Hypertherm HyPerformance Plasma HPR400 User Manual

Maintenance
5-2 HPR400XD Auto Gas – 806160
Air filter element replacement ..............................................................................................................................................................5-32
Coolant system servicing ...................................................................................................................................................................... 5-33
Draining the coolant system .......................................................................................................................................................5-33
Coolant system filter...............................................................................................................................................................................5-34
Filter replacement .........................................................................................................................................................................5-34
Coolant flow troubleshooting chart ....................................................................................................................................................5-35
Coolant flow tests ...................................................................................................................................................................................5-36
Before testing ................................................................................................................................................................................5-36
Bypass valve verification ............................................................................................................................................................. 5-37
Using the Hypertherm flow meter (128933) ..........................................................................................................................5-37
Manual pump operation ..............................................................................................................................................................5-38
Test 1 – return line ..................................................................................................................................................................... 5-39
Test 2 – supply line at ignition console .................................................................................................................................5-39
Test 3 – change the torch ........................................................................................................................................................5-40
Test 4 – supply line to the torch receptacle ........................................................................................................................5-40
Test 5 – return line from the torch receptacle (remove at the ignition console)..........................................................5-40
Test 6 – bucket test at the pump ...........................................................................................................................................5-41
Pump and motor troubleshooting ............................................................................................................................................. 5-42
Testing the flow sensor ............................................................................................................................................................... 5-42
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

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