Hypertherm HyPerformance HPR400XD Auto Gas User Manual

Maintenance
HPR400XD Auto Gas – 806160 5-59
3. Locate dipswitch S301 on the control board (PCB3) and move switch 5 to the ON position. The switch must be
returned to its original position before cutting.
4. Measure the open circuit voltage (OCV)
Attach the test leads of a DC volt meter to the NEG terminal and the WORK terminal on the I/O board. Turn ON the
power to start the chopper test. After the contactor (CON1) closes, read the OCV which should be about 360 VDC.
 • IftheOCVis0,thechopperisprobablyfaulty.Swapchopper1withchopper2forverication.Ifchopper1is
faulty, the error code should change to 106. Replace chopper 1.
 • IfOCVisabout360VDC,continuetostep5.
5. Swap current sensor 1 (CS1) with current sensor 2 (CS2). Move the sensor, but leave the power cable and the
control wiring in place.
 • Iftheerrorremainsonchopper1,replacetheI/OPCB.
 • Iftheerrorchangestochopper2,replaceCS1.
Chopper 2, 3, or 4 failure
1. Swap the current sensor for the chopper that failed with the current sensor for the next chopper in sequence.
 • Iftheerrormovestothenextchopperinsequence,replacethecurrentsensorforthechopperthatfailed.
 • Iftheerrorremainsontheoriginalchopper,continuetostep2.
2. Measure the OCV
 • ThechopperoutputsareconnectedinparallelattheI/Oboard,andthechoppersaretestedinsequence(1,3,2,
and 4). This means that if you measure the OCV at the NEG and WORK terminals on a fully functional HPR400XD,
the voltage will be 0 until the contactor (CON1) closes. Chopper 1 will turn on and you will measure 360 VDC.
Chopper 1 will turn off and the voltage will decrease to 0. Chopper 3 (1, 3, 2, and 4) will turn on next, and the
voltage will increase to 360 VDC and then decrease to 0 when chopper 3 turns off. This sequence repeats until all
4 choppers are tested.
Example:
If you get error 075 or 107, you know chopper 3 failed the test. Because chopper 1 and chopper 2 passed the
test, you know the incoming power and the I/O board are OK. If you measure the OCV at the NEG terminal and the
WORK terminal on the I/O board, you will see the voltage cycle from 0 to 360, back to 0, and then to 360 again,
because chopper 1 and chopper 2 are OK. If you do not get the third reading of 360 VDC from chopper 3, that
means chopper 3 is faulty. You can swap chopper 3 with chopper 2 for verification. The error code will move to
chopper 2, if chopper 3 is faulty. If the error does not move, or you measure an OCV of about 360 VDC for chopper3,
contact Hypertherm Technical Service at 800-643-9878.
Note: Return switch 5 on S301 to the OFF position before returning to normal cutting operations.

Hypertherm HyPerformance HPR400XD Auto Gas Specifications

General

Brand	Hypertherm
Model	HyPerformance HPR400XD Auto Gas
Category	Welding System
Language	English