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Hypertherm
Welding System
HPR130
Hypertherm HPR130 User Manual
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J6
J1.6
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1
GAS CLS PWR
041805
POWER D
ISTRI
BUTI
ON
PCB1
120VAC HO
T
120VAC RTN
3
2
J2
1
6
5
3
4
2
J1
1
J1.2
J1.1
120V HOT
+5V COM
120V RTN
+5V
+24V
+24V COM
9-B4
AB
10-D4
AC
RED
RED/BL
K
RED/BL
K
RED
BLU
WHT
BLU
WHT
RED/BL
K
11-D3
AE
RED
RE
MOTE ON/O
FF
7
5
6
WHT
RED
1
2
1A
2A
RED/BL
K
RED
WHT
RED
F1
D4 120VAC
D12 +24V
D8 +5V
8
7
9-D4
AB
GAS CONSO
LE
SW1
10-D4
AC
3X1
CABLE: 12367
4
DC POWER
GAS
CONSOLE
AC VAL
VE
DRIVER POWER
SHEET
SHEET
SHEET
SHEET
SHEET
A
B
C
432
D
432
1
A
B
C
1
D
17
9
01334
8
K
203
205
Table of Contents
English
9
Electromagnetic Compatibility (EMC
5
Assessment of Area
5
Warranty
7
Patent Indemnity
7
Table of Contents
9
Safety
15
Recognize Safety Information
16
Follow Safety Instructions
16
Cutting Can Cause Fire or Explosion
16
Electric Shock Can Kill
17
Static Electricity Can Damage Circuit Boards
17
Toxic Fumes Can Cause Injury or Death
18
A Plasma Arc Can Cause Injury and Burns
19
Arc Rays Can Burn Eyes and Skin
19
Grounding Safety
19
Compressed Gas Equipment Safety
20
Gas Cylinders Can Explode if Damaged
20
Noise Can Damage Hearing
20
Pacemaker and Hearing Aid Operation
20
A Plasma Arc Can Damage Frozen Pipes
20
Additional Safety Information
20
Warning Labels
22
Français
23
Sécurité
23
Section 1A
23
Identifier Les Consignes de Sécurité
24
Le Coupage Peut Provoquer un Incendie Ou Une Explosion
24
Suivre Les Instructions de Sécurité
24
L'électricité Statique Peut Endommager Les Cartes de Circuits Imprimés
25
Les Chocs Électriques Peuvent Être Fatals
25
Les Vapeurs Toxiques Peuvent Provoquer des Blessures Ou la Mort
26
L'arc Plasma Peut Provoquer des Blessures Ou des Brûlures
27
Les Rayons de L'arc Peuvent Brûler Les Yeux Et la Peau
27
Mise À la Masse Et À la Terre
27
Le Bruit Peut Provoquer des Problèmes Auditifs
28
Les Bouteilles de Gaz Comprimé Peuvent Exploser en Cas de Dommages
28
Pacemakers Et Prothèses Auditives
28
Sécurité des Bouteilles de Gaz Comprimé
28
Un Arc Plasma Peut Endommager Les Tuyaux Gelés
28
Étiquettes de Sécurité
30
Español
31
Seguridad
31
Section 1B SEGURIDAD
31
Reconocimiento de Información de Seguridad
32
Siga las Instrucciones de Seguridad
32
Los Cortes Pueden Provocar Incendios O Explosiones
32
El Choque Eléctrico Puede Provocar la Muerte
33
Electricidad Estática Puede Dañar Tablillas de Circuito
33
Humos Tóxicos Pueden Causar Lesiones O Muerte
34
El Arco de Plasma Puede Causar Lesiones y Quemaduras
35
Los Rayos del Arco Pueden Producir Quemaduras en Los Ojos y en la Piel
35
Seguridad de Toma a Tierra
35
Seguridad de Los Equipos de Gas Comprimido
36
Los Cilindros de Gas Pueden Explotar si Están Dañados
36
El Ruido Puede Deteriorar la Audición
36
Operación de Marcapasosy de Audífonos
36
Un Arco Plasma Puede Dañar Tubos Congelados
36
Etiquetas de Advertencia
37
Specifications
39
Section 2 SPECIFICATIONS
39
System Description
41
General
41
Power Supply
41
Ignition Console
41
Gas Console
41
Off-Valve
41
Torch
41
Specifications
42
System Gas Requirements
42
Power Supply
43
Ignition Console - 078172
44
Gas Consol - 078170
46
Gas Console - 078170
46
Off-Valve - 129816
47
Torch - 128818
48
Installation
49
Section 3 INSTALLATION
49
Upon Receipt
51
Claims
51
Installation Requirements
51
Noise Levels
51
Placement of System Components
51
Torque Specifications
51
Installation Requirements
52
System Components
53
Cables and Hoses
53
Supply Gas Hoses
53
Customer Supplied Power Cable
53
Recommended Grounding and Shielding Practices
54
Introduction
54
Types of Grounding
54
Steps to Take
55
Placement of the Power Supply
59
Install the Ignition Console
60
Placement of the Gas Console
62
Install the Off-Valve
63
Power Supply to Ignition Console Leads
64
Pilot Arc Lead
64
Negative Lead
64
Ignition Console Power Cable
66
Ignition Console Coolant Hoses
67
Power Supply to Gas Console Cables
68
Control Cable
68
Power Cable
68
Gas Console to Off-Valve Connections
70
Cable and Gas Hose Assembly
70
Gas Console to Off-Valve Cable
70
Off-Valve Cable
70
Power Supply to CNC Interface Cable
72
Optional Multi-System CNC Interface Cable
72
Notes to CNC Interface Cable Run List
73
Examples of Output Circuits
74
Examples of Input Circuits
75
Remote On/Off Switch
76
Torch Lead Assembly
77
Work Lead
78
Torch Connections
79
Connect the Torch to the Torch Lead Assembly
79
Connect the Torch to the Quick-Disconnect
82
Torch Mounting and Alignment
83
Mounting the Torch
83
Torch Alignment
83
Torch Lifter Requirement
83
Power Requirements
84
General
84
Line Disconnect Switch
84
Power Cable
84
Connect the Power
85
Torch Coolant Requirements
86
Standard Installation
86
Coolant for Cold Operating Temperatures
87
Coolant for Hot Operating Temperatures
88
Water Purity Requirements
88
Fill the Power Supply with Coolant
89
Gas Requirements
90
Setting the Supply Regulators
90
Gas Regulators
91
Supply Gas Plumbing
92
Connect the Supply Gases
92
Supply Gas Hoses
93
Operation
94
Section 4 OPERATION
94
Daily Start-Up
95
Check Torch
95
Controls and Indicators
96
General
96
Main Power Switch
96
Power Indicators
96
Manual Gas Console Operation
97
Consumable Selection
98
Mild Steel
98
Stainless Steel
98
Aluminum
99
Install Consumables
100
Cut Charts
101
Bevel Cutting
101
Marking
101
Consumables for Mirror-Image Cutting
101
Estimated Kerf Width Compensation
102
Changing Consumable Parts
115
Remove Consumables
115
Inspect Consumables
116
Inspect Torch
117
Inspect Electrode Pit Depth
118
Replace Torch Water Tube
119
Common Cutting Faults
120
How to Optimize Cut Quality
121
Tips for Table and Torch
121
Plasma Set-Up Tips
121
Maximize the Life of Consumable Parts
121
Additional Factors of Cut Quality
122
Additional Improvements
123
Maintenance
124
Section 5 MAINTENANCE
124
Iintroduction
126
Routine Maintenance
126
Introduction
126
System Description
127
Control and Signal Cables
127
Sequence of Operation
128
Gas System Valve Usage
129
Gas System Purge Cycle
129
Error Codes
133
Error Code Troubleshooting - 10 of 10
134
Error Code Troubleshooting - 1 of 10
135
Error Code Troubleshooting - 2 of 10
136
Error Code Troubleshooting - 3 of 10
137
Error Code Troubleshooting - 4 of 10
138
Error Code Troubleshooting - 5 of 10
139
Error Code Troubleshooting - 6 of 10
140
Error Code Troubleshooting - 7 of 10
141
Error Code Troubleshooting - 8 of 10
142
Error Code Troubleshooting - 9 of 10
143
Power Supply States
144
Plasma System Operation with Pump Timeout
145
CNC Operation with Pump Timeout
146
Initial Checks
147
Power Measurement
148
Power Supply Coolant System Servicing
149
Draining the Coolant System
149
Coolant System Filter and Strainer
150
Filter Replacement
150
Pump Strainer Cleaning
150
Coolant Flow Troubleshooting Chart
151
Coolant Flow Tests
152
Before Testing
152
Using the Hypertherm Flow Meter (128933)
152
Manual Pump Operation
153
Test 1 - Return Line
154
Test 2 - Supply Line at Ignition Console
154
Test 3 - Change the Torch
155
Test 4 - Supply Line to the Torch Receptacle
155
Test 5 - Return Line from the Torch Receptacle
155
Test 6 - Bucket Test at the Pump
156
Test 7 - Bypass the Check Valve
156
Pump and Motor Troubleshooting
157
Testing the Flow Switch
158
Gas Leak Tests
159
Power Supply Control Board PCB3
160
Power Supply Power Distribution Board PCB2
161
Start Circuit PCB1
162
Operation
162
Start Circuit Functional Schematic
162
Start Circuit Troubleshooting
162
Pilot Arc Current Levels
164
Gas Console Control Board PCB2
165
Gas Console Power Distribution Board PCB1
166
Gas Console AC Valve-Driver Board PCB3
167
Chopper Tests
168
Phase-Loss Detection Test
170
Torch Lead Test
171
Preventive Maintenance
172
Cooling System
173
Power Supply
176
Section 6 PARTS LIST
179
Power Supply
180
Ignition Console
185
Gas Console - 1 of 2
186
Gas Console - 2 of 2
187
Off-Valve
187
Hyperformance Torch
188
Torch Assembly
188
Torch Leads
188
Consumable Parts Kit - 128878
189
Consumables for Mirror-Image Cutting
190
Recommended Spare Parts
191
Wiring Diagrams
192
Introduction
192
Section 7 WIRING DIAGRAMS
192
Appendix A PROPYLENE GLYCOL SAFETY DATA / BENZOTRIAZOLE SAFETY DATA
214
Section 1 Chemical Product and Company Identification
214
Section 2 Composition / Information on Ingredients
214
Section 3 Hazards Identification
214
Chemical Product and Company Identification
214
Information on Ingredients
214
Hazards Identification
214
Section 4 First Aid Measures
215
Section 5 Fire Fighting Measures
215
Section 6 Accidental Release Measures
215
Section 7 Handling and Storage
215
First Aid Measures
215
Fire Fighting Measures
215
Accidental Release Measures
215
Handling and Storage
215
Section 8 Exposure Controls / Personal Protection
216
Section 9 Physical and Chemical Properties
216
Section 10 Stability and Reactivity
216
Section 11 Toxicological Information
216
Exposure Controls / Personal Protection
216
Physical and Chemical Properties
216
Stability and Reactivity
216
Toxicological Information
216
Section 12 Ecological Information
217
Section 13 Disposal Considerations
217
Section 14 Transport Information
217
Section 15 Regulatory Information
217
Section 16 Other Information
217
Ecological Information
217
Disposal Considerations
217
Transport Information
217
Regulatory Information
217
Other Information
217
Freezing Point of Propylene Glycol Solution
218
Software Functional Description
220
Appendix Cbevel CUTTING
224
Bevel Torch Dimensions
224
Bevel Cutting Definitions
225
Cut Charts
226
Torch Connections
229
Connect the Torch Lead Assembly to the Quick-Disconnect Assembly
229
Parts List
231
Consumables
231
Part Selection
232
Appendix B SOFTWARE FUNCTIONAL DESCRIPTION
235
Other manuals for Hypertherm HPR130
Field Service Bulletin
6 pages
5
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Hypertherm HPR130 Specifications
General
Brand
Hypertherm
Model
HPR130
Category
Welding System
Language
English
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