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Maintenance

HPR800XD Auto Gas – 806500 5-53

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 3, 2, 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. Swap the chopper that failed with the next chopper in sequence. Remember that the chopper test sequence is

chopper 1, chopper 3, chopper 2, and chopper 4.

 • Iftheerrormovestothepositionwhereyouinstalledthechopperthatfailed,replacethechopper.

 • Iftheerrorremainsontheoriginalchopper,theissueiswiththecontrolboardorwiring.

Note: Return switch 5 on S301 to the OFF position before returning to normal cutting operations.

Hypertherm HyPerformance Plasma HPR800XD User Manual

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