Hypertherm HyPerformance HPR130XD - User Manual

302 pages

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HyPerformance

Plasma

HPR130XD

Auto gas

Instruction manual

806330 – Revision 3

Main Page

Default Chapter5
- Assessment of Area5
- Electromagnetic Compatibility (Emc)5
Electromagnetic Compatibility Emc7
Warranty7
- Patent Indemnity7
- Table of Contents9
Section 118
Safety18
- Recognize Safety Information18
- Follow Safety Instructions18
- Inspect Equipment before Using18
- Responsibility for Safety18
- A Plasma Arc Can Damage Frozen Pipes18
- Static Electricity Can Damage Printed Circuit Boards18
- Grounding Safety19
- Electrical Hazards19
- Electric Shock Can Kill19
- Cutting Can Cause Fire or Explosion20
- Machine Motion Can Cause Injury20
- Compressed Gas Equipment Safety21
- Gas Cylinders Can Explode if Damaged21
- Toxic Fumes Can Cause Injury or Death21
- A Plasma Arc Can Cause Injury and Burns22
- Arc Rays Can Burn Eyes and Skin22
- Pacemaker and Hearing Aid Operation22
- Noise Can Damage Hearing23
- Dry Dust Collection Information23
- Laser Radiation24
- Additional Safety Information24
Section 225
Specifications25
- System Description27
- Specifications28
- IEC Symbols36
- Symbols and Marks37
Section 339
Installation39
- Upon Receipt41
- Claims41
- Installation Requirements41
- Noise Levels41
- Placement of System Components41
  - Torque Specifications41
- Installation Requirements42
  - System Components43
  - Cables and Hoses43
  - Supply Gas Hoses43
  - Customer-Supplied Power Cable43
- Recommended Grounding and Shielding Practices44
- Introduction44
  - Types of Grounding44
  - Grounding Practices44
  - Grounding Diagram47
- Placement of the Power Supply49
- Install the Ignition Console50
- Install the Metering Console52
- Placement of the Selection Console53
- Power Supply to Ignition Console Leads54
  - Pilot Arc Lead54
  - Negative Lead54
  - Ignition Console Power Cable56
  - Ignition Console Coolant Hoses57
- Power Supply to Selection Console Cables58
  - Control Cable58
  - Power Cable58
- Selection Console to Metering Console Connections60
  - Cable and Gas Hose Assembly60
- Power Supply to CNC Interface Cable62
  - Optional Multi-System CNC Interface Cable62
  - Notes to CNC Interface Cable Run List63
  - HPR130XD Auto Gas - 80633063
  - Examples of Output Circuits64
  - Examples of Input Circuits65
- Remote ON/OFF Switch (Provided by Customer)66
- Torch Lead Assembly67
- Torch Lead Junction Box (Optional)68
  - Install the Junction Box69
  - Connect the Leads70
- Work Lead74
- Torch Connections75
  - Connect the Torch to the Torch Lead Assembly75
  - Connect the Torch to the Quick-Disconnect79
- Torch Mounting and Alignment80
  - Mounting the Torch80
  - Torch Alignment80
- Torch Lifter Requirement81
- Hypernet81
- Power Requirements82
  - General82
  - Line Disconnect Switch83
  - Main Power Cable83
- Connect the Power84
- Torch Coolant Requirements85
  - Premixed Coolant for Standard Operating Temperatures85
  - Custom Coolant MIX for Cold Operating Temperatures86
  - Custom Coolant MIX for Hot Operating Temperatures87
- Water Purity Requirements87
- Fill the Power Supply with Coolant88
- Gas Requirements89
  - Setting the Supply Regulators89
- Gas Regulators90
- Supply Gas Plumbing91
  - Connect the Supply Gases92
- Supply Gas Hoses93
Section 495
Operation95
- Daily Start-Up97
  - Check Torch97
- Power Indicators98
- CNC Controller Requirements99
- CNC Screen Examples100
- Consumable Selection104
- Install and Inspect Consumables108
  - Install Consumables108
  - Inspect Consumables109
- Torch Maintenance111
- Torch Connections112
- Replace Torch Water Tube112
- Common Cutting Faults113
- How to Optimize Cut Quality114
- Cut Charts118
  - Overview118
- Bevel Cutting Definitions121
- Estimated Kerf-Width Compensation124
Section 5153
Maintenance153
- Introduction155
- Routine Maintenance155
- System Description156
  - Power and Signal Cables156
- Sequence of Operation157
- Gas System Purge Cycle158
- Gas System Valve Usage158
  - Marking Process160
- PCB Block Diagram161
- Error Codes162
  - Error Code Troubleshooting - Error Codes 000 to 018163
  - Error Code Troubleshooting - Error Codes 020 to 028, 224 to 228164
  - Error Code Troubleshooting - Error Codes 030 to 042, 231 to 234165
  - Error Code Troubleshooting - Error Codes 044 to 046166
  - Error Code Troubleshooting - Error Codes 047 to 053, 248 to 250167
  - Error Code Troubleshooting - Error Codes 054 to 061168
  - Error Code Troubleshooting - Error Codes 062 to 067, 265 to 267169
  - Error Code Troubleshooting - Error Codes 071 to 075, 273 to 275170
  - Error Code Troubleshooting - Error Codes 076 to 101, 276 to 301171
  - Error Code Troubleshooting - Error Codes 102 to 111, 302 to 308172
  - Error Code Troubleshooting - Error Codes 116 to 133, 316173
  - Error Code Troubleshooting - Error Codes 134 to 140, 334 and 338174
  - Error Code Troubleshooting - Error Codes 141 to 152, 346 to 351175
  - Error Code Troubleshooting - Error Codes 153 to 156, 354 to 356176
  - Error Code Troubleshooting - Error Codes 157 to 159, 357 to 359177
  - Error Code Troubleshooting - Error Codes 160 to 180178
  - Error Code Troubleshooting - Error Code 181, 182, 298, and 383179
- Power Supply States180
- Plasma System Operation with Pump Time-Out181
- CNC Operation with Pump Time-Out182
- Initial Checks183
- Power Measurement184
- Air Filter Element Replacement185
- Power Supply Coolant System Servicing186
  - Draining the Coolant System186
- Coolant System Filter and Strainer187
  - Filter Replacement187
  - Pump Strainer Cleaning187
- Coolant Flow Tests189
  - Before Testing189
  - Using the Hypertherm Flow Meter (128933)189
  - Manual Pump Operation190
  - Test 1 - Return Line191
  - Test 2 - Supply Line at Ignition Console191
  - Test 3 - Change the Torch192
  - Test 4 - Supply Line to the Torch Receptacle192
  - Test 5 - Return Line from the Torch Receptacle (Remove at the Ignition Console)192
  - Test 6 - Bucket Test at the Pump193
  - Test 7 - Bypass the Check Valve193
  - Pump and Motor Troubleshooting194
  - Testing the Flow Sensor195
- Gas Leak Tests196
  - Leak Test 1 (Inlet Leak Test)196
  - Leak Test 2 (System Leak Test)197
  - Leak Test 3 (Proportional Valve Test in the Metering Console)197
- Power Supply Control Board PCB3198
- Power Supply Power Distribution Board PCB2199
- Start-Circuit PCB1200
  - Operation200
  - Start Circuit Functional Schematic200
  - Start Circuit Troubleshooting200
- Pilot Arc Current Levels202
- Selection Console Control Board PCB2203
- Selection Console Power Distribution Board PCB1204
- Selection Console, AC Valve-Driver Board PCB3205
- Metering Console Control Board PCB2206
- Metering Console Power Distribution Board PCB1207
- Chopper Tests208
  - Automatic Chopper and Current Sensor Tests During Power-Up208
- Phase-Loss Detection Test210
- Torch Lead Test211
- Preventive Maintenance212
Section 6213
Parts List213
- Power Supply214
- Ignition Console219
- Torch Lead Junction Box (Optional)220
  - Ignition Console to Junction Box Leads221
- Selection Console222
- Metering Console224
- Hyperformance Torch225
- Consumable Parts Kits227
- Consumables for Mirror-Image Cutting228
  - Straight Cutting228
  - Bevel Cutting230
- Recommended Spare Parts231
  - Warning Label - 110647232
Section 7233
Wiring Diagrams233
- Introduction233
- Wiring Diagram Symbols233
- Discrete Output Functionality236
Appendix A259
Appendix A Hypertherm Torch Coolant Safety Data259
- Identification of the Substance/Mixture and of the Company Undertaking260
- Hazards Identification260
- Composition/Information on Ingredients261
- First Aid Measures261
- Fire-Fighting Measures261
- Accidental Release Measures261
- Handling and Storage262
- Exposure Controls/Personal Protection262
- Physical and Chemical Properties262
- 10 - Stability and Reactivity263
- 11 - Toxicological Information263
- 12 - Ecological Information263
- 13 - Disposal Considerations264
- 14 - Transport Information264
- 15 - Regulatory Information264
- 16 - Other Information265
- Freezing Point of Propylene Glycol Solution266
Appendix B Cnc Interface Protocol268
- Interface Hardware268
- Signal List268
- Serial Commands271
- Command Table (1272
- Error Codes287
- Status Codes291
- Gas Type Codes291
- CNC Requirements292
  - Auto Gas Console292
- Serial Interface Guidelines293
Appendix C Robotic Applications296
- Components for Robotic Applications296

Questions and Answers:

J
Joseph HullOct 30, 2025
What to do if Hypertherm HyPerformance HPR130XD flow switch test fails?
- A
  Amy AcostaOct 30, 2025
  If the Hypertherm Welding System flow switch test fails, wait 10 seconds to allow the flow rate to stabilize and wait for the test to finish. Check for leaks and loose connections between the selection and metering consoles. Ensure there are no obstructions in the plasma vent hose and inspect the shield holes for blockages, replacing the shield if needed. Verify the condition of consumable parts, proper preflow and cut-flow settings, and perform gas leak tests as described in the Maintenance section. Also, check for a spark across the spark gap and inspect CON1 and the pilot arc relay for wear. Perform gas flow, torch lead, and start circuit tests as described in the Maintenance section. Ensure proper pierce height, inspect the work lead for damage or loose connections, and confirm correct...