Hypertherm HyPerformance Plasma HPR400 User Manual

Table of ConTenTs
vi HPR400XD Auto Gas – 806160
Gas leak tests .......................................................................................................................................................................................... 5-43
Leak test 1 (inlet leak test) .........................................................................................................................................................5-43
Leak test 2 (system leak test) ....................................................................................................................................................5-44
Leak test 3 (proportional valve test in the metering console) ............................................................................................5-44
Power supply control board PCB3.....................................................................................................................................................5-45
Power supply power distribution board PCB2 ................................................................................................................................ 5-46
Start-circuit PCB1 ..................................................................................................................................................................................5-47
Operation .......................................................................................................................................................................................5-47
Start circuit functional schematic .............................................................................................................................................5-47
Start circuit troubleshooting ......................................................................................................................................................5-47
Pilot arc current levels............................................................................................................................................................................5-49
Pump motor drive board PCB7 ...........................................................................................................................................................5-50
Cooler power distribution board PCB1.............................................................................................................................................5-51
Cooler sensor board PCB2 .................................................................................................................................................................5-52
Selection console control board PCB2.............................................................................................................................................5-53
Selection console power distribution board PCB1 ........................................................................................................................ 5-54
Selection console, AC valve-driver board PCB3 ............................................................................................................................ 5-55
Metering console control board PCB2 ..............................................................................................................................................5-56
Metering console power distribution board PCB1 ......................................................................................................................... 5-57
Chopper tests ..........................................................................................................................................................................................5-58
Phase-loss detection test .....................................................................................................................................................................5-60
Torch lead test .........................................................................................................................................................................................5-61
Preventive maintenance .........................................................................................................................................................................5-62
Section 6
PARTS LIST ..............................................................................................................................................................................61
Power supply ..............................................................................................................................................................................................6-2
Cooler ...........................................................................................................................................................................................................6-6
Ignition console .........................................................................................................................................................................................6-8
Torch lead junction box (Optional).........................................................................................................................................................6-9
Ignition console to junction box leads .....................................................................................................................................6-10
Selection console ...................................................................................................................................................................................6-11
Metering console ....................................................................................................................................................................................6-13
HyPerformance torch ............................................................................................................................................................................. 6-14
Torch assembly ............................................................................................................................................................................. 6-14
Torch leads ....................................................................................................................................................................................6-15
Ohmic contact wire ......................................................................................................................................................................6-15
Consumable parts kits ........................................................................................................................................................................... 6-16
Consumables for mirror-image cutting ..............................................................................................................................................6-18
Straight cutting .............................................................................................................................................................................6-18
Mild steel ........................................................................................................................................................................................6-18
Bevel cutting ..................................................................................................................................................................................6-20
Recommended spare parts ..................................................................................................................................................................6-22
Warning Label – 110647 .........................................................................................................................................................6-24

Hypertherm HyPerformance Plasma HPR400 Specifications

General

Duty Cycle	100% at 400 A
Cutting Capacity	up to 50 mm (2 in)
Output Current	30-400 A
Input Voltage	200 – 480 V, 3-PH, 50/60 Hz
Gas Supply	Oxygen, Air, Nitrogen