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    HyPerformance Plasma HPR130TMInstruction Manual804570 – Revision 3HyPerformance PlasmaTM

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    HyPerformance PlasmaCutting Systems Instruction Manual(P/N 804570)Revision 3 – August, 2004© Copyright 2004 Hypertherm, Inc.All Rights ReservedHypertherm, HyPerformance, HyDefinition, LongLife and Command THC are trademarks of Hypertherm, Inc. and may be registered in the United States and/or ...

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    Hypertherm, Inc.Etna Road, P.O. Box 5010Hanover, NH 03755 USA603-643-3441 Tel (Main Office)603-643-5352 Fax (All Departments)info@hypertherm.com (Main Office Email)800-643-9878 Tel (Technical Service)service@hypertherm.com (Technical Service Email)800-737-2978 Tel (Customer Service)customer.servi...

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    ELECTROMAGNETIC COMPATIBILITY (EMC)EMC INTRODUCTIONHypertherm's CE-marked equipment is builtin compliance with standard EN50199. Theequipment should be installed and used inaccordance with the information below toachieve electromagnetic compatibility.The limits required by EN50199 may not beadequ...

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    WARRANTYiiHyperthermPlasma Systems9-01WARNINGGenuine Hypertherm parts are the factory-recommendedreplacement parts for your Hypertherm system. Any damagecaused by the use of other than genuine Hypertherm parts maynot be covered by the Hypertherm warranty.WARNINGYou are responsible for the safe us...

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    TABLE OF CONTENTSHyPerformance Plasma Instruction Manualiii1 6,Electromagnetic Compatibility (EMC) 6,.......................................................................................................................i 7,Warranty...................................................................

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    TABLE OF CONTENTSivHyPerformance Plasma Instruction Manual0 27,Ignition console 27,................................................................................................................................................2-3 27,Gas console 27,.................................................

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    TABLE OF CONTENTSHyPerformance Plasma Instruction Manualv3 57,Optional multi-system CNC interface 57,cable 57,...................................................................................................3-23 58,Notes to CNC interface 58,cable run list 58,...................................

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    TABLE OF CONTENTSviHyPerformance Plasma Instruction Manual0 98,Common cutting faults 98,............................................................................................................................................4-26 99,How to optimize 99,cut quality 99,............................

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    TABLE OF CONTENTSHyPerformance Plasma Instruction Manualvii0 134,Phase-loss detection test........................................................................................................................................5-33 135,Torch lead test 135,............................................

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    Hypertherm Plasma Systems1-1Section 1SAFETYIn this section: 14,Recognize Safety Information...................................................................................................................................1-2 14,Follow Safety Instructions 14,.........................................

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    SAFETY1-2HyperthermPlasma Systems11-98SAFETYRECOGNIZE SAFETY INFORMATIONThe symbols shown in this section are used toidentify potential hazards. When you see a safetysymbol in this manual or on your machine, understandthe potential for personal injury, and follow the relatedinstructions to avoid ...

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    Touching live electrical parts can cause a fatal shockor severe burn.• Operating the plasma system completes anelectrical circuit between the torch and theworkpiece. The workpiece and anything touchingthe workpiece are part of the electrical circuit.• Never touch the torch body, workpiece or ...

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    SAFETY1-4HyperthermPlasma Systems5/6/02SAFETYInstant-On TorchesPlasma arc comes on immediately when the torchswitch is activated.A PLASMA ARC CAN CAUSE INJURY AND BURNSThe plasma arc will cut quickly through gloves andskin.• Keep away from the torch tip.• Do not hold metal near the cutting pa...

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    SAFETYHypertherm Plasma Systems1-511-98SAFETY• Never lubricate cylinder valves or regulators with oilor grease.• Use only correct gas cylinders, regulators, hosesand fittings designed for the specific application.• Maintain all compressed gas equipment andassociated parts in good condition....

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    SAFETY1-6HyperthermPlasma Systems8-99SAFETYWARNING LABELThis warning label is affixed to some power supplies. It isimportant that the operator and maintenance technicianunderstand the intent of these warning symbols as described.The numbered text corresponds to the numbered boxes onthe label.1.Cu...

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    HyperthermSystèmes plasma1a-12/12/01Section 1aSÉCURITÉDans cette section : 20,Identifier les consignes 20,de sécurité.........................................................................................................................1a-2 20,Suivre les instructions de sécurité 20,......

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    SÉCURITÉ1a-2HyperthermSystèmes plasma2/12/01IDENTIFIER LES CONSIGNES DE SÉCURITÉLes symboles indiqués dans cette section sont utilisés pouridentifier les risques éventuels. Si vous trouvez un symbolede sécurité, que ce soit dans ce manuel ou surl’équipement, soyez conscient des risqu...

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    SÉCURITÉHyperthermSystèmes plasma1a-32/12/01Toucher une pièce électrique sous tension peut provoquerun choc électrique fatal ou des brûlures graves.• La mise en fonctionnement du système plasma ferme uncircuit électrique entre la torche et la pièce à couper. Lapièce à couper et tou...

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    SÉCURITÉ1a-4HyperthermSystèmes plasma5/6/02Torches à allumage instantanéL’arc plasma s’allume immédiatement après que la torchesoit mise en marche.L’ARC PLASMA PEUT PROVOQUER DES BLESSURES OU DES BRÛLURESL’arc plasma coupe facilement les gants et la peau.• Rester éloigné de l...

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    SÉCURITÉHyperthermSystèmes plasma1a-52/12/01• Ne jamais lubrifier les robinets des bouteilles ou lesrégulateurs avec de l’huile ou de la graisse.• Utiliser uniquement les bouteilles, régulateurs, tuyaux etaccessoires appropriés et conçus pour chaque applicationspécifique.• Entrete...

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    SÉCURITÉ1a-6HyperthermSystèmes plasma2/12/01Étiquette de sécuritéCette étiquette est affichée sur la source de courant. Il est importantque l’utilisateur et le technicien de maintenance comprennent lasignification des symboles de sécurité. Les numéros de la listecorrespondent aux num...

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    3HyPerformance Plasma Instruction Manual2-1Section 2SPECIFICATIONSIn this section: 27,System description 27,...................................................................................................................................................2-3 27,General 27,.........................

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    SPECIFICATIONS2-2HyPerformance Plasma Instruction Manual0

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    SPECIFICATIONSHyPerformance Plasma Instruction Manual2-33System descriptionGeneralHyPerformance plasma systems are designed to cut a wide range of thicknesses of mild steel, stainless steeland aluminum.Power supplyThe power supply is a 130-amp, 150-VDC constant-current supply. It contains the cir...

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    Gas quality and pressure requirementsQualityPressure +/- 10%Flow rateO2 Oxygen99.5% pure 827 kPa / 8.3 bar4250 l/h 150 scfh Clean, dry, oil-free120 psiN2 Nitrogen99.99% pure 827 kPa / 8.3 bar7080 l/h 250 scfhClean, dry, oil-free120 psiAirClean, dry, oil-free827 kPa / 8.3 bar7080 l/h 250 scfh120 p...

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    SPECIFICATIONSHyPerformance Plasma Instruction Manual2-53Power supplyGeneralMaximum OCV (U0)311 VDCMaximum output current (I2)130 AmpsOutput voltage (U2)50 – 150 VDCDuty cycle rating (X)100% @ 19.5 kw, 40° C (104° F)Ambient temperature/Duty cyclePower supplies will operate between -10° C and...

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    SPECIFICATIONS2-6HyPerformance Plasma Instruction Manual0Ignition console assembly – 078172• The ignition console may be mounted locally on the power supply (LHF) or remotely on the cutting table’sbridge (RHF). See Installation section for details.• Maximum cable length from the ignition ...

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    SPECIFICATIONSHyPerformance Plasma Instruction Manual2-73Horizontal mountingVertical mountingLHF mounting (local)Mounted on tableRHF mounting (remote)

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    SPECIFICATIONS2-8HyPerformance Plasma Instruction Manual0Gas console assembly – 078170• Maximum cable length from the power supply to the gas console is 46 m (150 ft).• Maximum cable length from the gas console to the off-valve assembly is 15 m (50 ft).• Position the gas console on top of...

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    SPECIFICATIONSHyPerformance Plasma Instruction Manual2-93Off-valve assembly – 129816• Maximum cable length from the off-valve to the torch lifter station is 1.8 m (6 ft).• Mount the off-valve assembly to the torch carriage on larger tables. On smaller tables it can be mounted toa bracket ju...

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    SPECIFICATIONS2-10HyPerformance Plasma Instruction Manual3Torch specifications – 128818• The outside diameter of the torch mounting sleeve is 50.8 mm (2.0 in.)1.8 m6'2.11 kg4.65 lb193 mm7.59"27 mm1.07"116 mm4.55"51 mm2.00"48 mm1.89"107 mm4.22"51 mm2.00"57 mm...

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    3HyPerformance Plasma Instruction Manual3-1Section 3INSTALLATIONIn this section: 37,Upon receipt 37,.............................................................................................................................................................3-3 37,Claims 37,........................

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    INSTALLATION3-2HyPerformance Plasma Instruction Manual3 63,Torch connection.....................................................................................................................................................3-29 64,Torch mounting and alignment........................................

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    INSTALLATIONHyPerformance Plasma Instruction Manual3-30Upon receipt• Verify that all system components on your order have been received. Contact your supplier if any itemsare missing.• Inspect the system components for any physical damage that may have occurred during shipping. If there isevi...

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    INSTALLATION3-4HyPerformance Plasma Instruction Manual0Installation requirementsABCD123456789101113E15161412

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    INSTALLATIONHyPerformance Plasma Instruction Manual3-50System componentsPower supplyIgnition consoleGas consoleOff-valve assemblyTorchCables and hosesPilot arc leadNegative leadIgnition control cableIgnition console coolant hosesGas control cableGas power cableGas console to off-valve hose and le...

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    INSTALLATION3-6HyPerformance Plasma Instruction ManualPlacement of system components• Place all system components in position prior to making electrical, gas and interface connections. Use thediagram in this section for component placement guidelines.• Ground all system components to earth. S...

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    INSTALLATIONHyPerformance Plasma Instruction Manual3-73System grounding requirementsThe plasma system must be grounded for safety reasons and to suppress EMI:• Safety The entire system – power supply, accessory enclosures, and worktable – must be grounded toprotect it and the operator from ...

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    INSTALLATION3-8HyPerformance Plasma Instruction Manual0Work table groundingIf a supplementary ground rod is installed near the worktable to reduce EMI, it must be connected directly to thePE ground of the building structure, connected to the service ground; or to earth, providing the resistance b...

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    INSTALLATIONHyPerformance Plasma Instruction Manual3-90Figure 2Alternate Ground Connection ConfigurationThe preferred cable routing for this configuration is as shown, but it is acceptable to “daisy-chain” the grounds forthe gas console and other equipment to the ignition console. The ignitio...

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    INSTALLATION3-10HyPerformance Plasma Instruction Manual0Placement of the power supplyADANGERELECTRICAL SHOCK CAN KILLRemove all electrical connections to power supply before moving or positioning. Transporting unitcan cause personal injury and equipment damage.The power supply can be moved by for...

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    INSTALLATIONHyPerformance Plasma Instruction Manual3-110Mount the ignition console• Mount the ignition console on the gantry (bridge) for the RHF configuration.• Mount the ignition console on the power supply for the LHF configuration.• Allow room to remove the top for servicing.B7 mm .028&...

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    INSTALLATION3-12HyPerformance Plasma Instruction Manual0LHF mountingHorizontal RHF mountingVertical RHF mounting

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    INSTALLATIONHyPerformance Plasma Instruction Manual3-130Placement of the gas console• Position the gas console near the cutting table. Allow room to remove the top and right side cover forservicing. Preferred orientation is shown in the figure below. The maximum length of cables between thepowe...

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    INSTALLATION3-14HyPerformance Plasma Instruction Manual3Install the off-valve• Mount the off-valve assembly near the torch lifter station. The maximum length of the gas hoses betweenthe off-valve assembly and the torch is 1.2 m (4 ft).DAAA-A30 mm1.18"4.7 mm0.187"19 mm.075"157 mm6...

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    INSTALLATIONHyPerformance Plasma Instruction Manual3-153Power supply to ignition console leadsPilot arc lead1Part no.Length1236831.5 m (5 ft)1236667.5 m (25 ft)12366715 m (50 ft)12373525 m (82 ft)12366835 m (115 ft)12366945.5 m (150 ft)Negative lead2Pilot arc leadNegative leadPart no.Length123702...

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    INSTALLATION3-16HyPerformance Plasma Instruction Manual3Pilot arc leadNegative leadPilot arc leadNegative lead1221Work lead

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    INSTALLATIONHyPerformance Plasma Instruction Manual3-170Ignition control cable3Part no.Length123684 1.5 m (5 ft)1236707.5 m (25 ft)12367115 m (50 ft)12373625 m (82 ft)12367235 m (115 ft)12367345 m (150 ft)CABLE SIGNAL LIST – power supply to ignition consolePower supply endIgnition console endPi...

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    INSTALLATION3-18HyPerformance Plasma Instruction Manual3Ignition console coolant hoses4RedGreenGreenRedPart no.Length1284991.5 m (4.33 ft)0284417.5 m (25 ft)02844215 m (50 ft)12807825 m (82 ft)02889635 m (115 ft)02844545.5 m (150 ft)4

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    INSTALLATIONHyPerformance Plasma Instruction Manual3-193Power supply to gas console cablesPart no.Length1237843 m (10 ft)1236917.5 m (25 ft)12371115 m (50 ft)12373725 m (82 ft)12373835 m (115 ft)12373945 m (150 ft)Control cable5Power cable6CABLE SIGNAL LIST – power supply to gas consolePower su...

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    INSTALLATION3-20HyPerformance Plasma Instruction Manual31X5J103J300FemaleMale56563X13X23X3

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    INSTALLATIONHyPerformance Plasma Instruction Manual3-213Cable and gas hose assembly7Gas console to off-valve cableOff-valve cable110986547231112 13 14End BEnd A ( male/pins)Gas console to off-valve connectionsCABLE SIGNAL LIST – gas console to off-valve cableGas console endOff-valve endPin # I/...

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    INSTALLATION3-22HyPerformance Plasma Instruction Manual37GreenRedBlackBlueGreenRedBlackBlue

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    INSTALLATIONHyPerformance Plasma Instruction Manual3-233WireInput/Input/colorPin #OutputSignal nameFunctionOutputNotesBlack1InputRx -RS-422 serial receiverOutputRed20InputRx +RS-422 serial receiverOutputBlack2OutputTx -RS-422 serial transmitterInputGreen21OutputTx +RS-422 serial transmitterInputB...

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    INSTALLATION3-24HyPerformance Plasma Instruction Manual3Notes to CNC interface cable run listNote 1.Inputs are optically isolated. They require 24 VDC at 7.3 mA, or dry-contact closure.Note 2.Outputs are optically isolated, open collector, transistors. The maximum rating is 24 VDC at 10 mA.Note 3...

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    INSTALLATIONHyPerformance Plasma Instruction Manual3-253Examples of output circuits1. Logic interface, active-high2. Logic interface, active-low3. Relay interface4. Do not use this configuration. Warranty will be void.High-impedence (≤10mA)10K(optional)CNC/PLC5VDC-24VDCCHPRE+-HPRCE+-5VDC-24VDCH...

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    INSTALLATION3-26HyPerformance Plasma Instruction Manual3Examples of input circuitsOutput fromCNC/PLCExternal relay(AC or DC)1. Relay interface+24VDCHPRPowerground2. Optocoupler interfaceCNC/PLC+24VDCHPRPowergroundTransistor-outputoptocoupler12V-24VDCCNC/PLC+24VDCHPRPowergroundPowergroundActive-hi...

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    INSTALLATIONHyPerformance Plasma Instruction Manual3-273Torch lead assembly10Plasma gas ventPart no.Length1289353 m (10 ft)1289344.5 m (15 ft)1287847.5 m (25 ft)12878515 m (50 ft)10Grey

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    INSTALLATION3-28HyPerformance Plasma Instruction Manual3Work lead11Work leadWork leadLower frame of work table (typical).Part no.Length1237021.5 m (4.33 ft)1236627.5 m (25 ft)12366315 m (50 ft)12373425 m (82 ft)12366435 m (115 ft)12366545.5 m (150 ft)Work tablePower supply

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    INSTALLATIONHyPerformance Plasma Instruction Manual3-293Torch connectionInstallation noteAlign the torch body to the torch leads and secure byscrewing completely together. Be certain that there is nospace between the torch body and the o-ring on the torchleads. See also Ignition console connectio...

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    INSTALLATION3-30HyPerformance Plasma Instruction Manual0Torch mounting and alignmentMounting the torchTorch alignmentTo align the torch at right angles to the workpiece, use a square at 0° and 90°. See figure above.See also Changing consumables in Section 4 to install consumables in the torch.I...

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    INSTALLATIONHyPerformance Plasma Instruction Manual3-313InputRated input currentRecommendedCable size at 15 mvoltagePhase@ 19.5 kW outputslow-burn fuse size(50 feet)200/208 VAC362/58 amps85 amps30 mm2 (3 AWG)240 VAC352 amps65 amps26 mm2 (4 AWG)400 VAC332 amps40 amps10 mm2 (8 AWG)440 VAC328 amps35...

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    INSTALLATION3-32HyPerformance Plasma Instruction Manual0Connect the power1. Insert the power cable through the strain relief at the rear of the power supply.2. Connect the ground lead (PE) to the GND terminal of TB1 as shown below.3. Connect the power leads to the terminals of TB1 as shown below....

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    INSTALLATIONHyPerformance Plasma Instruction Manual3-330Torch coolant requirementsThe power supply is shipped without any coolant in the tank. Hypertherm recommends a mixture of 30% propyleneglycol, 69.9% deionized water, and 0.1% benzotriazole. This mixture resists freezing to -12° C (+10° F) ...

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    INSTALLATION3-34HyPerformance Plasma Instruction Manual3Fill the power supply with coolantThe system will take 11.4 – 15.1 liters (3 to 4 gallons) of coolant depending on the length of the torch leads and ifthe system has a local or remote ignition console.The current display shows the flow rat...

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    INSTALLATIONHyPerformance Plasma Instruction Manual3-353Gas requirementsThe customer furnishes all gases and gas-supply regulators for the system. Use a high-quality, 2-stage pressureregulator located within 3 m (10 ft) of the gas console. See gas regulators in this section for recommendations. S...

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    INSTALLATION3-36HyPerformance Plasma Instruction Manual0Gas regulatorsLow-quality gas regulators do not provide consistent supply pressures and can result in poor cut quality and systemoperation problems. Use a high-quality, 1-stage, gas regulator to maintain consistent gas supply pressure, if us...

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    INSTALLATIONHyPerformance Plasma Instruction Manual3-370Supply gas plumbingRigid copper plumbing or suitable flexible hose may be used for all gas supplies. Do not use steel or aluminum pipe.After installation, pressurize the entire system and check for leaks.Recommended hose diameters are 9.5 mm...

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    INSTALLATION3-38HyPerformance Plasma Instruction Manual0Supply gas hosesPart no.Length0242057.5 m (25 ft)02415515 m (50 ft)02473825 m (82 ft)02420635 m (115 ft)02415945 m (150 ft)Oxygen hose12Part no.Length0246597.5 m (25 ft)02466015 m (50 ft)02474025 m (82 ft)02467635 m (115 ft)02467845 m (150 f...

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    3HyPerformance Plasma Instruction Manual4-1Section 4OPERATIONIn this section: 74,Daily start-up.............................................................................................................................................................4-2 74,Check torch 74,.........................

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    Daily start-upPrior to start-up, ensure that your cutting environment and that your clothing meet the safety requirements outlinedin the Safety section of this manual. Check torch1. Turn main disconnect switch to the power supply OFF.2. Remove the consumables from the torch and check for worn or ...

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    OPERATIONHyPerformance Plasma Instruction Manual4-33Controls and indicatorsGeneralThe main power switch for the HyPerformance plasma system is located on the gasconsole. There is no power switch on the power supply. The gas console controls allsystems functions. Error codes are shown in the LED d...

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    OPERATION34-4HyPerformance Plasma Instruction Manual1. Turn ON the power. 2. Follow instructions below using the settings provided in the Cut charts.Position #Instruction1Select PLASMA GAS.2Select SHIELD GAS.3, 4 & 7Position switch (7) to SET PREFLOW (3-4). Set plasma preflow (3). Set shield ...

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    Consumable selectionMild steel22019322019222018030A22018780A220181130AShieldNozzleRetaining capSwirl ringElectrode220179220179220188220182Shield cap220183220189220194220176220176220313220173OPERATIONHyPerformance Plasma Instruction Manual4-50Stainless steel22020122030822018045A22033980A220307130A...

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    OPERATION34-6HyPerformance Plasma Instruction ManualAluminum22020122030822018045A220307 (H35)220181 (Air)130AShieldNozzleRetaining capSwirl ringElectrode220179220197Shield cap220198220202220176220173220304 (H35)220176 (Air)Consumable selection (continued)

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    OPERATIONHyPerformance Plasma Instruction Manual4-73Install consumablesApply a thin coat of silicone grease on all o-rings.Do not overtighten parts! Only tighten until mating parts are seated.Clean current ring usinga cotton swab with wateror 3% hydrogen peroxide.

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    OPERATION34-8HyPerformance Plasma Instruction ManualCut chartsThe following Cut charts show the consumable parts, cutting speed and the gas and torch settings required foreach process.The numbers shown in the Cut charts are recommended to provide high-quality cuts with minimal dross. Becauseof di...

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    OPERATIONHyPerformance Plasma Instruction Manual4-93Estimated kerf width compensationThe widths in the chart below are for reference. Differences between installations and material composition maycause the specific user results to vary from those shown in the table.EnglishThickness (in)Process0.0...

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    OPERATION34-10HyPerformance Plasma Instruction ManualMild steelO2 Plasma / O2 Shield30 A Cutting220194220173220192220313220180220193 Flow Rates – lpm/scfhO2AirPreflow0 / 046 / 97Cutflow22 / 460/0*Pierce complete is recommended for these thicknessesNote: Air must be connected to use this proce...

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    OPERATIONHyPerformance Plasma Instruction Manual4-113Mild steelO2 Plasma / Air Shield80 A Cutting220189220173220187220176220179220188 Flow Rates – lpm/scfhO2AirPreflow0 / 076 / 161Cutflow23 / 4841 / 87

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    OPERATION34-12HyPerformance Plasma Instruction ManualMild steelO2 Plasma / Air Shield130 A Cutting220183220173220181220176220179220182 Flow Rates – lpm/scfhO2AirPreflow0 / 0102 / 215Cutflow33 / 7045 / 96

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    Flow Rates – lpm/scfhN2Preflow24 / 51Cutflow75 / 159OPERATIONHyPerformance Plasma Instruction Manual4-133Stainless steelN2 Plasma / N2 Shield45 A Cutting220202220173220308220304220180220201Note:This process produces a darker cut edge than the 45A, F5/N2 stainless steel process

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    OPERATION34-14HyPerformance Plasma Instruction ManualStainless steelF5 Plasma / N2 Shield45 A Cutting220202220173220308220304220180220201Note:This process produces a shinier cut edge than the 45A, N2/N2 stainless steel process Flow Rates – lpm/scfhF5N2Preflow0 / 043 / 91Cutflow8 / 1765 / 138

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    OPERATIONHyPerformance Plasma Instruction Manual4-153Stainless steelF5 Plasma / N2 Shield80 A Cutting220338220173220339220304220179220337 Flow Rates – lpm/scfhF5N2Preflow0 / 067 / 142Cutflow31 / 6555 / 116

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    OPERATION34-16HyPerformance Plasma Instruction ManualStainless steelN2 Plasma / N2 Shield130 A Cutting220198220173220307220179220197220176Note:This process produces a rougher, darker cut edge with more dross and less cut angle variation thanthe 130A, H35/N2 process Flow Rates – lpm/scfhN2Pref...

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    OPERATIONHyPerformance Plasma Instruction Manual4-173Stainless steelH35 Plasma / N2 Shield130 A Cutting220198220173220307220304220179220197Note:This process produces a smoother, shinier cut edge with less dross and greater cut angle variationthan the 130A, N2/N2 process Flow Rates – lpm/scfhH...

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    OPERATION34-18HyPerformance Plasma Instruction ManualAluminumAir Plasma / Air Shield45 A Cutting220202220173220308220176220180220201 Flow Rates – lpm/scfhAirPreflow45 / 95Cutflow78 / 165

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    OPERATIONHyPerformance Plasma Instruction Manual4-193AluminumAir Plasma / Air Shield130 A Cutting220198220173220181220176220179220197Note:This process produces a rougher cut edge with larger average angles than the 130A, H35/N2 process Flow Rates – lpm/scfhAirPreflow73 / 154Cutflow78 / 165

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    OPERATION34-20HyPerformance Plasma Instruction ManualAluminumH35 Plasma / N2 Shield130 A Cutting220198220173220307220304220179220197Note:This process produces a smoother cut edge with smaller average angles than the 130A, Air/Airprocess Flow Rates – lpm/scfhH35N2Preflow0 / 076 / 160Cutflow26 ...

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    OPERATIONHyPerformance Plasma Instruction Manual4-213Changing consumable partsRemove consumablesCheck the consumable parts daily for wear before cutting. Before removing consumables, bring the torch to theedge of the cutting table, with the torch lifter raised to its highest point to prevent the ...

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    OPERATION04-22HyPerformance Plasma Instruction ManualInspect consumablesPartCheck forActionCapNozzleSwirl ringElectrodeCenter surfaceWearO-rings1. DamageReplace electrode*2. LubricantApply a thin film of silicone lubricant if dry*Note:Always replace the nozzle and electrode as a set.DamageReplace...

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    OPERATIONHyPerformance Plasma Instruction Manual4-230All surfacesDirt or debrisClean surfacesErosion, missing materialReplace torchCracksReplace torchInternal burn or arcing marksReplace torchCurrent ring1. Dirt or debrisClean2. Pitted or missing materialReplace torchThreadsWear or damageReplace ...

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    OPERATION34-24HyPerformance Plasma Instruction ManualPartCheck forAction100204030402318060705090Inspect electrode pit depthElectrodeCenter surfaceWearReplace electrode if pit is deeper than 1 mm (0.040 in.)**Note:Always replace the nozzle and electrode as a set.Electrode pit depth gauge (004630)

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    OPERATIONHyPerformance Plasma Instruction Manual4-253Replace torch water tubeTurn OFF all power to the system.Remove consumables from torch. See Remove consumables in this section.WARNINGThe system is designed to go into an idle mode if the retaining cap is removed. However, DO NOTREMOVE CONSUMAB...

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    OPERATION04-26HyPerformance Plasma Instruction ManualCommon cutting faults• Torch pilot arc will initiate, but will not transfer. Causes can be:1. Work cable connection on the cutting table is not making good contact.2. Malfunction in the system. See Section 5..3. Torch-to-work distance is too ...

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    OPERATIONHyPerformance Plasma Instruction Manual4-270How to optimize cut qualityThe following tips and procedures will help produce square, straight, smooth and dross-free cuts.Tips for table and torch• Use a square to align the torch at right angles to the workpiece.• The torch may travel mo...

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    OPERATION04-28HyPerformance Plasma Instruction ManualAdditional factors of cut qualityCut angle A cut part whose 4 sides average less than 4° of cut angle is considered acceptable.Note:The squarest cut angle will be on the right side with respect to the forward motion of the torch.Note:To determ...

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    OPERATIONHyPerformance Plasma Instruction Manual4-290Straightness of the cut surface A typical plasma cut surface is slightly concave.The cut surface may become more concave, or convex. Correct torch height is required to keep the cutsurface acceptably close to straight. A strongly concave cut su...

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    3HyPerformance Plasma Instruction Manual5-1Section 5MAINTENANCEIn this section: 103,Introduction 103,...............................................................................................................................................................5-2 103,Routine maintenance 103,......

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    MAINTENANCE5-2HyPerformance Plasma Instruction Manual0IntroductionHypertherm assumes that the service personnel performing the troubleshooting testing are high-levelelectronic service technicians who have worked with high-voltage electro-mechanical systems. Knowledgeof final isolation troubleshoo...

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    MAINTENANCEHyPerformance Plasma Instruction Manual5-30System descriptionControl and signal cablesPower Cable: Provides 120 VAC to the Gas Console.Signal Cable: Provides process and status signals between the Power Supply and the Gas Console.Power Cable: Provides 120 VAC to the Ignition Consoleand...

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    MAINTENANCE5-4HyPerformance Plasma Instruction Manual3Sequence of operation1. Power-up – The system verifies that all of these signals are off at power-upCoolant flow offChopper current offTransfer offPhase Loss offChopper 1 over-temp offMagnetics over-temp offCoolant over-temp offPlasma start ...

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    MAINTENANCEHyPerformance Plasma Instruction Manual5-53PCB block diagram

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    MAINTENANCE5-6HyPerformance Plasma Instruction Manual3Error codesHyPerformance plasma system error codesError codes are displayed in the 3-digit LED display on the gas console.

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    Error code troubleshooting (1 of 6)MAINTENANCEHyPerformance Plasma Instruction Manual5-73

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    MAINTENANCE5-8HyPerformance Plasma Instruction Manual3Error code troubleshooting (2 of 6)

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    MAINTENANCEHyPerformance Plasma Instruction Manual5-93Error code troubleshooting (3 of 6)

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    MAINTENANCE5-10HyPerformance Plasma Instruction Manual3Error code troubleshooting (4 of 6)

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    MAINTENANCEHyPerformance Plasma Instruction Manual5-113Error code troubleshooting (5 of 6)

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    MAINTENANCE5-12HyPerformance Plasma Instruction Manual3Error code troubleshooting (6 of 6)

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    MAINTENANCEHyPerformance Plasma Instruction Manual5-133IDName00Idle02Purge03Idle 204Preflow05Pilot arc06Transfer07Ramp-up08Steady state09Ramp-down10Final ramp-down11Auto off12Test cutflow14Shutdown15Reset16Maintenance20Test preflow22Manual pump control23Inlet leak check24System leak checkPower su...

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    MAINTENANCE5-14HyPerformance Plasma Instruction Manual3Plasma system operation with pump timeout

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    MAINTENANCEHyPerformance Plasma Instruction Manual5-153CNC operation with pump timeoutUserpressesstart onCNCAssert the plasmastart and holdsignals to allplasma systemsIs the NOT READY FORSTART signal active onany plasma systemApply the startsignal and removethe hold signalNoCompletethe cut cycleR...

  • Page 117

    MAINTENANCE5-16HyPerformance Plasma Instruction Manual3Initial checksBefore tracking down specific problems, do a visual check and verify proper voltages are present at the powersource, transformers and power distribution board.1. Disconnect line power by turning main disconnect switch OFF.2. Rem...

  • Page 118

    MAINTENANCEHyPerformance Plasma Instruction Manual5-173Power measurementNote:Check lines in the following order:U to VU to WV to WCheck each line to ground. If oneline is 10% or higher than the other two,put that leg on U.WARNINGThere is line voltage at the contactor after the line disconnect swi...

  • Page 119

    MAINTENANCE5-18HyPerformance Plasma Instruction Manual3CautionThe coolant pump will be damaged if it is run without coolant.Immediately release the current selection knob (8) when coolant stopsflowing.Power supply coolant system servicingDraining the coolant systemVerify that the power is OFF, an...

  • Page 120

    MAINTENANCEHyPerformance Plasma Instruction Manual5-1932345Coolant system filter and strainerFilter replacement1. Turn OFF all power to the system.2. Remove housing.3. Remove and discard filter element.4. Install new filter element 027664.5. Re-install housing.Pump strainer cleaning1. Turn OFF al...

  • Page 121

    MAINTENANCE5-20HyPerformance Plasma Instruction Manual31. Turn OFF the power. Remove the return coolant hose (blue hose with red tape) from the manifold in the powersupply and place it in a 20 liter (5 gallon) container.2. Turn ON the power. Press and hold the current selection knob (8) and allow...

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    MAINTENANCEHyPerformance Plasma Instruction Manual5-213TP 206TP 210Testing the flow switch5. Reconnect the return hose to the pump and turn ON the power. Press and hold the current selection knob (8).6. Measure the VDC between TP210 and TP206.TP206 is common on PCB3. TP210 provides a filtered, 67...

  • Page 123

    MAINTENANCE5-22HyPerformance Plasma Instruction Manual3Gas leak test procedureThe system has two automatic leak test modes. The leak test mode is activated by switching the shield gasselector switch (2) to the TEST position and then switching the RUN/SET switch (7) to either SET PREFLOW orSET CUT...

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    MAINTENANCEHyPerformance Plasma Instruction Manual5-233Power supply control board PCB3Control PC Board LEDN300 ListLEDNOutputInputNotesLEDN1Machine motionLEDN2ErrorLEDN3Rampdown errorLEDN4Not readyLEDN5Soft start enableNot usedLEDN6Pilot arc enableLEDN7Corner currentLEDN8PierceLEDN9HoldLEDN10Plas...

  • Page 125

    MAINTENANCE5-24HyPerformance Plasma Instruction Manual3Power supply power distribution board PCB2D23D12D26D35D31D32D33D3D25D1D7D5D2Power distribution PC board LED listLEDOutputColorD1ContactorRedD2Pilot arc relayRedD3120 VAC (switched)GreenD5HF ignitionRedD7Surge selectRedD1224 VAC (switched)Gree...

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    MAINTENANCEHyPerformance Plasma Instruction Manual5-253Start circuit functional schematicStart circuit troubleshootingWARNINGSHOCK HAZARD: Always use caution when servicing a power supply when plugged in and the covers areremoved. Dangerous voltages exist within the power supply which could cause...

  • Page 127

    MAINTENANCE5-26HyPerformance Plasma Instruction Manual3D2 should always be illuminated.D1 illuminates as soon as the torch fires and will extinguish as soon as thearc transfers to the workpiece. If arc transfer is immediate, the LED will notilluminate.If there is no arc at the torch or if the arc...

  • Page 128

    MAINTENANCEHyPerformance Plasma Instruction Manual5-273Pilot arc current levelsThe pilot arc current level will change depending on the chosen process and arc current level. See table below.Pilot Arc CurrentPlasma Gas30-amps45-amps70-amps80-amps130-ampsO2202030N2202535H3535F52025Air2535Transfer C...

  • Page 129

    MAINTENANCE5-28HyPerformance Plasma Instruction Manual3Gas console control board PCB2Gas console control board LED listLEDSignal nameColorD1+ 5 VDCGreenD2+ 3.3 VDCGreenD4Coolant errorYellowD6Pressure errorYellowD8CAN- TXGreenD9CAN- RXGreenD10Voltage errorYellowD11Temperature errorYellowGas consol...

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    MAINTENANCEHyPerformance Plasma Instruction Manual5-293Gas console power distribution PCB1LEDSignal NameColorD1120 VAC (switched)GreenD7+ 5 VDCRedD9+ 24 VDCRed

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    MAINTENANCE5-30HyPerformance Plasma Instruction Manual3Gas console, AC valve-driver PCB3LEDSignal NameColorLEDSignal NameColorD1SV1RedD11SV11RedD2SV2RedD12SV12RedD3SV3RedD13SV13RedD4SV4RedD14SV14RedD5SV5RedD15SV15RedD6SV6RedD16SV16RedD7SV7RedD17SV17RedD8SV8RedD18SV18RedD9SV9RedD19SV19RedD10SV10Re...

  • Page 132

    MAINTENANCEHyPerformance Plasma Instruction Manual5-313Chopper module test procedureNote:Read voltages with a digital multimeter (DVM) capable of storing minimum and maximum readings.1. Turn OFF all power to the system. Disconnect the 2 terminals (Wire colors red andred/black) on the line filter ...

  • Page 133

    MAINTENANCE5-32HyPerformance Plasma Instruction Manual36. If the chopper does not output +311 VDC, verify that LED2 and D2 are illuminated. If they are extinguished,verify that 120 V is going to JP9.6, pins 1 and 2, on the chopper. If there is not 120 V at JP9.6, Inspect the wiringto the power di...

  • Page 134

    MAINTENANCEHyPerformance Plasma Instruction Manual5-333Phase-loss detection test1. Turn OFF all power to the system and remove the cover from CON1.2. Inspect the condition of the 3 contacts for excessive wear. If one of more of the contacts are worn excessively,replace CON1 and restart the system...

  • Page 135

    MAINTENANCE5-34HyPerformance Plasma Instruction Manual3Torch lead test1. Turn OFF all power to the system.2. Locate the start circuit assembly.041811WARNINGSHOCK HAZARD: Always use caution when servicing a power supply when plugged in and the covers areremoved. Dangerous voltages exist within the...

  • Page 136

    MAINTENANCEHyPerformance Plasma Instruction Manual5-350Preventative Maintenance Schedule Year________Daily:Verify proper inlet gas pressure -- See Instruction Manual, Specification sectionVerify proper gas flow settings -- Mandatory at every consumable change -- See Instruction Manual, Opera...

  • Page 137

    HyPerformance Plasma Instruction Manual6-10Section 6PARTS LISTIn this section: 138,Power supply 138,............................................................................................................................................................6-2 142,Ignition console 142,............

  • Page 138

    PARTS LIST06-2HyPerformance Plasma Instruction ManualPartItemNumberDescriptionDesignatorQty.1078177HyPerformance Plasma power supply: 200 volt078180HyPerformance Plasma power supply: 400 volt078181HyPerformance Plasma power supply: 480 volt078183HyPerformance Plasma power supply: 600 volt2129633G...

  • Page 139

    PARTS LIST0HyPerformance Plasma Instruction Manual6-3Power supplyPartItemNumberDescriptionDesignatorQty.1027634Filter housing1027664Filter element12127014Cap: coolant resevoir13129792Chopper assemblyCH1141270396" fan :230 CFM, 115 VAC 50-60 HZ2502707910" fan :450-550 CFM, 120 VAC 50-60 ...

  • Page 140

    PARTS LIST06-4HyPerformance Plasma Instruction ManualPower supplyPartItemNumberDescriptionDesignatorQty.1003149Relay: pilot arc, 120 VACCR112041837PCB: I/O13003139ContactorCON114109036*EMI filter: 60 amp, 440 VAC 3PH15109004Current sensor: hall 100 amp, 4 volt26129791Start circuit assemblyPCB1171...

  • Page 141

    PARTS LIST3HyPerformance Plasma Instruction Manual6-5PartItemNumberDescriptionDesignatorQty.1008551*Fuse: 7.5 amp, 600 voltF1, F22008709**Fuse: 20 amp, 500 voltF1, F222041808Control PCBPCB313041802Power distribution PCBPCB214129793Flow switch assemblyFLS15027978Heat exchanger assembly10271854&quo...

  • Page 142

    PARTS LIST06-6HyPerformance Plasma Instruction ManualIgnition console PartItemNumberDescriptionDesignatorQty.1078172Ignition Console2129831Coil assemblyT213041817HFHV Ignition PCB14129854TransformerT111234

  • Page 143

    PARTS LIST0HyPerformance Plasma Instruction Manual6-7Gas console – 1 of 2PartItemNumberDescriptionDesignatorQty.1078170Gas Console2041805Power distribution PCBPCB113041822Valve driver PCBPCB314005263Pressure sensorPT1-PT345006109Solenoid valveSV1-SV1414006112Replacement solenoid coil6005262Illu...

  • Page 144

    PARTS LIST36-8HyPerformance Plasma Instruction ManualGas console – 2 of 2PartItemNumberDescriptionDesignatorQty.1041814Control PCBPCB212129992Regulator assembly with elbow fittingPR1, PR3, PR433129993Regulator assembly with elbow and tee fittingPR21Off-valvePartItemNumberDescriptionDesignatorQt...

  • Page 145

    PARTS LIST3HyPerformance Plasma Instruction Manual6-9HyPerformance torchPartItemNumberDescription1128818130 amp machine torch assembly2220162Quick-disconnect torch3220340Water tube4220163Quick-disconnect recepticle5024751Insulating sleeve6220232Torch mounting sleeve assembly128879Torch kit: bulle...

  • Page 146

    PARTS LIST36-10HyPerformance Plasma Instruction ManualConsumable parts kit – 128878PartNumberDescriptionQty.001579Box: gray plastic1004630Electrode gauge assembly1026009O-ring: .208" X .070"5027012Lubricant: silicone 2-oz tube1044028O-ring: 1.364" X .070"2104119Tool: consuma...

  • Page 147

    PARTS LIST0HyPerformance Plasma Instruction Manual6-11Recommended spare partsPower supplyPartNumberDescriptionDesignatorQty.129633Green power lamp assembly1027634Filter housing1027664Filter element1129792Chopper assemblyCH111270396" fan :230 CFM, 115 VAC 50-60 HZ102707910" fan :450-550 ...

  • Page 148

    HyPerformance Plasma Instruction Manual7-10Section 7WIRING DIAGRAMSIntroductionThis section contains the wiring diagrams for the system. When tracing a signal path or referencing with the PartsList or Troubleshooting sections, please be aware of the following format to assist you in understanding...

  • Page 149

    WIRING DIAGRAMS7-2HyPerformance Plasma Instruction Manual0BatteryCap, polarizedCap, non-polarizedCap, feed-thruCircuit breakerCoax shieldCurrent SensorCurrent sensorDiodeDoor interlockFanFeedthru LCFilter, ACDC supplyFuseGround ClampGround, ChassisGround, EarthIGBTInductorLEDLightPinPlugPNP Trans...

  • Page 150

    WIRING DIAGRAMSHyPerformance Plasma Instruction Manual7-30Switch, Level,Normally ClosedTime Delay Closed,NO/OffTransformerElectrodeTorch SymbolsNozzleShieldTorchTransformer, Air CoreTransformer CoilValve, SolenoidVoltage SourceZener DiodeVAC SourceTriacSwitch, Pressure,Normally ClosedSwitch, Pres...

  • Page 151

    HyPerformance Plasma Instruction Manual7-53Discrete output functionality

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    7-73

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    7-93

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    7-113

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    7-133

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    7-153

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    7-173

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    7-333

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    7-353

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    7-373

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    7-393

  • Page 169

    0HyPerformance Plasma Instruction Manuala-1III. Power Upa. Processor boots in microprocessor mode and begins executing code in external flash memoryb. Limited initialization of DSP hardwarec. Checksum calculated on external flash and on DSP internal flash– if checksums don’t match copy code i...

  • Page 170

    SOFTWARE FUNCTIONAL DESCRIPTIONa-2HyPerformance Plasma Instruction Manual0• After delay wait for CAN watchdog message from a gas console• After CAN watchdog messages have been received, send a CAN reset message to the gas consoleand go to the Purge stateerror checking• Make sure start signa...

  • Page 171

    SOFTWARE FUNCTIONAL DESCRIPTIONHyPerformance Plasma Instruction Manuala-30• Pulse HF after 50 msec delay to allow pa relay to close.• If chopper current = 1⁄2 of pilot arc current, turn off HF and go to transfer state• If no chopper current after 10 HF pulses go to auto off state with err...

  • Page 172

    SOFTWARE FUNCTIONAL DESCRIPTIONa-4HyPerformance Plasma Instruction Manual0error checking• Check for no coolant flow (093)10. Final Rampdown• Chopper setpoints = 0error checking• Check for no coolant flow (093)11. Auto Off• Turn off pilot arc relay, pilot arc controller, HF, and machine mo...

  • Page 173

    0HyPerformance Plasma Instruction Manualb-1Appendix BPROPYLENE GLYCOL SAFETY DATABENZOTRIAZOLE SAFETY DATAIn this appendix:Propylene Glycol Safety DataSection 1 Chemical Product and Company Identification .............................................................................b-2Section 2 ...

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    0b-2HyPerformance Plasma Instruction Manual

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    0HyPerformance Plasma Instruction Manualb-3

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    0b-4HyPerformance Plasma Instruction Manual

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    0HyPerformance Plasma Instruction Manualb-5

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    0b-6HyPerformance Plasma Instruction ManualFigure b-1 Freezing Point of Propylene Glycol Solution% of Propylene GlycolTemperature, °F-70-60-50-40-30-20-100102030400102030405060

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    0HyPerformance Plasma Instruction Manualb-7

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    0b-8HyPerformance Plasma Instruction Manual

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    0HyPerformance Plasma Instruction Manualb-9

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    0b-10HyPerformance Plasma Instruction Manual

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