Hypertherm XPR460

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Diagnostics and Troubleshooting

392

811530 Instruction Manual XPR460

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For Your Records2
Safety Information5
Table of Contents6
Electromagnetic Compatibility (EMC)23
Warranty25
Patent Indemnity25
Limitation of Liability25
National and Local Codes26
Waterjet Product Warranty Coverage26
Liability Cap26
Specifications27
XPR Terminology for Plasma Cutting27
Plasma Cutting System Description and Components28
Plasma Power Supply Description28
Gas Connect Consoles Description28
Torchconnect Console Description29
Cooler Description29
Torch Description30
Plasma Power Supply Specifications30
Ecodesign Requirements for CE Models32
Gas Connect Console Specifications33
Torchconnect Console Specifications34
Cooler Specifications35
Torch Specifications36
Critical Raw Materials37
Safety and EMC Symbols and Marks38
IEC Symbols40
Qualifications and Requirements41
Document Requirements41
Operator Qualifications41
Qualifications of Service Personnel43
System Electrical Requirements44
Electrical Codes and Requirements44
General Input Power Requirements44
Line-Disconnect Switch Requirements45
Circuit Breaker or Fuse Requirements46
Main Power Cord Requirements46
Input Power Requirements for CE Units47
Remote On-Off Switch Requirements47
Process-Gas Requirements for All Gas Connect Consoles48
Plumbing Requirements for Supply Gases50
Regulator Requirements for Supply Gases53
Shield-Water Requirements (VWI and Optimix)55
Plumbing and Hose Requirements for Shield Water56
Additional Regulator Requirement for Shield Water When Pressure Is High56
Remove Shield Water from the Gas Connect Console56
Torque Specifications for Gas or Water Plumbing and Hose Connections57
Coolant Requirements57
Coolant Requirements for Operation between -10°C - 40°C (14°F - 104°F)58
Coolant Requirements for Operation in Temperatures above 40°C (104°F)59
Flow Requirements for Coolant60
Purity Requirements for Coolant Water60
Requirements to Put System Components in Position61
Configuration with the Core Gas Connect Console61
Configuration with the Coreplus Gas Connect Console62
Configuration with VWI or Optimix Gas Consoles63
Worksite Requirements for System Components65
Length Requirements for Hoses, Cables, and Leads66
Bend-Radius Requirements for Hoses, Cables, and Leads66
Correct Sizes for Connectors on Hoses, Cables, and Leads67
Distance Requirements between High-Frequency Cables and Control Cables68
Distance Requirements for Ventilation and Access68
Requirements for Ventilation68
Requirements for Service and Maintenance Access69
Distance Requirements for Communications69
Wireless Compliance69
Torch Mounting Bracket Requirements70
Torch Lifter Requirements70
CNC Requirements for Plasma Cutting Systems70
Remote On-Off Switch70
Adjustable Settings71
Display Settings71
Diagnostics and Troubleshooting71
Recommended Grounding and Shielding72
Types of Grounding72
Grounding Practices73
Example Grounding Diagram with a Plasma Cutting System76
Installation79
Before You Begin Installation79
Installation Checklist84
Configuration with Core Gas Connect Consoles87
Configuration with Coreplus Gas Connect Consoles89
Configuration with VWI or Optimix Gas Connect Consoles90
Installation Steps91
Put the System Components in Position91
Put the Plasma Power Supply in Position91
Lifting Equipment92
Put the Cooler in Position92
Put the Gas Connect Console in Position93
Put the Torchconnect Console in Position95
Ground the System Components98
Remove External Panels from the System Components101
Prepare the Hoses, Cables, and Leads105
Connect the Plasma Power Supply106
Connect the Cooler111
Connect the Gas Connect Console114
Connect the Gas Connect Console (Core, Coreplus) to the Torchconnect Console118
Connect the Pilot-Arc and Coolant Assembly for Core or Coreplus118
Connect the Power, CAN, and 3-Gas Assembly for Core121
Connect the Power, CAN, and 4-Gas Assembly for Coreplus122
Connect the Gas Connect Console (VWI, Optimix) to the Torchconnect Console123
Connect the Pilot-Arc, Coolant, and Shield-Water Assembly for VWI or Optimix123
Connect the Power, CAN, and 5-Gas Assembly for VWI or Optimix126
Supply Gas Installation127
Install Gas Regulators132
Connect Supply Gases to Core or Coreplus132
Connect the Supply Gases and Shield Water to VWI or Optimix134
Install the Torch-Lead Assembly to the Torch Receptacle136
Connect the Torch Lead to the Torchconnect Console141
Remove the Torch and Consumable Parts143
Install the Torch into the Torch Receptacle145
Install the Torch in the Torch Mounting Bracket147
Install the Consumables149
Connect Electric Power to the Cutting System151
Connect for Communication153
Communication Methods for XPR Cutting Systems153
Requirements for Ethercat154
Connect to the Plasma Power Supply with Ethercat155
Ethercat Cable Specifications156
Requirements for Serial RS-422156
Connect to the Plasma Power Supply with Serial RS-422157
Pinouts for Serial RS-422 Interface Cables160
Requirements for Discrete160
Connect to the Plasma Power Supply with Discrete162
Pinouts for the Discrete Interface Cables164
Pinouts for the Discrete Cable for the Expansion PCB165
Use the XPR Web Interface to Change the Arc Voltage Output Scale166
Requirements for the XPR Web Interface168
Web Interface Support Information169
Use AP Mode to Connect169
Use Network Mode to Connect171
Select an Existing Wireless Network173
Set up the Wireless Network Manually175
Access the XPR Web Interface after Setup in Network Mode178
Change the Limited AP Settings180
Change the Network Settings181
Reset the Wireless Module183
Disable the Wireless Connection Temporarily185
Disable the Wireless Connection Permanently187
Web Interface Screen Information188
Plasma Power Supply Screen190
Gas System Screen192
Text View192
Diagram View192
Log Screen195
Operate Screen195
Other Screen196
Change the Device that Has Control197
Use Ohmic Contact Sense198
Example of Internal Ohmic Contact Sense199
Example of External Ohmic Contact Sense200
Install a Remote On-Off Switch201
Examples of Output Circuits202
Logic Interface, Active High202
Logic Interface, Active Low203
Relay Interface203
This Circuit Voids the Warranty. Do Not Use204
Examples of Input Circuits205
Relay Interface205
Optocoupler Interface205
Amplified-Output Interface206
Redundant Remote On-Off Example Interface207
Install a Redundant Remote On-Off Switch207
Coolant Installation209
Overview of Cutting System Coolant209
Fill the Cutting System with Coolant209
Operation215
CNC Controls and Display215
Wireless Device Controls216
Power-Indicator Leds216
Sequence of Operation217
Power-Up State (1)217
Initial Checks State (2)218
Gas Purge/Pump on State (3)219
Wait for Start State (5)221
Preflow/Charge DC State (7)221
Ignite State (8)222
Pilot Arc State (9)224
Ramp-Up State (11)226
Steady State (12)227
Ramp-Down State (13)228
End of Cycle State (14)228
High-Voltage Relay Stages in the Ohmic Circuit229
Automatic Purges229
Gas-Change Purges for Optimix or VWI Cutting Systems230
Process-Setup Purges for All Plasma Cutting Systems230
Process Selection231
Use Process Ids for Optimal Settings231
Process ID Offsets / Overrides232
Cut Charts232
Process Core Thickness (PCT)233
Process Categories233
Torch Consumables236
Example Configurations for Consumables236
Ferrous (Mild Steel) Example Configurations236
Mild Steel - 30 a - O236
Mild Steel - 50 A, 80 A, 130 A, 170 A, 220 A, 300 A, and 460 a - O /Air237
Non-Ferrous (Stainless Steel and Aluminum) Example Configurations238
Non-Ferrous - 40 a - N and Air/Air238
Non-Ferrous - 60 a - F5/N O, and Air/Air238
N /N , N /H239
Non-Ferrous - 80 a - F5/N 2 , N 2 /N 2 , N 2 /H 2 O, Air/Air239
Non-Ferrous - 130 a - N240
/N 2 , MIX/N 2 , N 2 /H 2 O240
Non-Ferrous - 170 a - N , MIX/N O, Air/Air241
Non-Ferrous - 300 a - N , MIX/N O242
Recommendations for Maximum Consumable Life243
Arc Response Technology244
Automatic Torch Protection244
Automatic Ramp-Down Error Protection245
Maintenance247
Plasma System Maintenance247
Daily Inspections248
Remove the Power from the Cutting System249
Examine the Gas Regulators250
Examine the Shield Water Regulator (if Applicable)250
Examine the Connections and Fittings251
Remove the Torch and Consumable Parts252
Examine the Consumable Parts254
Examine the Torch256
Examine the Torch Receptacle258
Examine the Torch Lead259
Indicators of Emitter Wear259
Measure the Pit Depth of an Electrode261
Coolant Maintenance262
Calculations for Total Coolant Volume Estimates263
Total Estimated Volume in Liters263
Total Estimated Volume in U.S. Gallons263
Coolant Replacement and Its Significance263
Remove Old Coolant from the System264
Diagnostics and Troubleshooting269
Safety Considerations269
Initial Inspection Steps273
Remove the Power from the Cutting System274
Examine each PCB274
Measure the Line Voltage between the Terminals Inside the Plasma Power Supply276
PCB Names and Locations277
Diagnostic Code Conventions277
Diagnostic Codes278
General Troubleshooting Procedures293
Causes of Decreased Consumable Life293
Cuts Are Started or Stopped off the Surface of the Workpiece293
The Cut Settings Are Not Correct294
The Cutting Material Is Magnetic294
Cutting Faults that Can Occur Frequently294
The Pilot Arc Starts but Does Not Transfer to the Workpiece294
The Plasma Arc Does Not Cut Completely through the Workpiece, and There Is too Much Sparking on Top of the Workpiece294
There Is Dross on the Bottom of the Cut295
The Angle of the Cut Is Not Square295
Do a Gas Leak Test295
Coolant Flow Measurements298
Use the CNC or XPR Web Interface to Measure Coolant Flow298
Do a Container Test to Measure Coolant Flow299
Do a Test for Continuity between the Nozzle and Workpiece301
Safety Consideration for the XPR460301
Corrective Action302
Measure Resistance from Thermistors307
Do an Ohmic-Contact Test308
Troubleshooting Procedures for Diagnostic Codes311
CAN Communication Troubleshooting for Gas Connect Consoles311
Diagnostic Codes 500, 507, 508, 510, 602311
Symptoms311
Corrective Action311
CAN Communication Troubleshooting for Mixing Modules in Optimix Consoles313
Diagnostic Codes 501, 507, 508, 511313
Symptoms313
Corrective Action314
CAN Communication Troubleshooting for Torchconnect Consoles316
Diagnostic Codes 503, 507, 508, 513, 600316
Symptoms316
Corrective Action316
CAN Communication Troubleshooting for Choppers317
Diagnostic Codes 504 - 508, 514 - 516, 601, 604, 606317
Symptoms318
Corrective Action318
Troubleshooting for an Ignition Timeout320
Diagnostic Code 520320
Symptoms320
Corrective Action320
Troubleshooting for a Pilot Arc Timeout321
Diagnostic Code 521321
Symptoms321
Corrective Action321
Verification321
Troubleshooting for Gas Flow Process Timeouts322
Diagnostic Codes 522 - 525322
Symptoms322
Corrective Action322
Troubleshooting for Low Inlet Gas Pressure322
Diagnostic Codes 530, 531, 533322
Symptoms323
Corrective Action323
Verification323
Troubleshooting for Low Shield Water Pressure323
Diagnostic Code 532323
Symptoms324
Corrective Action324
Troubleshooting for Low Shield Gas Pressure324
Diagnostic Code 534324
Symptoms325
Corrective Action325
Troubleshooting for Low Coolant Flow326
Diagnostic Codes 540, 541, 542326
Symptoms326
Corrective Action326
Troubleshooting for High Coolant Flow328
Diagnostic Codes 543, 544328
Symptoms328
Corrective Action328
Troubleshooting for Low Current329
Diagnostic Codes 550, 552 - 554329
Symptoms329
Corrective Action329
Troubleshooting for High Current330
Diagnostic Codes 555, 556, 557330
Symptoms330
Corrective Action331
Troubleshooting for Over-Temperature Faults for Choppers and Coolant331
Diagnostic Codes 560 - 562, 587331
Symptoms332
Corrective Action332
Ohmic Resistance Values for Thermistors334
Troubleshooting for Start Switch Faults335
Diagnostic Codes 570, 571, 574 - 577335
Symptoms336
Corrective Action336
Troubleshooting for Over-Temperature Faults for Inductors and Transformers337
Diagnostic Codes 580 - 586, 589, 793337
Symptoms338
Corrective Action338
Troubleshooting for a Fan Timeout340
Diagnostic Code 588340
Symptoms341
Corrective Action341
Troubleshooting for Consumable Part Failure or no Chopper Current341
Diagnostic Codes 610 - 615 and 626 - 628341
Corrective Action342
Troubleshooting for a Ramp-Down Error342
Diagnostic Code 620342
Symptoms342
Corrective Action343
Troubleshooting for High DC Bus Voltage343
Diagnostic Code 621343
Symptoms343
Troubleshooting for Low DC Bus Voltage343
Diagnostic Code 622343
Symptoms344
Corrective Action344
Troubleshooting for Idle Choppers with Current345
Diagnostic Codes 623, 624, 625345
Symptoms345
Corrective Action345
Troubleshooting for Current Sensor Faults345
Diagnostic Code 631345
Corrective Action346
Troubleshooting for Arc Timeouts During the Ignite State346
Diagnostic Code 654346
Symptoms346
Troubleshooting for Current in Chopper During Preflow346
Diagnostic Code 655346
Symptoms347
Corrective Action347
Troubleshooting for a Console Reset Message347
Diagnostic Code 691347
Troubleshooting for Low Inlet Pressure for Hydrogen, Argon, or Nitrogen348
Diagnostic Codes 695 - 697348
Symptoms348
Corrective Action348
Permitted Inlet Pressures to Gas Connect Consoles349
Troubleshooting for Low Inlet Pressure for F5 Gas349
Diagnostic Code 700349
Symptoms350
Corrective Action350
Troubleshooting for Low Inlet Pressure for Water350
Diagnostic Code 701350
Symptoms351
Corrective Action351
Troubleshooting for Shield Gas Inlet Pressure in the Torchconnect Console352
Diagnostic Codes 702 - 705352
Symptoms352
Corrective Action353
Permitted Inlet Pressures to the Torchconnect Console353
Troubleshooting for Process-Gas Inlet Pressure Faults in the Torchconnect Console for Optimix Systems354
Diagnostic Codes 702, 705, 769, and 770354
Symptoms354
Corrective Action to Adjust the N 2 Regulator354
Corrective Action to Adjust the Ar Regulator356
Troubleshooting for Pressure Transducer Faults356
Diagnostic Codes 706 - 715356
Symptoms357
Corrective Action357
Troubleshooting for Invalid Processes358
Diagnostic Code 716358
Symptoms358
1: Invalid ID358
2: Invalid User358
3: Invalid User Source359
4: Invalid Process359
5: Not Allowed or System Not Ready359
6: Not Supported360
Troubleshooting Flowchart for Diagnostic Code 716360
Troubleshooting for Duty Cycle Limit on Proportional Valve Supply Voltage364
Diagnostic Code 719364
Symptoms364
Corrective Action364
Troubleshooting for Pressure out Is Greater than Pressure in364
Diagnostic Code 720364
Symptoms365
Corrective Action365
Troubleshooting for Gas Mixture Faults365
Diagnostic Codes 721 - 723, 726365
Corrective Action366
Troubleshooting for Gas Mixture Communication Errors366
Diagnostic Codes 724, 725, 742, 743366
Symptoms366
Troubleshooting for Solenoid Valve V1 in the Torchconnect Console367
Diagnostic Code 730367
Symptoms367
Corrective Action367
Troubleshooting for Solenoid Valves V4 - V12 in the Torchconnect Console367
Diagnostic Codes 733 - 741367
Symptoms368
Corrective Action368
Fan Diagnostic Codes Diagram368
Troubleshooting for Low Fan Speeds - MAGFAN371
Diagnostic Codes 744 - 746371
Symptoms371
Corrective Action371
Troubleshooting for Low Fan Speeds - HXFAN371
Diagnostic Codes 748 and 749371
Symptoms372
Corrective Action372
Troubleshooting for Low Fan Speeds - CAB FAN 1372
Diagnostic Codes 747 and 750372
Symptoms373
Corrective Action373
Troubleshooting for Phase Errors in Choppers373
Diagnostic Codes 752, 753, 754373
Corrective Action374
Troubleshooting for a Main Contactor Fault374
Diagnostic Code 764374
Symptoms374
Troubleshooting for an Inrush Contactor Fault375
Diagnostic Code 765375
Symptoms375
Corrective Action375
Troubleshooting for a Pump-Enable Fault or Remote-Relay Fault375
Diagnostic Codes 766, 767375
Corrective Action376
Troubleshooting for Gas Inlet Pressure Faults376
Diagnostic Codes 768 - 771376
Symptoms376
Corrective Action377
Troubleshooting for a Pilot Relay Fault377
Diagnostic Code 777377
Symptoms377
Safety Consideration for the XPR460378
Corrective Action378
Troubleshooting for High or Low Chopper Voltage379
Diagnostic Codes 779, 780, 781379
Symptoms379
Corrective Action379
Troubleshooting for High Voltage on the 24 V Power Supply379
Diagnostic Code 784379
Symptoms380
Corrective Action380
PCB Information381
Plasma Power Supply Power Distribution PCB (141577) Diagram381
Plasma Power Supply Control PCB (141545) Diagram382
DIP Switch Positions383
Plasma Power Supply Chopper PCB (141319) Diagram385
Plasma Power Supply Start Circuit PCB (141360) Diagram386
Plasma Power Supply I/O PCB (10085206) Diagram386
Fan Power Distribution PCB (141384) Diagram386
Gas Connect Console Control PCB (141375) Diagram387
Gas Connect Console High Frequency PCB (141563) Diagram388
Torch Connect Console Ohmic PCB (141368) Diagram389
Torch Connect Console Control PCB (141334) Diagram389
Cooler Control PCB (141524) Diagram390
Cooler Power Distribution PCB (141573) Diagram391
Parts List393
Plasma Power Supply Parts393
Outer Panel Parts394
Fans395
Coolant Adapters and Manifold in the Rear Compartment395
Coolant Adapters and Manifolds in Plasma Power Supply396
Transformers and Inductors396
Control Parts - 1397
Control Parts - 2398
Wire Harness and CAN Cables in the Plasma Power Supply398
Rear Compartment of the Plasma Power Supply399
Cooler Parts399
Cooler Outer Parts400
Cooler Interior Parts - View 1400
Cooler Interior Parts - View 2401
Cooler Interior Parts - View 3402
Cooler Interior Parts - View 4403
Gas Connect Console Parts404
Gas Connect Console High-Voltage Side Parts405
Gas Connect Console Manifold Side Parts406
Core Gas Connect Console Manifolds and Adapters407
Coreplus Gas Connect Console Manifolds and Adapters408
VWI Gas Connect Console Input and Output Manifolds and Adapters409
Optimix Gas Connect Console Input and Output Manifolds and Adapters411
VWI and Optimix Gas Connect Console Mixer, Resonators, Transducers, and Valves412
Gas Connect Console Wire Harness, Hose Kit, and CAN Cables413
Torchconnect Console Parts414
Torchconnect Console Easyconnect Side415
Torchconnect Console - Top415
Torchconnect Console Manifold Side - View 1416
Torchconnect Console Manifold Side - View 2417
Torchconnect Console Front Adapters and Valves418
Torch Assembly419
Torch Bracket419
Consumable Starter Kits420
Mild Steel Consumable Starter Kit (10083904)420
Mild Steel Consumable Starter Kit with Torch (10083905)421
Other Consumable and Torch Parts422
Cable, Hose, and Lead Parts423
Pilot-Arc Cables with Strain Relief423
Negative Cables with Strain Relief423
Power Cable, 120 VAC424
Power Cables, 220 VAC424
Coolant-Hose Assemblies (Cooler to Gas Connect Console)425
Coolant-Hose Assemblies (Cooler to Plasma Power Supply)425
CAN Cables425
Pilot-Arc and Coolant Assemblies (Core, Coreplus)426
Power, CAN, and 3-Gas Assemblies (Core)426
Power, CAN, and 4-Gas Assemblies (Coreplus)427
Pilot-Arc, Coolant, and Shield-Water Assemblies (VWI, Optimix)427
Power, CAN, and 5-Gas Assemblies (VWI, Optimix)427
Ethercat CNC Interface Cables428
Discrete CNC Interface Cables429
Discrete Cables for the Expansion PCB429
Serial CNC Interface Cables430
Work Cables431
Torch Leads431
Bevel Torch Leads432
Oxygen Hoses (Blue)432
Nitrogen or Argon Hoses (Black)432
Air Hoses (Black)433
Hydrogen or Nitrogen-Hydrogen (F5) Hoses (Red)433
Water (Optional Shield Fluid) Hoses (Blue)434
Preventive Maintenance Kits434
Tools435
Recommended Spare Parts435
Plasma Power Supply - Recommended Spare Parts435
Cooler - Recommended Spare Parts436
Gas Connect Consoles - Recommended Spare Parts436
Torchconnect Console - Recommended Spare Parts437
Torch - Recommended Spare Parts437
Descriptions of Warning Label Icons437
Wiring Diagrams439
Wiring Diagram Conventions439
Wiring Diagram Symbols439
Torch Symbols441
Valve States During Operation441
Valve States by Process ID442
Overview (Sheet 1 of 25)456
Plasma Power Supply 1 (Sheet 2 of 25)459
Plasma Power Supply 2 (Sheet 3 of 25)462
Plasma Power Supply 3 (Sheet 4 of 25)465
Plasma Power Supply 4 (Sheet 5 of 25)468
Plasma Power Supply 5 (Sheet 6 of 25)471
Plasma Power Supply 6 (Sheet 7 of 25)474
Plasma Power Supply 7 (Sheet 8 of 25)477
Gas Connect Console 1 (Sheet 9 of 25)480
Gas Connect Console 2 (Sheet 10 of 25)483
Torchconnect Console (Sheet 11 of 25)486
Cooler (Sheet 12 of 25)489
Coolant System 1 (Sheet 13 of 25)492
Coolant System 2 (Sheet 14 of 25)495
Gas System 1 Core (Sheet 15 of 25)498
Gas System 2 Coreplus (Sheet 16 of 25)501
Gas System 3 VWI (Sheet 17 of 25)504
Gas System 4 Optimix (Sheet 18 of 25)507
Ethercat Multi-Drop (Multi-System) Interface (Sheet 19 of 25)510
Serial RS-422 and Discrete Multi-Drop (Multi-System) Interface (Sheet 20 of 25)513
Discrete Multi-Drop (Multi-System) Interface (Sheet 21 of 25)516
Ethercat Connection to EDGE Connect (Sheet 22 of 25)519
Discrete and Serial RS-422 CNC Connections (Sheet 23 of 25)522
Discrete CNC Connections (Sheet 24 of 25)525
Wireless Subsystem Block Diagram (Sheet 25 of 25)528

Hypertherm XPR460 - Page 392

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