Hypertherm HyPerformance Plasma HPR800XD - Error Code Troubleshooting - Error Codes 157 to 159, 357 to 359

Maintenance
HPR800XD Auto Gas – 806500 5-25
Error code
number
Name Description Corrective action
157
Primary
357
Secondary
Chopper3
current at
power-up
HPR400XD
Only
Chopper 3 current signal
is active at power-up.
See wiring diagrams in section 7
1. Verify that the voltage at CS3 is correct.
2. Verify that the wiring between CS3 and PCB3 is correct
and not damaged.
3. Swap CS3 with CS2. If the error code changes to 156,
replace the original CS3.
158
Primary
358
Secondary
Chopper 4
current at
power-up
HPR400XD
Only
Chopper 4 current signal
is active at power-up.
See wiring diagrams in section 7
1. Verify that the voltage at CS4 is correct.
2. Verify that the wiring between CS4 and PCB3 is correct
and not damaged.
3. Swap CS4 with CS2. If the error code changes to 156,
replace the original CS4.
159
Primary
359
Secondary
Motor-drive
fault
HPR400XD
and
HPR800XD
The pump-motor-
drive board (PCB7) is
indicating a drive fault.
Note: The secondary
error code (359) may
display if the secondary
power supply is turned off
individually, or when the
entire system is turned
off. Customers with a
manual gas console will
not see this error code
when the entire system is
turned off.
1. Verify that the circuit breaker on PCB7 has not tripped. If it
has tripped, reset the breaker by pressing the button until
it is even with the top of the circuit breaker. If the circuit
breaker is not tripped and there is no power to PCB7,
verify that the fuse on PCB2 in the power supply is good.
2. If D32 on PCB7 illuminates, the solenoid valve and motor
are drawing too much current. D32 will only illuminate
for a short time, and extinguishes after the outputs from
the pump-motor-drive turn-off in response to the fault
condition. Verify the wiring to the solenoid valve and the
motor. Verify that the pump spins freely and is properly
mounted to the motor. Look for obstructions in the torch,
consumables, coolant lines, and in-line filter. Verify that the
solenoid valve is operating. Any of these can cause the
motor or solenoid valve to draw excessive current. Test
for low coolant flow by using the coolant flow test in this
section.
3. If D32 on PCB7 illuminates immediately at power-up, and
all the items above have been verified, replace PCB7.
4. If D30 on PCB7 illuminates, the IGBT drive has
encountered an over current condition. D30 will only
illuminate for a short time, and extinguishes after the
outputs from the pump motor-drive turn off. Follow the
same steps for D32 above.
5. If D31 on PCB7 illuminates, the heatsink thermistor is
indicating that the heatsink is too hot. Wait 10 minutes
for it to cool. If the error remains, verify that the wires
from heatsink on PCB7 are properly connected to the J6
connector on PCB7. If the error still remains, turn OFF all
power to the system and measure the resistance on the
J6 connector between pins 1 and 2. At 25° C (77° F) the
resistance should be 10k.
Error code troubleshooting – error codes 157 to 159, 357 to 359