Hypertherm HPR130 Manual Gas User Manual

HyPerformance Plasma
Manual Gas
Instruction Manual
804570 – Revision 5
HyPerformance
Plasma HPR130
TM
TM

Hypertherm HPR130 Manual Gas Specifications

General

Brand	Hypertherm
Model	HPR130 Manual Gas
Category	Welding System
Language	English

Summary

Electromagnetic Compatibility (EMC)

EMC Introduction

Explains compliance with EN50199 for CE-marked equipment and achieving compatibility.

Installation and Use

Methods of Reducing Emissions

Details techniques for mains supply, maintenance, cables, and bonding for interference reduction.

Section 1 SAFETY

Recognize Safety Information

Explains the use of safety symbols to identify potential hazards and avoid risks.

Follow Safety Instructions

Emphasizes reading all safety messages in the manual and on the machine labels.

Cutting Can Cause Fire or Explosion

Details fire prevention and explosion prevention measures for safe cutting operations.

Electric Shock Can Kill

Warns about fatal electric shock hazards and outlines essential prevention measures.

Cutting Can Produce Toxic Fumes

Highlights risks of toxic fumes and gases generated during cutting operations.

A Plasma Arc Can Cause Injury and Burns

Explains hazards from plasma arcs causing injury and burns, advising to stay clear.

Arc Rays Can Burn Eyes and Skin

Details how arc rays can cause burns to eyes and skin, recommending protective gear.

Grounding Safety

Provides guidelines for safe grounding of the system and components for electrical safety.

Compressed Gas Equipment Safety

Covers safety precautions for handling compressed gas equipment and cylinders.

Gas Cylinders Can Explode If Damaged

Warns about explosion hazards from damaged gas cylinders and outlines safe handling.

Noise Can Damage Hearing

Pacemaker and Hearing Aid Operation

Warning Label

Section 2 SPECIFICATIONS

System Description

Provides an overview of the HyPerformance plasma system components and their functions.

System Gas Requirements

Details gas quality, pressure, and flow rate requirements for different gases.

Power Supply Specifications

Lists general specifications, input power, and part numbers for the power supply.

Ignition Console Specifications

Provides dimensions, weight, and mounting options for the ignition console.

Gas Console Specifications

Details dimensions, weight, and cable length specifications for the gas console.

Off-valve Specifications

Torch Specifications

Section 3 INSTALLATION

Installation Requirements

System Grounding Requirements

Explains grounding for safety and EMI suppression, and proper connection procedures.

Suggested Ground Cable Routing

Power Supply Placement

Details placement instructions for the power supply, including ventilation and incline limits.

Install the Ignition Console

Instructions and diagrams for mounting the ignition console in RHF or LHF configurations.

Placement of the Gas Console

Guidance on positioning the gas console, including orientation and cable lengths.

Install the Off-valve

Power Supply to Ignition Console Leads

Ignition Control Cable

Ignition Console Coolant Hoses

Power Supply to Gas Console Cables

Gas Console to Off-valve Connections

Power Supply to CNC Interface Cable

Torch Lead Assembly

Work Lead

Torch Connections

Step-by-step instructions for connecting the torch to the torch lead assembly.

Connect the Torch to the Quick-Disconnect

Details how to align and secure the torch body to the quick-disconnect receptacle.

Torch Mounting and Alignment

Instructions for mounting and aligning the torch to the workpiece.

Power Requirements

Details electrical requirements, including switch and cable sizing based on voltage.

Line Disconnect Switch

Power Cable

Connect the Power

Step-by-step instructions for connecting the power cable to the system.

Torch Coolant Requirements

Specifies the recommended coolant mixture and associated warnings for system protection.

Water Purity Requirements

Fill the Power Supply with Coolant

Gas Requirements

Details customer responsibilities for supplying gases and regulators, and cautions on pressure.

Setting the Supply Regulators

Gas Regulators

Supply Gas Plumbing

Connect the Supply Gases

Supply Gas Hoses

Section 4 OPERATION

Daily Start-up

Procedures for daily checks, including environment and clothing, before operation.

Check Torch

Steps for inspecting and replacing torch consumables for optimal performance.

Controls and Indicators

Manual Gas Console Operation

Instructions for operating the gas console using cut charts and settings.

Consumable Selection

Guides on selecting appropriate consumables for mild steel, stainless steel, and aluminum.

Install Consumables

Step-by-step instructions for installing torch consumables correctly.

Cut Charts

Explains the use of cut charts for recommended parts, speeds, and settings.

Estimated Kerf Width Compensation

Changing Consumable Parts

Detailed instructions on how to remove and replace torch consumables safely.

Inspect Consumables

Guide on checking consumables for wear and damage, with actions for each part.

Inspect Torch

Inspect Electrode Pit Depth

Replace Torch Water Tube

Common Cutting Faults

Lists common cutting faults, their causes, and potential solutions.

How to Optimize Cut Quality

Provides tips for achieving square, straight, smooth, and dross-free cuts.

Tips for Table and Torch

Plasma Set-up Tips

Maximize the Life of Consumable Parts

Explains Hypertherm's LongLife process and techniques for extending consumable life.

Additional Factors of Cut Quality

Straightness of the Cut Surface

Piercing

How to Increase Cutting Speed

Section 5 MAINTENANCE

Introduction

Routine Maintenance

Sequence of Operation

Error Codes

Introduces HyPerformance plasma system error codes displayed on the gas console.

Error Code Troubleshooting (1 of 6)

Lists error codes 0-32 with descriptions and corrective actions.

Error Code Troubleshooting (2 of 6)

Lists error codes 32-62 with descriptions and corrective actions.

Error Code Troubleshooting (3 of 6)

Lists error codes 48-62 with descriptions and corrective actions.

Error Code Troubleshooting (4 of 6)

Lists error codes 65-100 with descriptions and corrective actions.

Error Code Troubleshooting (5 of 6)

Lists error codes 101-133 with descriptions and corrective actions.

Error Code Troubleshooting (6 of 6)

Lists error codes 134-153 with descriptions and corrective actions.

Power Supply States

Initial Checks

Power Measurement

Power Supply Coolant System Servicing

Coolant System Filter and Strainer

Coolant Flow Test Procedure

Outlines a procedure to test coolant flow and identify system issues.

Testing the Flow Switch

Gas Leak Test Procedure

Details two automatic modes for testing gas lines for leaks.

Power Supply Control Board PCB3

Power Supply Power Distribution Board PCB2

Start-circuit PCB1

Start Circuit Troubleshooting

Troubleshooting steps for issues with the start circuit, including safety warnings.

Pilot Arc Current Levels

Gas Console Control Board PCB2

Chopper Module Test Procedure

Detailed steps for testing the chopper module, including safety warnings.

Phase-Loss Detection Test

Procedure to test for phase loss and verify component connections.

Torch Lead Test

Preventive Maintenance

Introduces the importance of maintenance and the preventative maintenance protocol.

The Power Supply

Cooling System

Torch Main Body

Gas Flows

Ignition Console

System Grounding

Section 6 PARTS LIST

Power Supply Parts

Ignition Console Parts

Gas Console Parts (1 of 2)

Gas Console Parts (2 of 2)

Off-valve Parts

HyPerformance Torch Parts

Torch Leads Parts

Consumable Parts Kit

Lists components included in the standard consumable parts kit (Part No. 128878).

Recommended Spare Parts

Appendix A FUNCTIONAL DESCRIPTION OF SOFTWARE

Software Power-up Process

Software Initialization

Software Main Loop

Software Idle State

Software Purge Cycle

Software Idle2 State

Software Preflow_IHS State

Software Pilot Arc State