéger les autres personnes de la lumière et de la réverbération. les étincelles et le métal brûlant : • Gants à crispin. • Utiliser des lunettes de sécurité conformément aux codes locaux ou nationaux en vigueur. retirer de ses poches tout objet combustible comme les briquets au butane ou les allumettes. • 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. • Vêtements ignifuges couvrant toutes les parties exposées du corps.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. • Pantalon sans revers pour éviter que des étincelles ou des scories puissent s’y loger. • Avant le coupage. Indice de protection minimum (ANSI Z49.1:2005) 5 6 8 8 8 8 8 8 9 10 Indice de protection suggéré pour assurer le confort (ANSI Z49. Protection de la peau Porter des vêtements de sécurité pour se protéger contre les brûlures que peuvent causer les rayons ultraviolets. • Prévenir les autres personnes de ne pas regarder l’arc. • Ne jamais pointer la torche vers soi ou d’autres personnes. 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. 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. Utiliser des affiches ou des panneaux.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 . • Rester éloigné de l’extrémité de la torche. L’arc plasma coupe facilement les gants et la peau.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.

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

• Garder loin de soi et du même côté du corps le câble de retour et le faisceau de la torche. • Se tenir le plus loin possible de la source de courant. • 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. • Utiliser un casque de protection homologué lors de l’utilisation du système plasma. PACEMAKERS ET PROTHÈSES AUDITIVES Les champs magnétiques produits par les courants à haute tension peuvent affecter le fonctionnement des prothèses auditives et des pacemakers. 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. Hypertherm 1a-7 11/08 .SÉCURITÉ LE BRUIT PEUT PROVOQUER DES PROBLÈMES AUDITIFS Une exposition prolongée au bruit du coupage ou du gougeage peut provoquer des problèmes auditifs. • 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.

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. toutes les marques ne sont pas appliquées à chaque version d’un produit. 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). 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. Incorporated (UL) ou TÜV. En outre. 1a-8 11/08 Hypertherm . 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 raison des différends et des conflits relatifs aux règlements nationaux. Les produits sont évalués. 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.SÉCURITÉ SYMBOLES ET MARQUAGE Votre produit Hypertherm peut comporter une ou plusieurs des marques suivantes sur sa plaque signalétique ou à proximité. 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 CSA Les produits Hypertherm comportant la marque CSA répondent aux règlements des États-Unis et du Canada relatifs à la sécurité du produit. 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.

4.3 Wear complete body protection.1 Ne pas couper près des matières inflammables.2 Se protéger contre les chocs en s’isolant de la pièce et de la terre. AVERTISSEMENT Le coupage plasma peut être préjudiciable pour l’opérateur et les personnes qui se trouvent sur les lieux de travail.3 Se protéger entièrement le corps.osha.aws. Button shirt collar.2 Have a fire extinguisher nearby and ready to use. 4. 1.1 Porter un bon équipement de protection pour se protéger la tête. Remplacer les gants quand ils sont humides ou endommagés. les oreilles. 1. Cutting sparks can cause explosion or fire. 7. 2. 3. hands. 3. Replace if it is missing. Protect ears from noise. 3. 3. 2. Boutonner le col de la chemise. Les étincelles de coupage peuvent provoquer une explosion ou un incendie. Les rayons d’arc peuvent brûler les yeux et blesser la peau. Remove fumes with ventilation.2 Use forced ventilation or local exhaust to remove the fumes. endommagée ou usée (PN 110584 Rev C). Protéger les oreilles contre le bruit. Hazardous voltage.org) and OSHA Safety and Health Standards. Le non respect des ces instructions de sécurité peut entraîner la mort. éloigner la buse de soi. Suivre une formation. Only qualified personnel should operate this equipment. employer safety practices. and body. and material safety data sheets.2 Protect from shock by insulating yourself from work and ground.2 Utiliser une ventilation forcée ou un extracteur local pour dissiper les fumées. Failure to follow all these safety instructions can result in death. 2. Il s’allume instantanément quand on l’amorce. les mains et le corps.3 Do not operate in closed spaces. or worn (PN 110584 Rev C). 2. 7. les yeux. Seul le personnel qualifié a le droit de faire fonctionner cet équipement. Ne pas toucher les pièces sous tension. Plasma arc can injure and burn. 29 CFR 1910 (http://www. Ne pas enlever. Keep non-qualified personnel and children away.3 Ne pas utiliser un fût ou un autre contenant fermé comme table de coupage. 1. 3. 5. Refer to ANS Z49. 4.1 Turn off power before disassembling torch. La remplacer si elle est absente. Il est important que l’utilisateur et le technicien de maintenance comprennent la signification des symboles de sécurité. Do not remove. 4. 1. Cutting and Allied Processes” from American Welding Society (http://www. destroy. 3.2 Ne pas saisir la pièce à couper de la trajectoire de coupage. 1. Arc starts instantly when triggered. 1. Tension dangereuse. Risk of electric shock or burn.SÉCURITÉ ÉTIQUETTE DE SÉCURITÉ Cette étiquette est affichée sur la source de courant.3 Disconnect power before servicing. 1. Risque de choc électrique ou de brûlure. or cover this label. Use torches specified in the manual.1 Do not inhale fumes.1 Ne pas inhaler les fumées 4. Read and follow these instructions.1. Consult manual before operating. Le personnel non qualifié et les enfants doivent se tenir à l’écart. 5.2 Un extincteur doit être à proximité et prêt à être utilisé. 2.1 Couper l’alimentation avant de démonter la torche. ears. eyes. 6. détruire ni couvrir cette étiquette. Do not touch live parts.1 Porter des gants isolants. Utiliser exclusivement les torches indiquées dans le manual. 4. 3. Consulter le manuel avant de faire fonctionner. point the nozzle away from yourself. L’arc plasma peut blesser et brûler.1 Wear insulating gloves. 4. 6. 5. Replace gloves when wet or damaged. 2.gov).3 Ne pas couper dans des espaces clos. 2. Les fumées plasma peuvent être dangereuses. Plasma fumes can be hazardous. 1. Chasser les fumées par ventilation. Use welding helmet with the correct shade of filter. damaged. 5. Become trained. Hypertherm 1a-9 11/08 . Arc rays can burn eyes and injure skin. 4. “Safety in Welding. Utiliser un masque de soudeur avec un filtre de nuance appropriée.1 Wear correct and appropriate protective equipment to protect head. WARNING Plasma cutting can be injurious to operator and persons in the work area. 3. 2.2 Do not grip the workpiece near the cutting path.3 Couper l’alimentation avant l’entretien.1 Do not cut near flammables.3 Do not use a drum or other closed container as a cutting table.

2 Ne pas saisir la pièce à couper de la trajectoire de coupage. les oreilles. 3. éloigner la buse de soi. les yeux. Risque de choc électrique ou de brûlure.1 Couper l’alimentation avant de démonter la torche. 5. détruire ni couvrir cette étiquette. 1. Les fumées plasma peuvent être dangereuses. L’arc plasma peut blesser et brûler. 5. 1a-10 11/08 Hypertherm . 2. 2. endommagée ou usée (PN 110584 Rev C). 3. 4. 2. Suivre une formation. Remplacer les gants quand ils sont humides ou endommagés.SÉCURITÉ ÉTIQUETTE DE SÉCURITÉ Cette étiquette est affichée sur la source de courant. 1. La remplacer si elle est absente.1 Porter un bon équipement de protection pour se protéger la tête. 3. 7. Ne pas enlever. Chasser les fumées par ventilation. Utiliser exclusivement les torches indiquées dans le manual.3 Couper l’alimentation avant l’entretien. Les rayons d’arc peuvent brûler les yeux et blesser la peau. Le personnel non qualifié et les enfants doivent se tenir à l’écart. Il est important que l’utilisateur et le technicien de maintenance comprennent la signification des symboles de sécurité.3 Ne pas utiliser un fût ou un autre contenant fermé comme table de coupage.1 Porter des gants isolants.2 Se protéger contre les chocs en s’isolant de la pièce et de la terre.1 Ne pas couper près des matières inflammables. 4. Les numéros de la liste correspondent aux numéros des images.2 Un extincteur doit être à proximité et prêt à être utilisé. Les étincelles de coupage peuvent provoquer une explosion ou un incendie. Seul le personnel qualifié a le droit de faire fonctionner cet équipement.1 Ne pas inhaler les fumées.3 Ne pas couper dans des espaces clos.3 Se protéger entièrement le corps. 1. Utiliser un masque de soudeur avec un filtre de nuance appropriée. 1. Tension dangereuse. 6.2 Utiliser une ventilation forcée ou un extracteur local pour dissiper les fumées. Protéger les oreilles contre le bruit. les mains et le corps. 4. 3. Boutonner le col de la chemise. 2. Il s’allume instantanément quand on l’amorce. Ne pas toucher les pièces sous tension 4.

valeur du pire cas. 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.À certains endroits. (édition 2007) « Explosion Protection by Deflagration Venting » établit les exigences relatives à la conception. 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. 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. Note 1 – L’interprétation d’Hypertherm de ces nouvelles exigences est que.SÉCURITÉ Information sur le dépoussiérage À certains endroits. la poussière peut représenter un risque d’explosion potentiel. 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. autorité compétente. en publiant un manuel d’Hypertherm. Hypertherm 1a-11 11/08 . indice de déflagration » et autres termes. à l’installation. La norme NFPA 68 de la National Fire Protection Association des É.-U. 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. pour déterminer que toute la poussière produite n’est pas combustible. 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. sauf évaluation particulière du site. à l’emplacement. Voir le document NFPA68 pour obtenir des définitions et des explications des termes réglementaires tels que « déflagration. Hypertherm n’a pas l’intention. Note 2 – Les utilisateurs des manuels d’Hypertherm doivent consulter tous les règlements et lois fédéraux et locaux applicables et s’y conformer. adopté par référence. la poussière peut représenter un risque d’explosion potentiel.

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

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

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

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

• Pantalones sin dobladillos para impedir que recojan chispas y escorias. antes de comenzar a cortar. El número de matiz protector mínimo (ANSI Z49. Utilice carteles o letreros. El arco de plasma puede cortar a través de guantes y de la piel con rapidez.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. • Advierta a los demás que no debe mirarse el arco.1:2005) 5 6 8 8 8 8 8 8 9 10 El número de matiz sugerido para comodidad (ANSI Z49. Protección para la piel Vista ropa de protección para proteger la piel contra quemaduras causadas por la radiación ultravioleta de alta intensidad. 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. • Nunca apunte la antorcha hacia Ud.) 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. • Retire todo material combustible de los bolsillos.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 . por las chispas y por el metal caliente: • Guantes largos.1:2005) 5 6 8 9 9 9 9 9 12 14 Corriente de arco (amps. y bien un casco de soldar) con lentes con sombreado adecuado para proteger sus ojos de los rayos ultravioleta e infrarrojos del arco. • Manténgase alejado de la punta de la antorcha. • Utilice protección para los ojos de conformidad con los códigos locales o nacionales aplicables. • Roipa de combustión retardada y que cubra todas las partes expuestas. zapatos de seguridad y gorro. 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. • Utilice pantallas o barreras protectoras para proteger a los demás de los destellos. • Colóquese protectores para los ojos (gafas o anteojos protectores con protectores laterales. mismo o hacia otras personas. como encendedores a butano e inclusive cerillas. • No sostenga el metal junto al trayecto de corte.

Consulte los códigos locales o nacionales aplicables. • Asegúrese de que todas las conexiones eléctricas están firmemente realizadas para evitar sobrecalentamientos. • No permita nunca el contacto eléctrico entre el arco de plasma y un cilindro. SEGURIDAD DE LOS EQUIPOS DE GAS COMPRIMIDO • Nunca lubrique reguladores o válvulas de cilindros con aceite o grasa. reguladores. • Mantenga la tapa de protección en su lugar encima de la válvula. • 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. • Utilice solamente cilindros. No conecte el cable con la parte que va a quedar separada por el corte. 1b-6 11/08 Hypertherm . LOS CILINDROS DE GAS PUEDEN EXPLOTAR SI ESTÁN DAÑADOS Los cilindros de gas contienen gas bajo alta presión. llaves u otro tipo de herramientas para abrir de golpe la válvula del cilindro. • No exponga nunca los cilindros a calor excesivo. • No emplee nunca martillos. • No use nunca un cilindro que no esté de pie y bien sujeto. mangueras y conectores de gas correctos que hayan sido diseñados para la aplicación específica. • Manipule y utilice los cilindros de gas comprimido de acuerdo con los códigos locales o nacionales aplicables. 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. chispas. Mesa de trabajo Conecte la mesa de trabajo a una buena toma de tierra. de conformidad con los códigos eléctricos nacionales o locales apropiados. • 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.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. escorias o llamas. excepto cuando el cilindro se encuentre en uso o conectado para ser utilizado. Ajuste firmemente la tuerca de retención. Un cilindro dañado puede explotar. • Mantenga todo el equipo de gas comprimido y las piezas relacionadas en buen estado. asegúrese de conectar correctamente el alambre de toma a tierra del cordón de alimentación primaria.

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

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. Marcas CE Las marcas CE significan una declaración del fabricante de conformidad a las directivas y estándares aplicables Europeos. Estos productos fueron evaluados. comprobados. Los filtros EMC que necesitan cumplir con la Directiva Europea EMC están incorporados dentro de las versiones del producto con la marca CE. y certificados por CSA-Internacional. 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. 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 CSA Los productos de Hypertherm con la marca CSA cumplen con los reglamentos de Estados Unidos y Canadá para la seguridad del producto. 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. 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. o cerca de la placa de datos. 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.SEGURIDAD SÍMBOLOS Y MARCAS Su producto de Hypertherm puede tener una o más de las marcas que siguen en. Incorporated (UL) ó TÜV. Alternativamente. Debido a diferencias y conflictos en reglamentos nacionales. no todas las marcas se aplican a toda versión del producto. la Compatibilidad Electromagnético Europea (EMC). 1b-8 11/08 Hypertherm .

La remplacer si elle est absente. Es importante que el operador y el técnico de mantenimiento comprendan el sentido de estos símbolos de advertencia según se describen. Remplacer les gants quand ils sont humides ou endommagés.2 Protect from shock by insulating yourself from work and ground. Cutting and Allied Processes” from American Welding Society (http://www. 3. 4. Arc rays can burn eyes and injure skin. Consulter le manuel avant de faire fonctionner. 3. 4. destroy. Boutonner le col de la chemise. Only qualified personnel should operate this equipment.2 Have a fire extinguisher nearby and ready to use. 4. Hypertherm 1b-9 11/08 . Utiliser un masque de soudeur avec un filtre de nuance appropriée. Do not touch live parts.3 Ne pas couper dans des espaces clos. or worn (PN 110584 Rev C). Il s’allume instantanément quand on l’amorce. “Safety in Welding. Risque de choc électrique ou de brûlure. Les fumées plasma peuvent être dangereuses. 4. WARNING Plasma cutting can be injurious to operator and persons in the work area. Replace if it is missing. 2. Failure to follow all these safety instructions can result in death.2 Ne pas saisir la pièce à couper de la trajectoire de coupage.1 Couper l’alimentation avant de démonter la torche. AVERTISSEMENT Le coupage plasma peut être préjudiciable pour l’opérateur et les personnes qui se trouvent sur les lieux de travail. Tension dangereuse.2 Do not grip the workpiece near the cutting path.3 Disconnect power before servicing. 2.SEGURIDAD ETIQUETA DE ADVERTENCIA Esta etiqueta de advertencia se encuentra adherida a la fuente de energía. Plasma arc can injure and burn.3 Do not use a drum or other closed container as a cutting table. Plasma fumes can be hazardous. 1.2 Use forced ventilation or local exhaust to remove the fumes. 3. 7. Become trained. 5. 2. 2. employer safety practices. Use welding helmet with the correct shade of filter. 4. eyes. Le non respect des ces instructions de sécurité peut entraîner la mort.3 Do not operate in closed spaces. 1. 3. 5. Les rayons d’arc peuvent brûler les yeux et blesser la peau. 29 CFR 1910 (http://www. 1.3 Couper l’alimentation avant l’entretien. Arc starts instantly when triggered. 7.1 Ne pas couper près des matières inflammables. 3. endommagée ou usée (PN 110584 Rev C). Read and follow these instructions. 2.gov).1 Turn off power before disassembling torch. and material safety data sheets. Remove fumes with ventilation. Replace gloves when wet or damaged. les oreilles. Refer to ANS Z49. Consult manual before operating. Use torches specified in the manual.1 Ne pas inhaler les fumées 4. point the nozzle away from yourself. 1.2 Un extincteur doit être à proximité et prêt à être utilisé. Button shirt collar. 2. 4. les mains et le corps.1 Wear insulating gloves.2 Se protéger contre les chocs en s’isolant de la pièce et de la terre. 3.3 Se protéger entièrement le corps. Les étincelles de coupage peuvent provoquer une explosion ou un incendie. 6. Cutting sparks can cause explosion or fire. 6. 2. Risk of electric shock or burn.1 Porter un bon équipement de protection pour se protéger la tête. 1. Utiliser exclusivement les torches indiquées dans le manual. hands. L’arc plasma peut blesser et brûler.1. Suivre une formation. 1.3 Wear complete body protection. Do not remove. Le personnel non qualifié et les enfants doivent se tenir à l’écart.1 Wear correct and appropriate protective equipment to protect head. 4. damaged. éloigner la buse de soi.3 Ne pas utiliser un fût ou un autre contenant fermé comme table de coupage.org) and OSHA Safety and Health Standards. Ne pas toucher les pièces sous tension. 5.1 Porter des gants isolants.2 Utiliser une ventilation forcée ou un extracteur local pour dissiper les fumées.osha. 1. 3. Protect ears from noise. 3. and body.1 Do not inhale fumes. détruire ni couvrir cette étiquette. Seul le personnel qualifié a le droit de faire fonctionner cet équipement. Chasser les fumées par ventilation. or cover this label. 5. Ne pas enlever. Protéger les oreilles contre le bruit. 2.1 Do not cut near flammables.aws. ears. Hazardous voltage. Keep non-qualified personnel and children away. les yeux. 1.

Utilice protección para los oídos y abróchese el botón del cuello de la camisa. 3. 4. Es importante que el operador y el técnico de mantenimiento comprendan el sentido de estos símbolos de advertencia según se describen. El arco de plasma puede causar quemaduras y lesiones. 1. Proteja su cuerpo completamente. 2. Las chispas producidas por el corte pueden causar explosiones o incendios.2 Aíslese de la pieza de trabajo y de la tierra. No retire las etiquetas de advertencia ni las cubra con pintura. 4. El texto numerado corresponde a los cuadros numerados de la etiqueta. 5. Utilice un casco de soldar con el filtro de sombreado adecuado. La inhalación de los humos provenientes del área de corte puede ser nociva para la salud. 6.3 Proteja su cuerpo completamente.3 Utilice un ventilador para eliminar los humos.3 Antes de trabajar en una máquina. 2.1 Mantenga la cabeza fuera de los gases tóxicos. 2. No utilice guantes dañados o mojados. 7. 4. Los rayos del arco pueden producir quemaduras en los ojos y en la piel.2 Utilice ventilación forzada o un sistema local de escape para eliminar los humos. 1b-10 11/08 Hypertherm . desconecte el enchufe de entrada o la potencia primaria. 3. 5. 1.1 Apague la fuente de energía antes de desarmar la antorcha. 2. 3.1 Colóquese guantes aislantes.SEGURIDAD ETIQUETA DE ADVERTENCIA Esta etiqueta de advertencia se encuentra adherida a la fuente de energía. capacítese y lea las instrucciones completamente. 1. Antes de trabajar en la máquina o de proceder a cortar. Los electrochoques provocados por la antorcha o el cableado pueden ser fatales. 4. 3. Protéjase del electrochoque.3 No corte depósitos cerrados.2 No sostenga el material junto al trayecto de corte.2 Tenga a mano un extinguidor de incendios y asegúrese de que alguien esté preparado para utilizarlo.1 Mantenga los materiales inflamables lejos del lugar de corte. 1.1 Utilice un sombrero y gafas de seguridad.

o haga cambios significativos en el proceso o materiales que se usen con un sistema existente de colección de polvo seco. y este manual nunca debe interpretarse como si lo hiciera así. a no ser que se haya completado una evaluación específica del sitio para determinar que todo polvo generado no es combustible. al publicar todo manual de Hypertherm.S. pero en realidad aplica estos nuevos requisitos a todos los sistemas de colección de polvos secos. instalación. 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. Nota 2 – Los usuarios de los manuales de Hypertherm deberían consultar y cumplir con todas las leyes y reglamentos federales. Nota 1 – La interpretación de Hypertherm de estos nuevos requisitos es que. La NFPA 68 no identifica específicamente corte por plasma u otros procesos de cortes termales como si requirieran sistemas de respiraderos de deflagración. y uso de aparatos y sistemas para dar salida a gases de combustión y presiones después de todo evento de deflagración. 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. ubicación. Remítase a la NFPA 68 para definiciones y explicaciones de los términos reguladores como “deflagración. el polvo seco puede representar un peligro potencial de explosión. adoptada por referencia.SEGURIDAD Información sobre la colección de polvo seco En algunos sitios. 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. estatales y locales aplicables. el valor Kst. Hypertherm. mantenimiento. 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. Hypertherm 1b-11 11/08 . de manera que el tamaño y tipo del respiradero de explosión pueda diseñarse. no intenta urgir acción que no esté en cumplimiento con todos los reglamentos y normas. AHJ. índice de deflagración” y otros términos. La edición del 2007 de “U.

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

SPECIFICATIONS 2-2 HPR130XD Manual Gas Instruction Manual .

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

2 requirements are: • Particulates – no more than 100 particles per cubic meter of air at a Size of 0.99% pure Clean.4. dry.0 microns in the largest dimension. oil-free ** Clean. 35% Hydrogen) 99. dry.1 mg per cubic meter of air. Nitrogen is used as a purge gas.98% pure (F5 = 95% Nitrogen. 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 . dry.4° F). • Oil – the concentration of oil can be no more than 0.99% pure Clean. oil-free Pressure +/. ** ISO standard 8573-1 Class 1.5 to 5.995% pure (H35 = 65% Argon. 5% Hydrogen) 99.5% pure Clean.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.2 99.1 to 0. and air are required for all systems. oil-free 99. • Water – the pressure dewpoint of the humidity must be less than or equal to 3° C (37.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. nitrogen.5 microns in the largest dimension and 1 particle per cubic meter of air at a Size of 0. dry.

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 (+/.10%) (U1 x I1 x 1.4 mm 22.5 kw.5 21.3" HPR130XD Manual Gas Instruction Manual 2-5 .5 kg 700 lb 967. 40° C (104° F) Power supplies will operate between -10° C and +40° C (+14° and 104° F) 0.5 21.5 mm 42.5 21.5 21.9 mm 6.5 * The 380 volt CCC regulatory approval only applies to 50 Hz operation 1079.5 21.1" 317.5 21.1" 566.73) 21.5" 154.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% @ 19.7 mm 38.5 21.

• Maximum cable length from the ignition console to the torch lifter station is 20 m (65 ft). See Installation section for details.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).1 kg 20 lb 216 mm 8.625" 283 mm 11. Allow room to remove the top for servicing. 219 mm 8.125" 194 mm 7. • The ignition console may be mounted horizontally or vertically.625" 9.5" 152 mm 6" 2-6 HPR130XD Manual Gas Instruction Manual .

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.88" 178 mm 7" 2-8 HPR130XD Manual Gas Instruction Manual .5" 359 mm 14. • Maximum cable length from the gas console to the off-valve assembly is 20 m (65 ft). 292 mm 11.125" 317 mm 12.5" 14 kg 31 lb 276 mm 10. • Mount the gas console on top of the power supply or near the CNC on the cutting table.SPECIFICATIONS Gas console – 078532 • Maximum cable length from the power supply to the gas console is 75 m (250 ft).

7 mm 0.62" 30 mm 1. A 70 mm 2.18" 165 mm 6.18" 1.75" A Vent hole: Do not block 19 mm 0. • Mount the off-valve assembly to the torch carriage on larger tables.SPECIFICATIONS Off-valve – 078534 • Maximum cable length from the off-valve to the torch lifter station is 1.5" A-A HPR130XD Manual Gas Instruction Manual 2-9 .5 lb 4.8 m (6 ft).75" 157 mm 6. • The vent hole on the manifold must be kept clear at all times. On smaller tables it can be mounted to a bracket just above the bridge.1 kg 2.187" 92 mm 3.

8 mm (2.60" 1.59" 49 mm 1.25" 2" 43 ° 345 mm 13.00" 95 mm 3.8 m 6' 193 mm 7.0 in). • The minimum bend radius for the torch leads is 152.4 mm (6.91" 104 mm 4. 1.9 kg 4.0 in).SPECIFICATIONS Torch – 228520 • The outside diameter of the torch mounting sleeve is 50.2 lb 2-10 HPR130XD Manual Gas Instruction Manual .10" 51 mm 2.74" 51 mm 57 mm 2.

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

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

All communications regarding claims must include the model number and serial number located on the back of the power supply. Hypertherm will furnish you with a copy of the bill of lading upon request.8 41. See also Noise can damage hearing in the Safety section of this manual. Noise levels Acceptable noise levels as defined by national and local codes may be exceeded by this plasma system. Direct any technical questions to the nearest Hypertherm Technical Service Department listed in the front of this manual.6-9. Claims for defective or missing merchandise – If any of the merchandise is defective or missing. gas and interface connections. If you need additional assistance. Contact your supplier if any items are missing. The decibel readings at 12 m (39. If there is evidence of damage. call Customer Service listed in the front of this manual. call Customer Service listed in the front of this manual. refer to Claims.INSTALLATION Upon receipt • Verify that all system components on your order have been received.4 m (4. • To prevent leaks in the system. • Inspect the system components for any physical damage that may have occurred during shipping. Always wear proper ear protection when cutting or gouging. This work should be performed only by qualified. dBC (MaxP) and 99. Placement of system components • Place all system components in position prior to making electrical.2 Max Level. licensed personnel. If you need additional assistance. 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. contact your supplier.34 m (1.4 ft) from the front of torch. Use the diagram in this section for component-placement guidelines. or your authorized Hypertherm distributor. dBA.25-7 30-40 HPR130XD Manual Gas Instruction Manual 3-3 . or your authorized Hypertherm distributor. Claims Claims for damage during shipment – If your unit was damaged during shipment.6 Lav5. Installation requirements All installation and service of the electrical and plumbing systems must conform to national and local electrical and plumbing codes.6 ft) from the floor and 0.12 ft) above the arc are: 119. • Ground all system components to earth. See Recommended grounding and shielding practices in this section for details. 1. Data was taken while cutting at 130 A using an O2/Air process on a dry cutting table. or your authorized Hypertherm distributor.5-55 lbf-in 75-85 360-480 lbf-ft 6. you must file a claim with the carrier.

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 .

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

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

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

It is bolted to the gantry. close to the motor. 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.INSTALLATION Cable to ground bus on the cutting table Component ground cables Example of a good gantry ground bus. A single heavy cable then goes from the gantry ground bus to the ground bus bolted to the table. * 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 .

• 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. HPR130XD Manual Gas Instruction Manual 3-11 .INSTALLATION A Placement of the power supply ELECTRICAL SHOCK CAN KILL DANGER Remove all electrical connections to the power supply before moving or positioning. 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. Do not place any filter device over the air intake locations. Allow 1 m (3 ft) of space on all sides of the power supply for ventilation and service. • Do not place the power supply on an incline greater than 10° to prevent it from toppling. which reduces cooling efficiency and VOIDS THE WARRANTY. Transporting the unit can cause personal injury and equipment damage. • Cooling air is drawn in through the front panel and is exhausted through the rear of the unit by a cooling fan.

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 .

123865* 123419 123834 123420 123670 123422 123835 123423 123671 Length 2.1 m (7 ft) 3 m (10 ft) 4.5 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.5 m (25 ft) 9 m (30 ft) 10 m (35 ft) 12 m (40 ft) 15 m (50 ft) Part no.5 m (75 ft) 25 m (82 ft) 30 m (100 ft) 35 m (115 ft) 37. 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 .INSTALLATION 3 Ignition console power cable Cable signal list – power supply to ignition console Power supply end Pin No.5 m (15 ft) 6 m (20 ft) 7. 123836 123425 123736 123426 123672 123938 123673 123837 123838 Length 20 m (65 ft) 22. 1 Part no.

INSTALLATION 4 Ignition console coolant hoses Red Green Part no.5 ft) 3 m (10 ft) 4.5 m (25 ft) 10 m (35 ft) 15 m (50 ft) Part no.5 m (15 ft) 7. 228030* 028652 028440 028441 128173 028442 Length 0. 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 .7 m (2.

5 m (25 ft) 10 m (35 ft) 15 m (50 ft) Part no. 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 .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. 123785* 123846 123964 123674 123847 123675 Length 3 m (10 ft) 4. 123784* 123839 123963 123691 123840 123711 Length 3 m (10 ft) 4. 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.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. 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 (25 ft) 10 m (35 ft) 15 m (50 ft) Part no.INSTALLATION Power supply to gas console cables 5 Control cable Part no.

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

128989 128990 128782 128967 128786 128991 Length 3 m (10 ft) 4.5 m (15 ft) 7. 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.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 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 7 Green Blue Black HPR130XD Manual Gas Instruction Manual Red Green Black Blue Red 3-23 .

123210 123211 123212 123022 123213 123214 123215 Length 3 m (10 ft) 4.5 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. 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 (15 ft) 6 m (20 ft) 7.5 m (75 ft) 25 m (82 ft) 30 m (100 ft) Part no.5 m (55 ft) 20 m (65 ft) 22. 123216 123023 123494 123851 123217 123741 123218 Length 13.INSTALLATION 8 Power supply to CNC interface cable Part no. 123742 123219 123220 123852 123853 Length 35 m (115 ft) 37.5 m (25 ft) 9 m (30 ft) 10 m (35 ft) 12 m (40 ft) Part no.5 m (45 ft) 15 m (50 ft) 16. 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.

Outputs are optically isolated.3 mA. A jumper is required on J304 to use 24 V power. or dry-contact closure. The maximum rating is 24 VDC at 10 mA. Machine motion is selectable and is used for configurations with multiple plasma systems.INSTALLATION Notes to CNC interface cable run list Note 1. They require 24 VDC at 7. Note 2. The shielding must be terminated to the metal housings at each end to ensure proper grounding and to provide the best shielding. Note 3. The external relay’s life may be improved by adding a metallized-polyester capacitor (0. open collector. HPR130XD Manual Gas Instruction Manual 3-25 . Note 4.022μF 100 V or higher) in parallel with the relay contacts. transistors. CNC +24 VDC provides 24 VDC at 200 mA maximum. Inputs are optically isolated. Caution: The CNC cable must be constructed using cable with 360 degree shielding and metal housing connectors at each end.

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 .INSTALLATION Examples of output circuits 1. Logic interface. active-high HPR C + E 10K (optional) 5 VDC-24 VDC CNC/PLC High-impedance (≤10 mA) 2. Warranty will be void. Do not use this configuration. 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.

022μF 100 V or higher) in parallel with the relay contacts. 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 . Optocoupler interface +24 VDC CNC/PLC HPR Transistor-output optocoupler Power ground 3. 1.INSTALLATION Examples of input circuits Note: The external relay's life may be improved by adding a metallized-polyester capacitor (0. Relay interface +24 VDC Output from CNC/PLC External relay (AC or DC) Power ground HPR 2.

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

228291 228292 228293 228294 228295 228296 228297 228547 Length 2 m (6 ft) 3 m (10 ft) 4.INSTALLATION 10 Torch lead assembly Part no.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. Caution: 10 Do not alter the length of the hoses. 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. HPR130XD Manual Gas Instruction Manual 3-29 .5 m (15 ft) 6 m (20 ft) 7.

INSTALLATION Work lead Work table Part no. 3-30 HPR130XD Manual Gas Instruction Manual .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). 123661 123813 123662 123814 123663 123815 Length 3 m (10 ft) 4.5 m (15 ft) 7.

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. Sleeve Braided cover 4. 2. Coolant return hose 2WRENCHES HPR130XD Manual Gas Instruction Manual 3-31 . They are taped together to help prevent twisting. Uncoil the first 2 meters (6. 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. 3.INSTALLATION E Torch connections Connect the torch to the torch lead assembly 1.5 ft) of the leads on a flat surface.

6.INSTALLATION 5.5 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 . 123983 123984 123985 123986 123987 123988 123989 123990 123991 Length 3 m (10 ft) 6 m (20 ft) 7. Sleeve Braided cover 6b. Ohmic contact wire part numbers (Not part of the HPR130XD system. 6a. Shown for reference only) Part no. Connect the pilot arc lead (yellow). Connect the optional ohmic contact wire. 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.

Connect the coolant supply hose (green). Connect the plasma-gas vent hose (white). push the connector-collar toward the torch. To make a connection. Connect the shield gas hose (blue).INSTALLATION 7. 9. Note: The connectors in steps 7–10 are push-to-connect fittings. To disconnect a fitting. 10.5 in.). HPR130XD Manual Gas Instruction Manual 3-33 . 13 mm (0. and pull the hose away from the torch. push the hose fitting into the appropriate connector until it stops. Connect the plasma gas hose (black). connector-collar 8.

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

See also Torch connections earlier in this section for torch lead connections to ignition console.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. Be certain that there is no space between the torch body and the o-ring on the torch leads. HPR130XD Manual Gas Instruction Manual 3-35 .

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

slow-blow fuses and power cables are customer-supplied and must be chosen as outlined by applicable national and local electrical codes.01 seconds and up to 12 times the rated input current (FLA) for 0. The power supply has a steady-state current listed in the table below. 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. 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.5 kW output 62/60 amps 57 amps 52 amps 33 amps 32 amps 28 amps 26 amps 21 amps Recommended time delay. Use a separate. 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) @ 19.7 mm2 (3 AWG) 26. and line voltage fluctuation).3 mm2 (8 AWG) 8.1 seconds. Use a motor-start circuit breaker or equivalent if time delay high inrush fuses are not permitted by local and national codes.7 mm2 (3 AWG) 21. however actual sizes required will vary based on individual site electrical line conditions (including but not limited to source impedance.3 mm2 (8 AWG) 8.2 mm2 (4 AWG) 8.3 mm2 (10 AWG) Cable AWG recommendations taken from table 310-16 of the National Electric Code handbook (USA). and regulatory requirements.INSTALLATION Power requirements General All switches. line impedance. primary. Installation must be performed by a licensed electrician. product inrush characteristics. line disconnect switch for the power supply. The power supply must be wired into one of the branch-feed circuits.3 mm2 (8 AWG) 8.3 mm2 (8 AWG) 5. 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 . Recommendations on fuse and circuit breaker sizing are listed below.

table 310. Installation must be performed by a licensed electrician and according to applicable national and local codes. 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.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). 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. 3-38 HPR130XD Manual Gas Instruction Manual . 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.

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

Antifreeze contains corrosion inhibitors that will damage the torch coolant system. Hypertherm premixed coolant consists of 69. 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. if temperatures during operation are ever outside of this range. Refer to the Material Safety Data Sheets Appendix for data on safety. Before filling the coolant system. If swallowed.9% water. seek immediate medical attention. Refer to the custom coolant mix recommendations.INSTALLATION Torch coolant requirements The system is shipped without any coolant in the tank. and 0. Caution: Never use automotive anti-freeze in place of propylene glycol. determine what coolant mix is correct for your operating conditions. 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).1% benzotriazole. Upon contact. 10/16/08 3-40 HPR130XD Manual Gas Instruction Manual . flush skin or eyes with water. and harmful or fatal if swallowed. Always use purified water in the coolant mixture in order to prevent damage to the pump and corrosion in the torch coolant system. Observe the warning and cautions below. handling and storage of propylene glycol and benzotriazole. 30% propylene glycol.

Failure to do so could result in a cracked torch head. °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 . 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. hoses or other damage to the torch coolant system due to freezing. the percentage of propylene glycol must be increased.INSTALLATION Custom Coolant mix for cold operating temperatures (below -12° C / 10° F) Caution: For operating temperatures colder than the temperature stated above. Use the chart below to determine what percentage of propylene glycol to use in the mixture. Note: Maximum percentage of glycol should never exceed 50%. Mix 100% glycol (028873) with the premixed Hypertherm coolant (028872) to increase the percentage of glycol.

Always use water that meets the minimum and maximum specifications in the table below when using a custom coolant mix.5 18 1000 Resistivity mΩ-cm at 25° C 18.055 0. 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. Contact a water specialist for advice in choosing a water filtration system. reverse osmosis.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). and 1 part benzotriazole (BZT) to 300 parts of water. Treated water refers to a mixture of purified water. Water that does not meet the maximum purity specifications below can also cause problems.010 0.001 Dissolved solids (ppm of NaCl) 0 0.054 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. BZT (128020) acts as a corrosion inhibitor for the copper based coolant system contained in the plasma system.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 . Use water purified by any method (deionization. water softeners. sand filters.5 495 Grains per gallon (gpg of CaCO2) 0 0. Water purity measurement method Conductivity S/cm at 25° C 0.3 2 0.206 8. Deionized water that is too pure will cause leaching problems with the coolant system plumbing. that meets the specifications below. For operations in very warm temperatures treated water will provide the best cooling properties.) as long as the water purity meets the specifications in the table below. etc.

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

2-stage pressure regulator located within 3 m (10 ft) of the gas console. • • • • Cut speeds can decrease Cut quality can deteriorate Cutting thickness capability can decrease Parts life can shorten Caution: Setting the supply regulators 1. 4. air and nitrogen are required for all systems. Gas supply pressures not within the specifications in Section 2 can cause poor cut quality. Move switch (7) to the CUTFLOW position (right position). Use a high-quality. 6.3 bar (120 psi). While gas is flowing adjust the supply regulator for the plasma gas to 8. Note: Oxygen. Move switch (7) back to the RUN position (center).3 bar (120 psi).3 bar (120 psi). See gas regulators in this section for recommendations. 5.INSTALLATION Gas requirements The customer must furnish all gases and gas-supply regulators for the system. Nitrogen is used as a purge gas. move switch (7) on the gas console to SET PREFLOW. 3. Set all gas regulator pressures to 8. See Section 2 for gas and flow specifications. Move switch (7) to the RUN position. Turn OFF the power to the system. Turn ON the power to the system. 7. 2. While gas is flowing adjust the supply regulator for the shield gas pressure to 8. 8. 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. poor consumable life and operational problems. 3-44 HPR130XD Manual Gas Instruction Manual . After the purge cycle stops.

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

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. As a precaution. pressurize the entire system and check for leaks. Do not use steel or aluminum pipe. Installation must be made in accordance with national and local codes.INSTALLATION Supply gas plumbing Rigid copper plumbing or suitable flexible hose may be used for all gas supplies. nitrogen or argon-hydrogen. Caution: When configuring the gas console to the supply gases. Flashback arrestors are required (unless not available for specific gases or required pressures) to prevent fire from propagating to supply gas. use a hose designed for inert gas to carry air. hose connections and fittings are acceptable for use with oxygen. WARNING 3-46 HPR130XD Manual Gas Instruction Manual . argon-hydrogen and methane. Recommended hose diameters are 9.5 mm (3/8 in) for lengths < 23 m (75 ft) and 12. make sure that all hoses. Note: When cutting with oxygen as the plasma gas. After installation.5 mm (1/2 in) for lengths > 23 m (75 ft). For flexible-hose systems. air must also be connected to the gas console to achieve the proper mixtures in the preflow and cutflow conditions. Hypertherm recommends that an exhaust ventilation system be installed when cutting with oxygen.

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

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. 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. 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.5 m (15 ft) 7.5 m (15 ft) 7.5 m (15 ft) 7. 024210 024203 024134 024211 024112 024763 Length 3 m (10 ft) 4.5 m (25 ft) 10 m (35 ft) 15 m (50 ft) 20 m (65 ft) Part no. 024671 024658 024659 024765 024660 024766 Length 3 m (10 ft) 4.INSTALLATION Supply gas hoses 12 Oxygen hose Part no.5 m (15 ft) 7. 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 . 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.5 m (25 ft) 10 m (35 ft) 15 m (50 ft) 20 m (65 ft) Part no. 024607 024204 024205 024760 024155 024761 Length 3 m (10 ft) 4.5 m (25 ft) 10 m (35 ft) 15 m (50 ft) 20 m (65 ft) Part no.

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

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

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

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

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

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

replace the electrode when the pit depth is 0. 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.06 inches or greater.OPERATION Inspect consumables Inspect Look for Erosion. Center surface: Emitter wear . O-rings: Damage Lubricant 4-10 HPR130XD Manual Gas Instruction Manual . replace when damaged Replace swirl ring Apply a thin film of silicone lubricant if the o-rings are dry In general. 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. For the 400 amp mild steel electrode and all SilverPlus electrodes. replace the electrode when the pit depth is 0.a pit forms as the emitter wears.04 inches or greater. 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.

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

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

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

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

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

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

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

The arc voltage setting is dependent on the bevel angle and the setup of the cutting system. Equivalent thicknesses are listed in the cut chart. The vertical distance from the lowest point of the torch to the surface of the workpiece. Equivalent thickness is equal to the nominal thickness divided by the cosine of the bevel angle. The arc voltage setting on one system may be different from a second system even if the workpiece is the same thickness. The largest number is for a 45° bevel cut with a clearance of 3 mm (0.120 in). The vertical thickness of the workpiece. If the torch is perpendicular to the workpiece. The smallest number is for a straight cut (bevel angle = 0°). The arc voltages for bevel cutting are not supplied in the bevel cut charts.OPERATION Bevel cutting definitions Bevel angle The angle between the center line of the torch and a line that is perpendicular to 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 length of the cut edge. A range of torch-to-work distances are listed in the cut chart. The maximum bevel angle is 45°. 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 bevel angle is zero.

135" 1/4" 3/8" 1/2" 3/4" 1" HPR130XD Manual Gas Instruction Manual 4-19 .071 0.047 0.483 0.245 2.083 1.803 1.642 3.043 0.021 0.107 0.718 1.042 0.083 2.372 1.109 0.OPERATION Estimated kerf-width compensation The widths in the chart below are for reference.054 0.073 0.074 0.533 0.019 0.015 0.083 0.006 0.769 2.194 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 1.086 0.429 1.5 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 0.381 0.060" 0.023 0.072 0.114 0.229 1.075 0.095 0.829 1.104 0.107 0.068 0.032 1.879 2.073 0.080 0.896 0. Differences between installations and material composition may cause the specific user results to vary from those shown in the table.184 2.718 2.413 2.009 0.092 2.905 2.516 1.896 1.067 1.114 0.060 0.082 0.057 0.108 2.769 2.727 1.448 1.049 0.740 1.152 2.854 2.082 0.053 0.346 1.135 0.584 0.109 0.

10 0.048 0.5 0.030 0.5 0.4 0.8 1 1.090 0.0 Plasma Shield Plasma Shield Plasma Shield 15 15 1.7 0.110 0.5 in 0.7 1.5 0.075 0.5 2 2.1 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 2.135* 3/16* 1/4* Arc Torch-to-Work Cutting Voltage Distance Speed Volts 114 115 116 117 119 120 122 123 128 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 0.5 2.050 in ipm 215 200 170 155 110 85 60 50 40 30 25 Initial Pierce Height in factor % Pierce Delay Time seconds 0.0 Plasma Shield Plasma Shield Plasma Shield 15 15 O2 O2 80 35 92 5 75 0.2 1.036 0.7 1.3 180 0.024 0.105 0.2 0.OPERATION Mild steel O2 Plasma / O2 Shield 30 A Cutting Note: Air must be connected to use this process.018 0.3 O2 O2 80 35 92 5 75 1.5 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 0.3 180 0.060 0.3 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 English Select Gases Set Preflow Set Cutflow Material Thickness in 0.2 2.1 0.4 2.

08 0.1 0.0 2.0 0.5 3.030 0.OPERATION Mild steel O2 Plasma / O2 Shield 50 A Cutting Note: Air must be connected to use this process.105 0.5 2 O2 O2 70 30 75 15 2.0 factor % Pierce Delay Time seconds Plasma Shield Plasma Shield Plasma Shield English Select Gases Set Preflow Set Cutflow Material Thickness in 0.10 factor % Pierce Delay Time seconds Plasma Shield Plasma Shield Plasma Shield O2 O2 70 30 75 15 0.04 ipm 270 210 160 125 110 80 60 50 35 25 Initial Pierce Height in 0.1 0.16 0.2 0.6 200 0.3 mm 1. 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 0.12 0.2 1.05 200 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 2.8 1 1.135 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 0.060 0.4 Initial Pierce Height mm 2.5 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 2.0 0.5 in 0.0 0.3 0.3 0.0 mm/m 6500 5000 4150 3200 2700 2200 1800 1400 1200 950 780 630 4.2 0.036 0.075 0.0 1.5 1.048 0.08 0.10 0.10 Marking Speed mm/min 6350 2540 ipm 250 100 Arc Voltage Volts 118 77 HPR130XD Manual Gas Instruction Manual 4-21 .06 0.5 2.

200 0.8 0.0 6.3 0.8 0.3 0.1 0.0 200 0.5 mm/m 9810 7980 6145 4300 3045 1810 1410 1030 545 Initial Pierce Height mm 3.0 in 0.9 Plasma Shield Plasma Shield Plasma Shield 30 O2 Air 50 30 72 2.2 0.100 ipm 400 290 180 155 110 75 50 37 25 Initial Pierce Height in 0.1 0.7 0.160 200 0.8 factor % 150 Pierce Delay Time seconds 0.250 250 0.075 0.5 0.105 0.5 3.12 Marking Speed mm/min 6350 2540 ipm 250 100 Arc Voltage Volts 130 78 4-22 HPR130XD Manual Gas Instruction Manual .5 0.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 2.135 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 0.10 0.3 250 2.7 0.0 15 5.5 English Select Gases Set Preflow Set Cutflow Material Thickness in 0.150 factor % 150 Pierce Delay Time seconds 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 2.100 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 2.9 Plasma Shield Plasma Shield Plasma Shield 30 O2 Air 50 30 72 0.2 4.080 15 0.

135 3/16 1/4 3/8 1/2 5/8 3/4 in 0.8 0.12 Marking Speed mm/min 6350 2540 ipm 250 100 Arc Voltage Volts 130 78 HPR130XD Manual Gas Instruction Manual 4-23 .7 0.6 mm/m 9810 7980 6145 4300 3045 1810 1410 1030 545 Initial Pierce Height mm 3.8 factor % 150 Pierce Delay Time seconds 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 2.9 Plasma Shield Plasma Shield Plasma Shield 48 O2 Air 50 48 72 2.200 0.6 English Select Gases Set Preflow Set Cutflow Equivalent Minimum Torch-to-Work Cutting Material Clearance Distance Speed Thickness in in 0.2 0.5 3 4 6 10 12 15 20 mm 2.0 200 0.10 0.3 0.08 0.0 in 0.2 4.34 ipm 400 290 180 155 110 75 50 37 25 Initial Pierce Height in 0.5 – 8.250 250 0.7 0.160 200 0.0 – 8.0 6.34 24 0.1 – 0.1 0.5 3.150 factor % 150 Pierce Delay Time seconds 0.3 250 2.9 Plasma Shield Plasma Shield Plasma Shield 48 O2 Air 50 48 72 0.6 24 5.8 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 2.5 0.105 0.5 0.0 2.75 0.1 – 0.1 0.08 – 0.5 – 8.3 0.

5 mm/m 6505 5550 4035 2680 2200 1665 1050 550 375 255 7.7 1.0 5.240 0.110 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 2.8 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 2.2 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 0.6 200 factor % Pierce Delay Time seconds 0.0 1.5 0.160 0.1 0.220 0.5 3.8 Plasma Shield Plasma Shield Plasma Shield English Select Gases Set Preflow Set Cutflow Material Thickness in 0.8 4.2 0.7 1.10 0.3 0.150 0.180 ipm 240 190 150 110 80 60 45 20 15 10 Initial Pierce Height in 0.3 0.6 190 Edge start Initial Pierce Height mm 5.0 4.100 0.5 2.130 0.120 0.6 6.0 6.3 3.300 190 Edge start 200 factor % Pierce Delay Time seconds 0.0 1.200 0.0 3.0 in 0.5 0.8 3.1 0.260 0.

0 – 8.3 0.0 6.1 0.080 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 2.5 0.4 190 220 Edge start 200 factor % Pierce Delay Time seconds 0.0 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 0.1 0.6 4. Use ohmic contact during IHS.2 7.0 12 15 20 25 49 32* 38 mm 2. Turn preflow on during IHS.0 5.340 0.340 0.220 0.12 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: 1.3 0.5 0.6 6.340 0.6 190 220 Edge start Metric Select Gases Set Preflow Set Cutflow Minimum Clearance mm Initial Pierce Height mm 5.0 – 8.8 4.100 – 0.260 0.130 – 0.0 1.6 3.135 3/16 1/4 3/8 1/2 5/8 3/4 1 1-1/4* 1-1/2 in 0.340 0.110 – 0.340 0.0 Plasma Shield Plasma Shield Plasma Shield 30 33 O2 Air 15 80 23 0.340 0.5 – 8.6 2.2 0.180 – 0.200 0. 2.240 0.7 1. Use pierce complete when piercing HPR130XD Manual Gas Instruction Manual 4-25 .340 ipm 240 190 150 110 80 60 45 20 15 10 Initial Pierce Height in 0.0 in 0.6 200 factor % Pierce Delay Time seconds 0.120 – 0.6 mm/m 6505 5550 4035 2680 2200 1665 1050 550 375 255 10.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 2.150 – 0.8 – 8. 3.8 4.6 3.8 – 8.3 – 8.0 1.5 3.10 0.300 0.2 0.160 – 0.6 4.6 3.5 – 8.7 1.

048 0.3 English Select Gases Set Preflow Set Cutflow Material Thickness in 0.5 2.10 0.2 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 0.075 0.105 0.1 0.150 150 0.060 0.1 Plasma Shield Plasma Shield Plasma Shield N2 N2 35 5 55 60 2.0 0.2 0.8 150 0.8 1 1.5 in 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 0.036 0. F5/N2 stainless steel process.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 3. 4-26 HPR130XD Manual Gas Instruction Manual .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.2 1.135 Arc Torch-to-Work Cutting Voltage Distance Speed Volts 94 95 97 101 103 0.100 in ipm 240 210 180 160 120 75 Initial Pierce Height in factor % Pierce Delay Time seconds 0.5 2 2.0 0.

5 2.5 in 0. N2/N2 stainless steel process.0 English Select Gases Set Preflow Set Cutflow Material Thickness in 0.075 0.150 15 0.3 0.5 2.2 3.105 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 2.8 1 1.8 150 F5 N2 35 25 55 60 15 101 102 103 104 110 0. HPR130XD Manual Gas Instruction Manual 4-27 .2 1.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 0.5 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 2.048 0.060 0.3 190 0.036 0.5 2 2.10 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.2 Initial Pierce Height in factor % Pierce Delay Time seconds Plasma Shield Plasma Shield Plasma Shield 60 F5 N2 35 25 55 150 0.080 190 0.4 0.5 0.135 3/16 1/4 99 100 102 104 108 110 0.100 Arc Torch-to-Work Cutting Voltage Distance Speed Volts in ipm 240 190 150 130 90 65 45 30 0.

120 ipm 105 60 45 25 Initial Pierce Height in 0.8 4.3 0.2 0.0 2.0 mm/m 2180 1225 560 Initial Pierce Height mm 4.150 0.135 3/16 1/4 3/8 Arc Torch-to-Work Cutting Voltage Distance Speed Volts 108 110 112 120 in 0.5 3.170 0.100 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 2.2 150 0.110 0.5 factor % 150 Pierce Delay Time seconds 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 0.12 Marking Speed mm/min 6350 2540 ipm 250 100 Arc Voltage Volts 95 60 4-28 HPR130XD Manual Gas Instruction Manual .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 3.3 0.0 in 0.5 3.180 0.180 factor % Pierce Delay Time seconds 0.5 3.120 0.

5 0.0 in 0.3 0.8 4.150 0.0 3.140 0. HPR130XD Manual Gas Instruction Manual 4-29 .5 0.8 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 2.12 Marking Speed mm/min 6350 2540 ipm 250 100 Arc Voltage Volts 140 75 Note: This process produces a rougher. H35/N2 process.3 mm/m 1960 1300 900 670 305 Initial Pierce Height mm 6.5 3.170 ipm 75 55 30 25 15 Initial Pierce Height in 0.0 Edge start factor % 200 Pierce Delay Time seconds 0. and the cut edges are closer to perpendicular than the 130 A.120 0.240 0.3 0.10 0.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 3.5 3.0 7. darker cut edge with more dross.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 0.280 Edge start factor % 200 Pierce Delay Time seconds 0.

3 0.5 7.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. N2/N2 process.5 0.3 Plasma Shield Plasma Shield Plasma Shield 0.3 Plasma Shield Plasma Shield Plasma Shield 4.8 1. 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 0.0 in 0.310 170 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 2.8 1.10 0.5 3. 4-30 HPR130XD Manual Gas Instruction Manual .12 Marking Speed mm/min 6350 2540 ipm 250 100 Arc Voltage Volts 130 75 Note: This process produces a smoother. shinier cut edge with less dross.3 0.5 0.180 0.

3 0.170 – 0.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 3.5 – 10.400 0.150 – 0.12 Marking Speed mm/min 6350 2540 ipm 250 100 Arc Voltage Volts 140 75 HPR130XD Manual Gas Instruction Manual 4-31 .400 0.0 mm/m 1960 1300 900 670 305 Initial Pierce Height mm 6.120 – 0.140 – 0.0 – 10.5 0.8 Plasma Shield Plasma Shield Plasma Shield N2 N2 20 65 70 80 0.400 ipm 75 55 30 25 15 Initial Pierce Height in 0.240 0.5 3.0 3.0 in 0.400 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 2.280 Edge start factor % 200 Pierce Delay Time seconds 0.0 4.3 – 10.0 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 0.8 Plasma Shield Plasma Shield Plasma Shield N2 N2 20 65 70 80 2.0 7.5 0.3 0.0 Edge start factor % 200 Pierce Delay Time seconds 0.10 0.0 3.8 – 10.

3 Plasma Shield Plasma Shield Plasma Shield H35 N2 20 40 70 80 2.400 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 0.310 170 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 2.080 0.5 – 10.8 1.5 0.3 0.180 – 0.8 1.12 Marking Speed mm/min 6350 2540 ipm 250 100 Arc Voltage Volts 130 75 4-32 HPR130XD Manual Gas Instruction Manual .0 7.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 0.3 Plasma Shield Plasma Shield Plasma Shield H35 N2 20 40 70 80 0.5 0.5 3.10 0.0 4.3 0.0 in 0.

180 0.5 0.102 0.5 2 2.2 1.040 0.110 0.064 0.0 0.4 0.5 2.8 3.6 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 2.070 0.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 1.8 150 2.5 3.120 0.3 0.150 150 0.051 0.2 40 1.2 0.10 0.3 0.5 in 0.10 Marking Speed mm/min 6350 2540 ipm 250 100 Arc Voltage Volts 85 75 HPR130XD Manual Gas Instruction Manual 4-33 .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 0.6 English Select Gases Set Preflow Set Cutflow Material Thickness in 0.5 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 2.7 4.100 0.

110 0. 4-34 HPR130XD Manual Gas Instruction Manual .5 0.240 0.8 1.5 0.260 0.0 in 0.220 0.120 0.140 0.6 6.6 7.5 4.8 1.3 0.2 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 2.3 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 2.160 ipm 90 60 45 40 30 20 Initial Pierce Height in 0.0 mm/m 2370 1465 1225 1050 725 525 Initial Pierce Height mm 5.0 6.10 0.5 3.0 N/A 200 factor % Pierce Delay Time seconds 0.3 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 0.2 0.0 3.12 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.3 0.3 3.8 3. H35/N2 process.280 N/A 200 factor % Pierce Delay Time seconds 0.130 0.

5 0.5 7.0 in 0. HPR130XD Manual Gas Instruction Manual 4-35 .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 4.7 factor % 130 170 Edge start Pierce Delay Time seconds 0.8 1.10 0. Air/Air process.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 0.3 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 2.12 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.5 3.8 1.180 in 0.0 mm/m 1615 1455 1305 940 540 Initial Pierce Height mm 6.5 mm 5.310 factor % 130 170 Edge start Pierce Delay Time seconds 0.260 0.3 0.200 ipm 65 55 50 40 20 Initial Pierce Height in 0.5 0.3 0.

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

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

see the Preventive Maintenance Schedule. property damage or personal injury. The large blue capacitors store high voltage. Knowledge of final isolation troubleshooting techniques is also assumed. on the chopper and the heatsinks. Refer to the Safety section for operating precautions and warning formats. Contact the Technical Services department listed at the front of this manual with any questions regarding the maintenance schedule or procedures. located at the end of this section. WARNING Routine maintenance For a complete list of routine maintenance recommendations. maintenance personnel must perform all testing with safety in mind. 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. Even if the power is off. dangerous voltages exist at the capacitor terminals. In addition to being technically qualified. SHOCK HAZARD Use extreme care when working near the chopper modules. Discharging any capacitor with a screwdriver or other implement may result in an explosion.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.

Control cable: Provides 120 VAC control power to the solenoid valves. Power cable: Provides 120 VAC to the ignition console and control power to the off-valve assembly. Signal cable: Provides process and status signals between the power supply and the gas console. 5-4 HPR130XD Manual Gas Instruction Manual .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 . 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. Idle Gas pressure ok Coolant flow on Chopper current off Line voltage ok 4. Preflow – 2 second flow of gas 5. main contactor and pilot arc relay are on High frequency present Chopper current sensor = pilot arc current 6. 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. Ramp-down – Current and gas flow decreases after plasma start has been removed Cutflow gas off 10.MAINTENANCE Sequence of operation 1. 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. 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.

or N2/Air) to a fuel gas process (H35/N2. or 12 seconds with a manual gas console. a preflow purge and a cutflow purge. 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. or 12 seconds with a manual gas console. if nitrogen is not connected to the gas system. for 12 seconds. there will be 3 stages to the purge process. or F5/N2) or the reverse. 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 . If error code 42 is not resolved in 3 minutes. the system automatically goes through a purge process. The purge process has 2 stages. or the operator changes from one process to another. There are 2 exceptions to the process described above. Nitrogen will purge the gas system first. Exception 2 – no purge process will occur if the operator changes from any process to a nitrogen marking process.MAINTENANCE Gas system purge cycle When the system is turned on. it will be replaced by error code 139 (purge time-out error). Gas system valve usage The following tables show which valves are active for each cutting process. Note: Error code 42 (low nitrogen gas pressure) will be displayed. The preflow purge gas is turned on for 8 seconds with an auto gas console. Air/Air. The preflow and cutflow purges will follow the nitrogen purge.

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.

Verify proper preflow and cut-flow settings. 2. Look for leaks and loose connections between the selection console and the metering console. No action required. HPR130XD Manual Gas Instruction Manual 5-11 . is running. Perform gas flow test (see Maintenance section). 5. 6. Verify that the consumable parts are in good condition. Perform gas leak tests (see Maintenance section). Corrective action None needed. Pump output has exceeded 15. 012 013 Test passed The test was successful. Replace the shield if the holes are blocked. test signal). 9. 016 Verify that there is no obstruction in the plasma vent hose. 017 Inspect the holes in the shield for obstructions. 4. Plasma pressure did not decrease in the time allowed. Test in progress One of the gas test modes Wait for the test to finish. which indicates a leak.MAINTENANCE Error code troubleshooting – error codes 000 to 020 Error code number 000 Name No error Description System is ready to run. 7. Verify that there are no restrictions in the coolant system. Inspect CON1 and pilot arc relay for excessive wear. 020 No current detected from No pilot arc chopper at ignition and before 1-second timeout. 8. Verify spark across spark gap. 3. 1. 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. The test ensures that the coolant flow is correct before firing the torch. The gas pressure in channel 2 is decreasing. 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. Perform start circuit test (see Maintenance section).5 bar (225 psi). Perform torch lead test (see Maintenance section). Verify that coolant filters are in good condition. 018 1. 015 Look for leaks and loose connections between the selection console and the metering console. Shield pressure did not decrease in the time allowed. which indicates a leak. Perform chopper test (see Maintenance section). 2.

scrap cutting. Perform chopper test (see Maintenance section). Inspect power cord. Only 5. etc). Replace board if fuses are blown. Verify that the consumable parts are in good condition. Verify pierce delay time. 1. 025 026 027 Phase imbalance to Lost phase chopper after contactor engaged or while cutting. 4. Inspect work lead for damage or loose connections. 5. scrap cutting. HPR400 Chopper 3 after transfer. remove cover on contactor and inspect contacts for excessive wear. 7. Verify arc did not lose contact with plate while cutting (hole HPR400 cutting. 2. Lost current 2. after pilot arc current was 3. Verify arc did not loose contact with plate while cutting Lost transfer transfer completed. Chopper 1 Chopper 1 after transfer. Inspect work lead for damage or loose connections. etc). Verify proper cut-flow gas settings. Try connecting work lead directly to the plate.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. etc). 5-12 HPR130XD Manual Gas Instruction Manual . established. 5. 3. Verify pierce delay time. 4. Disconnect power to power supply. Inspect phase loss fuses on Power Distribution board. Chopper 3 Lost the current signal from 3. Verify pierce delay time. Perform chopper test (see Maintenance section). 024 1. Lost current Lost the current signal from 3. scrap cutting. Verify proper pierce height. Chopper 2 Lost the current signal from 3. Lost current 2. 5. Verify that the consumable parts are in good condition. 1. Verify proper cut-flow gas settings. Perform chopper test (see Maintenance section). 4. Verify phase-to-phase voltage to power supply. 028 1. (hole cutting. Verify proper cut-flow gas settings. Verify proper cut-flow gas settings. 5. etc). and input to chopper for loose connections. Lost the transfer signal after 4. Verify arc did not lose contact with plate while cutting (hole cutting. 3. Verify pierce delay time. contactor. Verify that the consumable parts are in good condition. Verify proper preflow and cut-flow settings. Verify arc did not lose contact with plate while cutting (hole Only cutting. HPR260 Chopper 2 after transfer. 1. work lead 500 milli-seconds 2. scrap cutting. Verify that the consumable parts are in good condition. 2. 2. Perform chopper test (see Maintenance section). Perform phase loss test (see Maintenance section). 6. 4.

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. Only 031 Start lost 1. 1. it could be waiting for an IHS complete input from another torch. 2. 3. 030 Gas system error A failure has occurred in Auto Gas the gas system. 4.27 bar (120 psi). HPR130XD Manual Gas Instruction Manual 5-13 . 034 Lost current Lost the current signal Chopper 4 from Chopper 4 after HPR400 transfer.MAINTENANCE Error code troubleshooting – error codes 030 to 042 Error code number Name Description Corrective action 1. Start signal was received 2. Verify arc did not lose contact with plate while cutting (hole cutting. gas process and an oxidizer process. Check the interface cable for damage. Replace the relay. Verify that cable number 5 (power supply-to-gas console control cable) is not damaged and is properly connected to PCB3 and to the rear of the gas console. 2. Verify that D1 (+5 VDC) and D2 (+3.34 bar (5 psi) – marking (N2) gas During N2 purge. or low inlet-gas pressure. If CNC interface cable is good and it is a 1-torch system. then PCB2 or PCB3 has failed. 032 Hold timeout Hold signal was active for longer than 60 seconds. Verify proper cut-flow gas settings. scrap cutting. Verify that the gas regulator is set to 8. Inspect interface cable for damage. 0. when 2. was established. 3. 3. See pressure changing between a fuel Setting the supply regulators (Installation section). 3. Verify that the consumable parts are in good condition. etc). 2. The hold wires may be short-circuiting inside. These LEDs indicate power to PCB2. or poor and then lost before an arc electrical connections. If interface cable is good and a relay is not driving the start input. this relay is either bouncing when activated or the contacts are faulty.07 bar (30 psi) – cutting 1. 4.Verify that the nitrogen supply is turned on and inspect gas Low nitrogen supply pressure and volume of gas remaining in supply tanks. 033 Precharge time-out Auto Gas Only Selection console was not This is a warning for a possible gas restriction in the leads. able to charge the lines to Verify that there are no restrictions in the plasma and shield the correct value. Verify pierce delay time. 1. hoses. Use the CAN tester to verify which board needs to be replaced. the CNC is dropping the start signal before a steady state arc has been established. If a mechanical relay is being used to provide the HPR with a start signal. 5. faulty crimps. Perform chopper test (see Maintenance section). change PCB3. The CNC is maintaining this input. 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. Only 042 Nitrogen gas pressure under lower limit of 2.

58 bar (110 psi) – manual disconnect plasma and shield hoses exiting off-valve. pins 3 and 4. less than the lower limit of 5. It should be about 0. pins 3 and 4 on PCB2 in the power supply. Verify gas supply pressure settings. Verify 120 VAC voltage on plug J2. Verify gas regulator settings on gas console with cut chart. J2. Plasma gas pressure over 3. 4.65 bar (140 psi) – auto If pressures decrease a valve is not functioning or no power to the valve. High plasma upper limit of: 4. If AC voltage on PCB2.4. See Setting the supply regulators (Installation section). 5-14 HPR130XD Manual Gas Instruction Manual . 2. Inspect gas supply pressure and volume of gas remaining in supply tanks.38 VDC.38. If the voltage on plug J4 is greater than 108 VAC. but the DC voltage on TP23 and TP2 is less than 0. Verify the voltage on PCB1 in the cooler with a DC volt meter. is greater than 108 VAC and the DC voltage between TP23 and TP2 on PCB1 in the cooler is also greater than 0. gas pressure 7. If the AC voltage on PCB2 in the power supply at J2. 2.34 bar (5 psi) – preflow Low plasma 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. 2. See Setting the supply regulators (Installation section). verify minimum 108 VAC operation is voltage on plug J4. between PCB2 in the power supply and J4 on PCB1.45 bar (50 psi) – cutflow gas pressure (cutting) 0. Verify power to valves. replace PCB1. verify the CAN link between PCB3 in the power supply and PCB1 in the cooler. 108 VAC and DC voltage between TP23 and TP2 on The normal lower limit for PCB1 is less than 0. Solenoid at off-valve is not opening. Verify the gas regulator settings on gas console with the parameters in the cut charts. 3.34 bar (5 psi) – cutflow (marking) 1. Perform gas leak tests (Maintenance section). is greater than 102 VAC (120 VAC -15%). 4.415 VDC between TP23 and Line voltage is close to or TP2 on PCB1. pins 3 and 4. 6. 045 1. 046 Low line voltage 1. Verify input-line voltage at PCB2 in the power supply and PCB1 in the cooler. Verify fuses on PCB2 in the power supply. 3. Verify the wiring 108 VAC (120 VAC -10%). 9. pins 1 and 2 on PCB1. Voltage needs to be within 10% of nominal (120 VAC).4.38 VDC.4.

See Setting the supply regulators (Installation section).14 bar gas pressure (2 psi). CAN communications 3. If the voltage on plug J4 is less than 132 VAC. 048 CAN error 050 1. verify the CAN link between PCB3 in the power supply and PCB1 in the cooler. 3. 4. Verify gas regulator settings on gas console with cut chart. 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. 2. If the AC voltage on PCB2 in the power supply on plug J2. 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. Verify wiring between (120 VAC +10%). 4. It Should be about 0. 1. is less than (120 VAC +15%). Verify input-line voltage at PCB2 in the power supply and PCB1 in the cooler. If circuit is open. and LEDN300J is illuminated with CNC Interface cable removed from PCB3.415 VDC between TP23 and greater than the upper limit TP2 on PCB1. If the circuit is closed either the CNC is issuing a plasma start or the CNC interface cable is damaged. 132 VAC and DC voltage between TP23 and TP2 on PCB1 The normal upper limit for is greater than 0. PCB2 in the power supply and J4 on PCB1. 4. of 138 VAC 5.4. is less than 132 VAC and the DC voltage between TP23 and TP2 on PCB1 in the cooler is also less than 0. but the DC voltage on TP23 and TP2 is greater than 0.3 VDC) are illuminated between the power supply on PCB2 inside the gas console. Start signal Plasma start signal input is 3.44 VDC. 4. Stop or clear the cutting program. power to PCB2. 2.44 VDC. Perform gas leak tests (Maintenance section). Verify that D1 (+5 VDC) and D2 (+3. pins 3 and 4. 2. Shield pressure is below Low shield lower limit of 0. 6. replace PCB1. Verify that the CNC interface cable is not damaged. 5.44. power-up power supply. 1. The plasma start signal to the plasma was not dropped after the last cut. Voltage needs to be within 10% of nominal (120 VAC).4. 3. pins 3 and 4. 2. 053 HPR130XD Manual Gas Instruction Manual 5-15 . Verify 120 VAC voltage on plug J2. pins 3 and 4 on PCB2 in the power supply. J2.4.MAINTENANCE Error code troubleshooting – error codes 047 to 053 Error code number Name Description Corrective action 047 High line voltage 1. then PCB2 or PCB3 has failed. 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. replace PCB3. These LEDs indicate and the gas console. If AC voltage on PCB2. Verify gas supply pressure and that a sufficient volume of gas remains in your supply. Verify fuses on PCB2 in the power supply. Verify the voltage on PCB1 in the cooler with a DC volt Line voltage is close to or meter. Use the CAN tester to verify which board needs to be replaced. verify maximum 132 VAC voltage operation is 132 VAC on plug J4. If power is present at PCB2 and PCB3 and both gas console cables are good. pins 1 and 2 on PCB1.

upper limit of: gas 3. replace the control board.the process parameters may not have been downloaded. Verify power to valves. Increase or decrease the (50 psi) or greater than inlet gas pressure to correct the problem. Verify that gas pressure transducer P2 is between 3. 5-16 HPR130XD Manual Gas Instruction Manual . 058 060 061 1. No plasma the gas selector knob.45 bar 1. Shield gas pressure is over High shield 2. Auto gas . If no LED is illuminated. Increase or decrease the Auto Gas when mixing or greater than inlet gas pressure to correct the problem. Only 9. 9. Reset the knob. Verify that the process information can be Manual gas .The selection console (manual) is illuminated. See Setting the supply regulators (Installation section). Verify pressure settings on gas console with cut chart. Increase or decrease the Auto Gas 9. 4.MAINTENANCE Error code troubleshooting – error codes 054 to 061 Error code number Name Description Corrective action 054 1. proper working condition. Motor valve 2 inlet pressure 1. a valve is not functioning or no power to the valve. Cut gas 2 outlet pressure is less than 3.65 bar (140 psi).38 bar (20 psi) (50 psi) and 9.45 bar pressure (50 psi) or greater than (50 psi) and 9. MV1 inlet pressure Auto Gas Only MV2 inlet pressure Auto Gas Only Motor valve 1 inlet pressure 1. 1.65 bar (140 psi) in the inlet gas pressure to correct the problem.65 bar (140 psi) for nonmixing and mixing. 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 . Verify that gas pressure transducer P4 is between 3.the selector knob (2) may be set between not receiving signals from positions.45 bar (50 psi) and 9. Manual gas .65 bar (140 psi).45 bar Cut gas 2 (50 psi) for non-mixing. Verify that the correct consumables are properly installed.45 bar (50 psi) and 9. or 1.65 bar (140 psi) – auto pressures decrease.58 bar (110 psi) – manual pressure disconnect plasma and shield hoses exiting off-valve. 7. If the problem still exists. Only selection console.65 bar (140 psi).3 lpm coolant flow (0.45 bar is less than 3.45 bar pressure less than 1. If 9. Verify that gas pressure transducer P1 is between 3.65 bar (140 psi).45 bar is less than 3. 3. 9. console control board is 2. Verify that gas pressure transducer P3 is between 3. Perform the coolant flow test procedure in the Maintenance section of the manual. Coolant flow is less than Low the required 2.65 bar (140 psi).The gas viewed on the CNC screen. 055 056 057 Cut gas 1 outlet pressure is Cut gas 1 less than 3. Verify gas supply regulator settings. 2. Increase or decrease the (50 psi) or greater than inlet gas pressure to correct the problem.6 gpm). console is not receiving the verify that the fuse on the power distribution PCB is in plasma gas type signal.65 bar (140 psi). Solenoid at off-valve is not opening.

The gas viewed on the CNC screen. If no LEDs are console is not receiving the illuminated. If wiring is good. Spinning fan blades should be difficult to see. is less than or equal to 2.202. Verify that the voltage on the rear side of J3. inspect wiring between the transformer's temperature sensor and J3. 4.9 VDC. If the voltage is low. 1. If the voltage is low. If wiring is good and overtemp error does not clear after 30 minutes of the power supply idling with the fans running.MAINTENANCE Error code troubleshooting – error codes 062 to 067 Error code number Name Description Corrective action 062 1. No shield gas the gas selector knob. pins 2 and 3 Chopper 1 has overheated. Blow dust out of system especially from fans and large power transformer. If voltage is low or near 0 VDC. 4. Allow the power supply to idle with the fans running for a minimum of 30 minutes to cool the large power transformer. especially from fans and heat sink of chopper. Spinning fan blades should be difficult to see. Verify that all the large fans are operating properly. 3. Verify that all chopper fans are operating properly. Replacement kit part number is 228309. pins 5 and 6 Chopper 2 has overheated.202 pins 13 and 14. 3. 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 . 6. 065 Chopper 1 overtemp 066 Chopper 2 overtemp HPR260 HPR400 Only 067 Magnetics overtemp Power transformer has overheated. Manual gas . Replace the transformer's temperature sensor if it is open or shorted. the transformer has overheated. is less than or equal to 2.the selector knob (2) may be set between not receiving signals from positions. is equal to or less than 3.the process parameters may not have been downloaded. If wiring is good and overtemp error does not clear after 30 minutes of the power supply idling with the fans running.202 pins 4 and 5. 1. HPR130XD Manual Gas Instruction Manual 5-17 .202. 3. Reset the knob. replace the chopper. If the problem still exists. Verify that all chopper fans are operating properly. Auto gas . on PCB3. verify that the fuse on the power distribution shield gas type signal. 5. especially from fans and heat sink of chopper. on PCB3.2 VDC. Verify that the process information can be Manual gas . verify correct wiring between chopper temperature sensor and J3. 4. 2. Verify that the voltage on rear side of J3. 3. replace the control board. Blow dust out of system. Look for shorts between wires or to ground. replace the chopper. PCB is in proper working condition.202 pins 14 and 15. 5. console control board is 2. Blow dust out of system.202 pins 1 and 2. 1. 5. 2.The selection gas console (manual) is illuminated. 4. Spinning fan blades should be difficult to see.9 VDC. verify correct wiring between chopper temperature sensor and J3. 2. Verify that the voltage on rear side of J3.

verify correct wiring between chopper temperature sensor and J3. verify correct wiring between chopper temperature sensor and J3.5 pins 6 and 8. 3. pins 5 and 6. 076 See the chopper test later in this section.202. 5.202 pins 10 and 11. If voltage is low. Spinning fan blades should be difficult to see. replace the chopper. inspect wiring between coolant temperature sensor and J1. Verify that the large fan in the cooler is running.8 VDC. the coolant has overheated. especially from fans and heat sink of chopper. 4. 2.5. 071 Coolant overtemp Torch coolant has overheated. 3. Verify that the voltage on rear side of J3. replace the chopper. If wiring is good and overtemp error does not clear after 30 minutes of the power supply idling with the fans running. 2. let system idle with the fans running for 30 minutes to cool. pins 11 and Chopper 4 has overheated.202 pins 7 and 8. is equal to or lower than 2. 072 Auto gas. A current less than 10 amps has been detected by current sensor 4.9 VDC. Auto Gas Only 1. Verify that the airflow to the gas console is not restricted. 073 Chopper 3 overtemp HPR400 Only 1. 4. Verify that all chopper fans are operating properly. 6. especially from fans and heat sink of chopper. 1. Sensor part number is 229224. Replace the coolant temperature sensor if it is open or shorted. control board Control board has overtemp exceeded 90° C (194° F). for shorts to wires or ground. 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. If wiring is good. especially from the heat exchanger. is less than or equal to 2.202. 4. 5. If the voltage is low.9 VDC. 2. 5-18 HPR130XD Manual Gas Instruction Manual . 12 on PCB3. on PCB3. Verify that the voltage on rear side of J3. 3. is less than or equal to 2. Verify that the voltage on the rear side of J1. Blow dust out of the cooler. If wiring is good and overtemp error does not clear after 30 minutes of the power supply idling with the fans running. A current less than 10 amps has been detected by current sensor 3. pins 8 and 9 Chopper 3 has overheated.MAINTENANCE Error code troubleshooting – error codes 071 to 076 Error code number Name Description Corrective action 1. Verify that all chopper fans are operating properly. 5. If the voltage is low. Spinning fan blades should be difficult to see. Blow dust out of system. Blow dust out of system.

See the chopper test later in this section. Swap CS1 with CS2. Verify that the sensor is not open or shorted. Verify that the voltage at CS1 is correct. Verify that the coolant filter is in good condition. If the error code changes to 156. 103 A current greater than High current 35 amps has been on CS1 detected by current sensor 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. High current on CS2 HPR260 HPR400 Only A current greater than 35 amps has been detected by current sensor 2. HPR260 overtemp at power-up. or that the sensor is open. 095 See the chopper test later in this section. 2. High current on CS4 HPR400 Only A current greater than 35 amps has been detected by current sensor 4. flow lost or never was satisfied. If this is a new system. 099 1. Verify that the wiring between CS1 and PCB3 is correct and not damaged. If no jumper is present. or that the sensor is open. If no jumper is present. power-up 2. 4. Verify that the CNC drives the plasma start signal for at least 10 seconds to allow the timed-out pump to turn on again. the chopper is overheated and needs time to cool to 83° C (181. follow start procedure. No coolant Coolant flow signal was 3. Verify that the transformer temperature sensor has not been bypassed or the wires to the temperature sensor are not shorted out in the harness.MAINTENANCE Error code troubleshooting – error codes 093 to 105 Error code number Name Description Corrective action 093 1. See wiring diagrams in section 7 100 101 Magnetics Main transformer is overtemp at indicating an overtemp at power-up power-up. 3. Perform coolant flow tests (Maintenance section). See the chopper test later in this section. the main transformer is overheated and needs time to cool to 150° C (302° F). 2.4° F). the chopper is overheated and HPR400 needs time to cool to 83° C (181. overtemp at power-up. 104 See the chopper test later in this section. Chopper 2 1. if it is not open or shorted. 105 A current less than Low current 10 amps has been on CS1 detected by current sensor 1. replace the original CS1.4° F). Only 1. HPR130XD Manual Gas Instruction Manual 5-19 . 102 Chopper 1 Chopper 1 current signal current at is active at power-up power-up 1. 2. 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. 2.

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

then reconnect JA. replace the motor valve.MAINTENANCE Error code troubleshooting – error codes 124 to 134 Error code number Name Description Corrective action 1. If either illuminates. 2. illuminated on PCB2 inside the gas console.4 VDC or greater at idle. replace PCB3. Verify that the part numbers of PCB2 and PCB3 are correct. 2. Verify that the wiring between CS1 and PCB3 is correct and not damaged. b) If the chopper does not go into overcurrent. a) If LED1 is extinguished with the connector removed. replace the current sensor. white to black = 0 VDC at idle and varies with current output (4 VDC = 100 amps). 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. b) If possible. replace PCB3. These LEDs indicate power to PCB2. Measure voltage across current sensor. 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. Ratio is 4 VDC = 100 amps. a) Red to black = +15 VDC. 5. Green to black = -15 VDC. If they do not illuminate.3 VDC) are received a CAN message. replace the chopper. then PCB2 or PCB3 has failed. take a voltage reading on current sensor while trying to cut. 3. 134 Chopper 1 overcurrent Chopper 1 current feedback has exceeded 160 amps. 124 MV2 error Auto Gas Only Motor valve 2 did not move into position within 60 seconds. Remove connector JA. If the chopper still goes into overcurrent. Verify that D1 (+5 VDC) and D2 (+3. c) If the current sensor voltage is approximately 6.1 from the chopper and verify that LED1 is extinguished. If power is present at PCB2 and PCB3 and both gas console cables are good. console type installed or has not 4. 1. Use the CAN tester to verify which board needs to be replaced. 133 1.1 and try to fire the torch. Verify that LED D19 or D20 is illuminating on the AC valve driver PCB in the selection console. HPR130XD Manual Gas Instruction Manual 5-21 . The power supply control 3.

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

replace the chopper. 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. Ratio is 4 VDC = 100 amps. 1. or that the sensor is open. Replace the control board.4 VDC or greater at idle. Remove connector JC. replace the current sensor. condition. Communication problem to the flash chip on the selection console control board. Replace the control board. 146 1. a) Red to black = +15 VDC. c) If the current sensor voltage is approximately 6. Replace the control board. 145 1. or that the sensor is open. overtemp at power-up. Replace the control board. Green to black = -15 VDC. Corrective action 1. Measure voltage across current sensor. If no jumper is present.4° F).1 and try to fire the torch. replace PCB3. 1. 147 151 Software has detected an Software fail incorrect state or 1. 154 Chopper 3 overcurrent HPR400 Only Chopper 3 current feedback has exceeded 160 amps.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. 152 1.1 from the chopper and verify that LED1 is extinguished. 153 1. a) If LED1 is extinguished with the connector removed. 3. take a voltage reading on current sensor while trying to cut.4° F). 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. HPR130XD Manual Gas Instruction Manual 5-23 . If the chopper still goes into overcurrent. If no jumper is present. b) If possible. 2. the chopper is overheated and needs time to cool to 83° C (181. the chopper is overheated and needs time to cool to 83° C (181. then reconnect JC. Verify that the wiring between CS3 and PCB3 is correct and not damaged. white to black = 0 VDC at idle and varies with current output (4 VDC = 100 amps). 2. 2. Replace power supply control board. Communication problem Internal flash to the flash chip on error the power supply control board. EEPROM memory on PS EEPROM power supply control error board not working. b) If the chopper does not go into overcurrent. overtemp at power-up.

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 .

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

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.

8 1. Verify that the system has the correct level of coolant. An in-line flow meter (part number 128933) is available from Hypertherm. 2.0 Float . when refilling the system after completing steps 1 and 2. 3. 2.8 . Square in both axis. Before testing Note: Coolant must be drained from the system before the in-line filter is cleaned (step 1 below).MAINTENANCE Coolant flow tests If the LED display on the gas console shows a coolant flow error (093 or 060).6 . The following “bucket” tests give a good idea of the flow rate. An in-line flow meter is the most accurate way to measure the flow rate.6 1.4 . Clean the filter/strainer.4 1. Take your reading from the edge shown below. turn OFF the system and then ON again to clear the error. but can not be used with all the tests described.2 Flow direction 5-36 HPR130XD Manual Gas Instruction Manual . 1.0 1.0 Read from this edge Example shown 1. Hold the flow meter upright. 2. 1. Then perform the following tests to find the cause of the problem. Replace the filter on the rear of the power supply. 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 1. The coolant in the system will drain out as soon as the in-line filter is removed.2 1.1 1.

3.6 gpm) for the system to operate. Write down the coolant flow rate shown on the gas console's LED display. 1. 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. Note: A flow diagram can be found on schematic 013375. Coolant flow must be greater than 2.MAINTENANCE Manual pump operation If the LED display on the gas console shows coolant flow error 093.3 lpm (0. 2. Turn ON the power. Release the current selection knob (8) and then turn OFF the power. The recorded flow rate will be used for comparison during some of the tests. or the power will have to be turned off and then on again. 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.

and place it in a 3. If there is no flow. go to test 3. 3. If the container is full in 65 seconds or less. Write down how long it takes to fill the container. Write down the flow rate from the flow meter. and connect the flow meter to measure the flow rate. 2. 2.8 liter (1 gallon) container.MAINTENANCE Test 1 – return line Note: An in-line flow meter is required to complete this test. A Hypertherm coolant container works well. If it takes more than 65 seconds to fill the container. go to test 7.8 gpm. Turn ON the pump manually (see step 1 under “Manual pump operation”). If the flow rate is less than 0. 1. Turn ON the power. go to pump and motor troubleshooting. Turn ON the pump manually (see step 1 under “Manual pump operation”). Torch-lead coolant hoses 1. 5-38 HPR130XD Manual Gas Instruction Manual . Reconnect the coolant lines. Measure how long it takes to fill the container. Measure the flow rate on the flow meter. Test 2 – supply line at ignition console Note: Remove the torch-lead coolant hoses to access the supply line. Turn OFF the power. go to test 6. Remove the supply coolant line (blue hose with green tape) from the RHF/LHF console. 3. Turn OFF the power. go to test 2. Remove the return coolant line (blue hose with red tape). If the flow rate is 0. Turn ON the power. Reconnect the return coolant line (blue hose with red tape).8 gpm or more.

Reconnect the coolant supply line to the torch receptacle. go to test 4. Write down how long it takes to fill the container. 3.9 gpm or more. If the container is full in 65 seconds or less.9 gpm. Turn ON the pump manually (see step 1 under “Manual pump operation”). If there is no obstruction or kink.8 liter (1 gallon) container. A Hypertherm coolant container works well. Replace the return coolant line. 2. 3. Test 4 – supply line to the torch receptacle 1. Measure how long it takes to fill the container. there is an obstruction in the torch receptacle. replace the torch. If the flow rate shown on the LED display is 0. If it takes more than 65 seconds to fill the container. Turn OFF the power. A Hypertherm coolant container works well. Turn ON the power.MAINTENANCE Test 3 – change the torch 1. replace the torch leads. Reconnect the return coolant line. Measure how long it takes to fill the container. If the flow rate is still less than 0. and look at the flow rate on the LED display on the gas console. Remove the coolant supply line from the torch receptacle. Caution: Coolant will flow from the hose very quickly. Turn ON the pump manually (see step 1 under “Manual pump operation”).8 liter (1 gallon) container. 2. go to test 5. and place it in a 3. Replace the torch receptacle. Remove the return coolant line (blue hose with red tape) from the RHF/LHF console. let it run for 60 seconds. Turn ON the pump manually (see step 1 under “Manual pump operation”). HPR130XD Manual Gas Instruction Manual 5-39 . If the container is full in 65 seconds or less. and place it in a 3. If it takes more than 65 seconds to fill the container. Turn OFF the power. Replace the torch and consumables with a new torch and new consumables. there is an obstruction in the return coolant line (from the RHF/LHF console to the power supply). 2. look for an obstruction or kink in the coolant hose between the torch and the LHF/RHF console. Write down how long it takes to fill the container. Turn ON the power. Test 5 – return line from the torch receptacle (remove at the ignition console) 1.

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

If the flow shown on the LED display is more than 0. replace the flow switch. HPR130XD Manual Gas Instruction Manual 5-41 . If you are still not getting flow from the pump. The arrow points up. Coolant will drain out of the torch during every consumable change if the check valve is bypassed. turn the pump on manually. Turn ON the power supply. If the flow shown on the LED display is less than 0. verify that the solenoid valve and check valve are working correctly.MAINTENANCE Test 7 – continued 5.8 gpm. If the motor will not turn on. as shown. verify that the fuse is OK. but the pump is not running. replace the check valve.8 gpm. and make sure there is power to the motor. 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. Note: The check valve must be oriented correctly. and note the coolant flow rate shown on the LED display on the gas console.

MAINTENANCE Testing the flow sensor 1.45 VDC and the flow is equal to or above 3. 67% scaled. replace the flow switch. TP210 provides a filtered. If the TP210 voltage reading is below 0.3 lpm (0. TP 206 TP 210 041993 5-42 HPR130XD Manual Gas Instruction Manual . Measure the VDC between TP210 and TP206.67 VDC at the flow switch) equals 2. 2. Turn ON the power. voltage from the flow switch.6 gpm).45 VDC (0.0 lpm (1 gpm). TP206 is common on PCB3. 0.

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

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 .

with little impedance. It allows the initial pilot arc current to flow through the pilot arc lead quickly. 2. The start circuit performs 2 functions: 1. Dangerous voltages exist within the power supply which could cause injury or death. the start circuit introduces impedance to the pilot arc lead to aid in transferring the arc to the workpiece. See schematic below. 5-46 HPR130XD Manual Gas Instruction Manual . After initial pilot arc current is established.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. 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.

but a pilot arc is established. The work lead connection to the cutting table should be clean and have good contact to the table. D1 D2 15kΩ or H8 WORK + – H9 NOZZLE 5. Note: Resistance value may slowly increase to the correct value due to the capacitance in the circuit. the board may need to be replaced. • The work lead should not have any cuts or breaks.5 kΩ between H8 and D50 (–). • Fire the torch in the air and verify that D1 is illuminated. 3. • Verify that LED-D2 is illuminated. • Verify a resistance of about (≈) 1 Ω across the R1 resistor.5kΩ R1 1Ω HPR130XD Manual Gas Instruction Manual 5-47 . Verify a resistance of about (≈) 5. If arc transfer is immediate. 2. 4. D1 illuminates as soon as the torch fires and will extinguish as soon as the arc transfers to the workpiece.MAINTENANCE D2 should always be illuminated. If there is no arc at the torch or if the arc will not transfer: 1. Verify a resistance of about (≈) 15 kΩ between snubber and H8. If it is not illuminated. If the resistance value is not correct. the board may need to be replaced or the board may not be receiving power. the LED will not illuminate. Remove wires from H8 (WORK) and H9 (NOZZLE) studs on the board. Verify a resistance of 1Ω or less. Turn OFF all power to the system. replace the board. If it is not illuminated.

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.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 Current. right digit Plasma cutflow. right digit Shield cutflow. right digit Current. 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. right digit Shield preflow. left digit Plasma cutflow. left digit Shield preflow. center 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

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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

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

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

find the leak within the system. Do not use alcohol. Make sure that the correct amount of lubricant – a thin film – is applied to these o-rings. At the torch main body. oil-free surface. Close the gas supply valve at the source. 9.e. Check that the retaining or shield cap is tightened securely to the torch main body. D. The back of the power supply. HPR130XD Manual Gas Instruction Manual 5-57 . then check for coolant leaks. C. Damage to the threads usually results from not cleaning the torch and retaining cap threads properly. check the coolant tank for dirt and particulates. 12. and C. See torque specs in the Installation section of this manual. Verify that proper Hypertherm coolant is being used. If no pitting is observed. Perform a coolant flow test as described in this manual. there may be a 0. so that dirt and particulates accumulate in the threads. B. Inspect the coolant-circulating system’s filter element at the rear of the power supply. Gas flows 15. 11.3 bar (120 psi). Check that all connections between the torch and torch leads are tight. replace it. Watch for a pressure drop. Repeat for each line from a gas supply source. Pitting on the current ring generally indicates improper maintenance (i. clean the current ring with a clean cotton swab and hydrogen peroxide. 13. Consult the Parts List in this manual for part numbers. Replace the torch if you find cracks. pipe cleaner or clean cloth. If the filter is a brownish color. When removing consumables. Inspect the current ring inside the torch main body. Inspect all hose fittings at the rear of the torch for wear. If the gas supply line is a hose. Damage to the fitting threads may indicate that overtightening has occurred. Pressurize the gas line to 8. Clean all threads on the front end of the torch head with hydrogen peroxide and a cotton swab. The current ring should be smooth and not pitted. Proper Hypertherm coolant (028872) is a red liquid. always place them on a clean. Inspect all o-rings on the torch body and consumables. Primary locations to inspect are these: A. 14. lack of regular cleaning). Remove and plug the inlet gas fitting at the gas console. 10. If any pressure continues to drop. B.5 bar (5 to 7 psi) drop due to hose-stretch. Torch main body 7. Too much lubricant may obstruct gas flows. but do not overtighten. Do not use alcohol. Inspect the torch insulator for cracks. Also. Check each gas line from the gas supply.3 to 0. since dirty consumables may cause the torch to malfunction. as follows: A. 8. 6. dry. At the ignition console.MAINTENANCE Cooling system 5. Verify that the water tube is straight and has no pitting on the end.

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

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

Inspect hose fittings 14. Inspect current ring 9. dust and particulates 20. Verify proper fit of retaining or shield cap 13. Perform coolant flow test A. Inspect for particulates and blow out 2. Inspect for proper system component grounding 23. Inspect for hose restrictions P NP A. Coolant flow checked at _________ gallons per minute ( _________ l/min) 16. Inspect torch-to-torch-lead connections 18. Inspect plumbing from gas supply NP A. Perform gas leak test A. Inspect wiring harnesses 3. Inspect water tube 8. 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 . Inspect torch leads System grounding P P NP NP 22. Motor valve hoses P NP B. Inspect filter element 6. Gas console to motor valve P NP C. Inspect cables NP A. Inspect main contactor 4. Inspect for moisture. Nitrogen pressure drop at ____________ psi in 10 minutes ( ____________ bar) NP 17. 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 compressed air filter system P 19. Clean threads on torch front end 10. Oxygen pressure drop at ____________ psi in 10 minutes ( ____________ bar) B. Inspect torch and consumable o-rings 12. Inspect pilot arc relay Coolant system P P NP NP P 5. Inspect spark gap subassembly 21. Oxygen NP B. Control cable from off-valve to gas console 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. Air NP D. Nitrogen-Hydrogen (F5) NP E. 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. Argon-Hydrogen (H35) NP F. Nitrogen or argon NP C. CommandTHC NP B. Inspect Vespel torch insulator 11.

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 900 arc hours+ 2 Years or 1200 arc hours 2.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.5 Years or 1500 arc hours 3 Years or 1800 arc hours 3.5 Years or 2100 arc hours HPR130XD Manual Gas Instruction Manual 5-61 .

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 5.5 Years or 3900 arc hours Repeat schedule starting at 6 months or 300 arc hours 5-62 HPR130XD Manual Gas Instruction Manual .5 Years or 3300 arc hours 6 Years or 3600 arc hours 6.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.

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

with label Green power lamp assembly Designator Qty. with label Panel: Front.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. 2 3 4 5 6 1 1 1 1 1 6-2 HPR130XD Manual Gas Instruction Manual .

5 KW. 3 ph.5 KW. 3 ph. 60 HZ 600 volt main transformer: 19. 50 HZ 440 volt main transformer: 19. 50-60 HZ 480 volt main transformer: 19. 3 ph.5 KW. 60 HZ 380 volt main transformer: 19. 60 HZ Kit: Thermistor replacement for main transformer Designator Qty.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 . 3 ph.5 KW. 115 VAC 50-60 HZ 10" fan: 450-550 CFM. 50-60HZ 240 volt main transformer: 19. 3 ph.5 KW. 50 HZ 220 volt main transformer: 19. 3 ph. 3 ph.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. 50 HZ 400 volt main transformer: 19. 120 VAC 50-60 HZ 200 volt main transformer: 19. 3 ph.5 KW.5 KW.

4 volt Inductor: 4MH Designator CR1 PCB6 CON1 PCB1 CS3 CS1 Qty. 120 VAC PCB: I/O Contactor EMI filter: 60 amp. 440 VAC 3PH Start circuit assembly Current sensor: Hall 100 amp. 1 1 1 1 1 1 1 1 * 400 volt power supply only 6-4 HPR130XD Manual Gas Instruction Manual . 4 volt Current sensor: Hall 100 amp.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.

2 2 1 1 1 1 1 2 1 1 1 1 CLT SOL * 380. 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". 240 volt Kit: Motor with clamp Designator F1. 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.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. 600 volt Fuse: 20 amp. F2 F1.5 amp. 440. 400.

50-60 HZ Designator T2 Qty. 50-60 HZ Control transformer: 440 volt. 50-60 HZ Control transformer: 480 volt. 50-60 HZ Control transformer: 600 volt. 50 HZ Control transformer: 400 volt. 50-60 HZ Control transformer: 220 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. 1 1 1 1 1 1 1 1 6-6 HPR130XD Manual Gas Instruction Manual . 60 HZ Control transformer: 380 volt.

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. 1 1 1 HPR130XD Manual Gas Instruction Manual 6-7 .

SV4.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. SV3. 1 1 4 11 3 1 6-8 HPR130XD Manual Gas Instruction Manual . SV8-SV14 SV1. SV5. SV6. SV7 SW1 Qty.

1 5 5 1 1 2 HPR130XD Manual Gas Instruction Manual 6-9 . PR4 PR2 Qty. PR3.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. 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.

water tube and seal Quick disconnect kit: o-ring and connector 6 6-10 HPR130XD Manual Gas Instruction Manual . 181 mm (7 in) Torch mounting sleeve assembly: Short.5 in) Torch mounting sleeve assembly: Long.75 in) 2" spanner wrench Torch kit: o-rings.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. 114 mm (4. 248 mm (9.

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.5 m (15 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 . 228291 228292 228293 228294 228295 228296 228297 228547 Length 2 m (6 ft) 3 m (10 ft) 4.PARTS LIST Torch leads Part no. 123983 123984 123985 123986 123987 123988 123989 123990 123991 Length 3 m (10 ft) 6 m (20 ft) 7. Shown for reference only) Part no.

208" X 0.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: 0.364" 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. 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 .208" X 0.070" Lubricant: Silicone 1/4-oz tube O-ring: 1.364" X 0.070" Lubricant: Silicone 1/4-oz tube O-ring: 1.070" 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.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.

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 .

1 6-14 HPR130XD Manual Gas Instruction Manual . 200 psi Kit: Motor. 480 and 600 volt power supplies Ignition console Part Number 041817 129854 Description HFHV Ignition PCB Transformer Designator T1 Qty. 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. 1/3 HP. 120 VAC PCB: I/O Contactor Current sensor: Hall 100 amp. 240 volt. F2 PCB3 PCB2 FLS CLT SOL * 400.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.5 amp. 115 VAC 50-60 HZ 10" fan: 450-550 CFM. 4 volt Start circuit assembly Fuse: 7. 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. 120 VAC 50-60 HZ Relay: Pilot arc. 70 gpm. 1 1 1 2 1 Off-valve Part Number 006109 Description Solenoid valve Designator V16-V19 Qty. 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.

HPR130XD Manual Gas Instruction Manual 7-1 . 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. Wiring Diagram Symbols Wiring diagram symbols and their identification precede the system wiring diagrams in this section.Section 7 WIRING DIAGRAMS Introduction This section contains the wiring diagrams for the system. When tracing a signal path or referencing with the Parts List or Troubleshooting sections. Lining up the coordinates will bring you to the source or destination blocks (similar to a road map). 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.

Earth IGBT Inductor LED Lamp MOV Pin Socket Plug PNP Transistor Potentiometer Relay. polarized WIRING DIAGRAMS Cap. non-polarized Cap. Dry Resistor SCR Shield Shunt Spark Gap Receptacle 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. Normally Closed Battery Cap. Chassis Ground.7-2 Fuse Ground Clamp Ground. AC Relay. Solid State. Solid State. AC . Coil Relay. Normally Open Push Button. Normally Closed Relay. Solid State. DC Relay. Normally Open Relay.

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

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 .

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. 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 .

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 .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 J9.022UF CS3 G SHEET 4-C1 + .4 J4 J1 J1.22UF 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 .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 J1 AJ SHEET 13-C2 CABLE: 123662 RED/BLK 20 19 RED J9.6 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 .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.

B J4 2-A4 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 J2.7 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 J2.2 1 2 BLU WHT J7 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 J2.12 1 2 J13 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 J2.3 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 J2.14 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 J2.1 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 J2.15 J15 1A 1 2 1B BLK 3 4 BLK 1C 5 SHEET BC 6 9-D4 RED/BLK SHEET A RED J2.13 1 2 J2 J2.11 BLK 1 2 3 4 WHT 5 6 J1 J2.

1 RED RED/BLK J1 J3 NO COM 3 2 1 120VAC RTN 120VAC HOT SHEET Y 3-B1 D 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 J3.301 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 J3.106 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 J8.107 1 2 J106 J3.4 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 J3.201 TP210 2 3 TP206 +24V COM COOLANT FLOW SENSOR A+3.302 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.

4 3 2 1 D SHEET M 3-D4 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 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 .

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 .303A J12.

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 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 J3.303B PCB3 POWER SUPPLY CONTROL 041993 J5 J13.5 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 .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 J1.1 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.

8 J8 1 2 CABLE: 123692 BLK BLK J2.4 J4 1 2 3 4 5 6 7 8 J2.4 3 2 1 J7 BLU WHT 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 .

6 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 J3.4 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 .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 J3.2 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.

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 .

2) On multi-system installations refer to the illustration. and there are intermittent communication failures (PS Link Failure). 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 must be closed. Only remove the termination jumper on the serial isolation board that is connected to the HPR power supply. 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. See sheet 17 for more details.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). 3) If a Hypertherm Automation Controller is being used. 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. try removing the jumpers on J106 and J107 on the control board. and the termination jumper (J6 or J8) on the serial isolation board in the controler.

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 . 0. Connect one terminal of the Remote On/Off cable to position #2 on TB2 and the other terminal to position #3. 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. See figure below for details. Connect customer supplied Remote On/Off cable in series with the power supply and the gas console power switch. and the termination jumper (J6 or J8) on the serial isolation board in the controler.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. and there are intermittent communication failures (PS Link Failure). J106 & J107 as shown. TB2 7 7 2) For a multi-system installation set up as described above. Machine Motion (J303). Relocate the white wire on TB2 from position #3 to position #2. 24Vac.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). Only remove the termination jumper on the serial isolation board that is connected to the HPR power supply. try removing the jumnpers on J104 and J105 on the control board. 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).

J106 & J107 as shown above. set Serial ID as shown for the second system. supply-CNC will have a common connection node with the CNC. supply-CNC) used for serial communication between Pwr. 4) For a four system installation set up as described above. set Serial ID as shown for the third system. try removing the jumpers on J106 and J107 on the control board.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. 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 . See figure on Sheet 19 for details. 5) All machine interface cables (Pwr. and the termination jumper (J6 or J8) on the serial isolation board in the controler. set Serial ID as shown for the fourth system. Only remove the termination jumper on the serial isolation board that is connected to the HPR power supply. Machine Motion (J303). 2) For a two system installation duplicate a second power supply and Command THC as illustrated for a single 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). 7) If a Hypertherm Automation controller is being used. 6) The CNC will need a dedicated I/O port for each Command THC. and there are intermittent communication failures (PS Link Failure). 3) For a three system installation set up as described above.

5) For a four system installation. set SW1 on the 141131 board as shown in Unit 1. set Serial ID (S100). set SW1 on the 141131 boards as shown in Units 1 through 3. set SW1 on the 141131 boards as shown in Units 1 through 4. 4) For a three system installation. 2) For a single 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 . and Machine Motion (J303) as shown. All 041993 DIPSWITCH and jumper settings are the same. serial IDs are determined by the 141131 board setting. Jumpers J106 and J107 should be installed.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. 3) For a two system installation.

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

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

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

E. M. Good general ventilation.S Nil.0 1.0 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.L.K HSE EH:40 Not listed If exposed to mists.5-7. Recommended Recommended. 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. PVC. Z Other effects Acute Chronic Not determined Not determined a-4 9/2/04 Hypertherm Plasma systems ./O.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. 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. Eye wash station in immediate area of use. U.E.

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. 4. 6. 5.. Labeling Information R Phrases S Phrases EI NECS No. EC annex 1 Classification German WGK Irritant R 36/37/38. 3.6mg/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. 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 1.4mg/l. express or implied. This information is based on data believed to be reliable. Inc. EC 50): 15. Algae(96hr. Hypertherm Plasma systems a-5 9/2/04 . LC 50): 39mg/l. and the Product is intended to be used in a manner that is customary and reasonably foreseeable. Tlm):28mg/l. in connection with the use of this information. Since actual use and handling are beyond our control. Tlm):28mg/l. 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. LC 50): 141. is made and no liability is assumed by Hypertherm. 2. Minnow (96hr. Daphina magna (48 hr. Trout (96 hr. no warranty. 22 S 24/25.

°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 .

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

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

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

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

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

5 m (12 ft) 4.5 m (75 ft) 30 m (100 ft) 45 m (150 ft) c-2 HPR130XD Manual Gas Instruction Manual . Extensions can be found in the table below Part number 223059 223060 223061 223062 223063 Length 1.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.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 (8 ft) gas leads. Note: Consumable life will be reduced if the 2.5 m (15 ft) 6 m (20 ft) 7. applications.4 m (8 ft) Ohmic contact wire is part of the lead set. Over all length 2 m (6 ft) 2.5 m (8 ft) gas leads are used. They are available with 2 m (6 ft). or 2. or bevel.5 m (5 ft) 3 m (10 ft) 4.5 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.

Leather overwrap – 024866 The leather overwrap is 3 m (10 ft) long. The length of the rotational sleeve is 142. It is an optional component. Robotic teaching torch (laser pointer) – 228394 • Mount the laser pointer in the torch sleeve to provide accurate positioning and alignment of the torch. and does not need to be used to use the torch leads listed above. Rotational mounting sleeve clamp (optional) – 220900 The rotational sleeve has a larger diameter than standard sleeves (57 mm/2. and is designed to be installed over the leads from where they attach to the torch. This adds protection in applications where molten metal will splash back on the leads.25 in).6 in).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. • Use for online programming/teaching and robotic alignment systems.5 mm (5. HPR130XD Manual Gas Instruction Manual c-3 .

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