Hypertherm HyPerformance HPR130XD

Hypertherm HyPerformance HPR130XD

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InstallatIon

3-4 HPR130XD Auto Gas – 806330

Installation requirements

A

B

C

D

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3

4

5

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E

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Table of Contents

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

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