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Maintenance

5-58 HPR400XD Auto Gas – 806160

Chopper tests

Automatic chopper tests during power-up

When the power is turned ON, the contactor will close and each chopper will automatically test in sequence (1, 3, 2,

and 4). If the status changes to 3, all choppers passed the test. After the tests are complete the unit will advance to the

purge cycle unless an error is detected on one of the choppers.

As each chopper is turned on, the current ﬂows into the surge circuit and is measured for high and low limits. If the

chopper passes the test, the next chopper is tested.

If chopper 1 passes the test and one of the other choppers fails, you can assume that the main contactor, the input

power, and the surge circuit are OK.

Error codes:

Chopper 1 – low-current error code 105 Chopper 2 – low-current error code 106

Chopper 1 – high-current error code 103 Chopper 2 – high-current error code 104

Chopper 3 – low-current error code 075 Chopper 4 – low-current error code 076

Chopper 3 – high-current error code 107 Chopper 4 – high-current error code 095

Chopper 1 failure

1. Turn OFF all power to the system.

2. Remove the cover over the main contactor (CON1) and inspect

the contacts for arcing or damage.

 • Ifthecontactsaredamaged,replacethecontactor.

 • IfthecontactsareOK,replacethecover,turnONthepower,

and continue to step 3.

Excessive wear

CON1

WARNING

SHOCK HAZARD

Use extreme care when working near the chopper modules. Each large electrolytic capacitor (blue-

cased cylinder) stores large amounts of energy in the form of electric voltage. Even if the power is

off, dangerous voltages exist at the capacitor terminals, on the chopper, and the diode heatsinks.

Never discharge any capacitor with a screwdriver or other implement… explosion, property

damage and/or personal injury will result.

Hypertherm HyPerformance Plasma HPR400 User Manual

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