HPR260XD Manual PDF
HPR260XD Manual PDF
HPR260XD ®
Manual gas
Instruction manual
806340 – Revision 2
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HyPerformance Plasma
HPR260XD Manual Gas
Instruction Manual
(P/N 806340)
Hypertherm, Inc.
Hanover, NH USA
www.hypertherm.com
Hypertherm, HyPerformance, HyDefinition, LongLife and CommandTHC are trademarks of Hypertherm, Inc.
and may be registered in the United States and/or other countries.
Hypertherm, Inc. Hypertherm Europe B.V.
Etna Road, P.O. Box 5010 Vaartveld 9
Hanover, NH 03755 USA 4704 SE
603-643-3441 Tel (Main Office) Roosendaal, Nederland
603-643-5352 Fax (All Departments) 31 165 596907 Tel
info@hypertherm.com (Main Office Email) 31 165 596901 Fax
800-643-9878 Tel (Technical Service) 31 165 596908 Tel (Marketing)
technical.service@hypertherm.com (Technical Service Email) 31 165 596900 Tel (Technical Service)
800-737-2978 Tel (Customer Service) 00 800 4973 7843 Tel (Technical Service)
customer.service@hypertherm.com (Customer Service Email)
Hypertherm Japan Ltd.
Hypertherm Automation Level 9, Edobori Center Building
5 Technology Drive, Suite 300 2-1-1 Edobori, Nishi-ku
West Lebanon, NH 03784 USA Osaka 550-0002 Japan
603-298-7970 Tel 81 6 6225 1183 Tel
603-298-7977 Fax 81 6 6225 1184 Fax
03/08/11
Electromagnetic compatibility (EMC)
ElEctRoMAgNEtIc coMPAtIbIlIty (EMc)
The limits required by EN60974-10 may not be d. Safety critical equipment, for example guarding of
adequate to completely eliminate interference when the industrial equipment.
affected equipment is in close proximity or has a high
degree of sensitivity. In such cases it may be necessary e. Health of the people around, for example the use of
to use other measures to further reduce interference. pacemakers and hearing aids.
This cutting equipment is designed for use only in an f. Equipment used for calibration or measurement.
industrial environment.
g. Immunity of other equipment in the environment. User
Installation and use shall ensure that other equipment being used in the
environment is compatible. This may require additional
The user is responsible for installing and using the protection measures.
plasma equipment according to the manufacturer’s
instructions. h. Time of day that cutting or other activities are to be
carried out.
If electromagnetic disturbances are detected then it shall
be the responsibility of the user to resolve the situation The size of the surrounding area to be considered
with the technical assistance of the manufacturer. In will depend on the structure of the building and other
some cases this remedial action may be as simple activities that are taking place. The surrounding area
as earthing the cutting circuit, see Earthing of the may extend beyond the boundaries of the premises.
work piece. In other cases, it could involve constructing
an electromagnetic screen enclosing the power source
and the work complete with associated input filters. In all Methods of reducing emissions
cases, electromagnetic disturbances must be reduced to Mains supply
the point where they are no longer troublesome.
Cutting equipment must be connected to the
mains supply according to the manufacturer’s
Assessment of area recommendations. If interference occurs, it may be
Before installing the equipment, the user shall make an necessary to take additional precautions such as filtering
assessment of potential electromagnetic problems in of the mains supply.
the surrounding area. The following shall be taken into
account:
liability cap
In no event shall Hypertherm’s liability, if any,
whether such liability is based on breach of
contract, tort, strict liability, breach of warranties,
failure of essential purpose or otherwise, for
any claim, action, suit or proceeding (whether
in court, arbitration, regulatory proceeding or
otherwise) arising out of or relating to the use of
the Products exceed in the aggregate the amount
paid for the Products that gave rise to such claim.
Section 1
SAFETY.......................................................................................................................................................................................1-1
Recognize safety information...................................................................................................................................................................1-2
Follow safety instructions..........................................................................................................................................................................1-2
Electrical hazards........................................................................................................................................................................................1-2
Electric shock can kill.................................................................................................................................................................................1-3
Cutting can cause fire or explosion........................................................................................................................................................1-4
Toxic fumes can cause injury or death...................................................................................................................................................1-5
Static electricity can damage circuit boards........................................................................................................................................1-6
Compressed gas equipment safety........................................................................................................................................................1-6
Grounding safety........................................................................................................................................................................................1-6
Gas cylinders can explode if damaged..................................................................................................................................................1-6
A plasma arc can cause injury and burns..............................................................................................................................................1-7
Arc rays can burn eyes and skin..............................................................................................................................................................1-7
Noise can damage hearing.......................................................................................................................................................................1-8
Pacemaker and hearing aid operation...................................................................................................................................................1-8
A plasma arc can damage frozen pipes................................................................................................................................................1-8
Dry dust collection information................................................................................................................................................................1-9
Laser radiation.......................................................................................................................................................................................... 1-10
Symbols and marks................................................................................................................................................................................. 1-11
Additional safety information................................................................................................................................................................. 1-11
Warning labels.......................................................................................................................................................................................... 1-12
Section 1a
SÉCURITÉ................................................................................................................................................................................1a-1
Identifier les consignes de sécurité..................................................................................................................................................... 1a-2
Suivre les instructions de sécurité........................................................................................................................................................ 1a-2
Risques électriques................................................................................................................................................................................. 1a-2
Les chocs électriques peuvent être fatals.......................................................................................................................................... 1a-3
Le coupage peut provoquer un incendie ou une explosion........................................................................................................... 1a-4
Les vapeurs toxiques peuvent provoquer des blessures ou la mort............................................................................................ 1a-5
Sécurité des bouteilles de gaz comprimé.......................................................................................................................................... 1a-6
Mise à la masse et à la terre.................................................................................................................................................................. 1a-6
L’électricité statique peut endommager les cartes de circuits imprimés.................................................................................... 1a-6
Les bouteilles de gaz comprimé peuvent exploser en cas de dommages................................................................................. 1a-6
L’arc plasma peut provoquer des blessures ou des brûlures........................................................................................................ 1a-7
Les rayons de l’arc peuvent brûler les yeux et la peau.................................................................................................................... 1a-7
Le bruit peut provoquer des problèmes auditifs............................................................................................................................... 1a-8
Un arc plasma peut endommager les tuyaux gelés......................................................................................................................... 1a-8
Pacemakers et prothèses auditives..................................................................................................................................................... 1a-8
Information sur le dépoussièrage......................................................................................................................................................... 1a-9
Radiation au laser..................................................................................................................................................................................1a-10
Symboles et marquage.........................................................................................................................................................................1a-11
Étiquettes de sécurtité..........................................................................................................................................................................1a-12
Sección 1b
SEGURIDAD............................................................................................................................................................................1b-1
Reconocimiento de información de seguridad................................................................................................................................. 1b-2
Cumplimiento de instrucciones de seguridad.................................................................................................................................. 1b-2
Riesgos de electrocución...................................................................................................................................................................... 1b-2
Las descargas eléctricas pueden matar............................................................................................................................................. 1b-3
Los cortes pueden producir incendios o explosiones..................................................................................................................... 1b-4
Los vapores tóxicos pueden producir lesiones o la muerte........................................................................................................... 1b-5
Seguridad de equipos de gas comprimido....................................................................................................................................... 1b-6
Seguridad de toma a tierra.................................................................................................................................................................... 1b-6
La electricidad estática puede dañar las placas de circuitos........................................................................................................ 1b-6
Los cilindros de gas pueden explotar si están dañados................................................................................................................. 1b-6
El arco de plasma puede producir lesiones y quemaduras........................................................................................................... 1b-7
Los rayos del arco pueden quemar los ojos y la piel....................................................................................................................... 1b-7
Los ruidos pueden dañar la audición.................................................................................................................................................. 1b-8
Funcionamiento de marcapasos y audífonos.................................................................................................................................... 1b-8
El arco de plasma puede dañar las tuberías congeladas............................................................................................................... 1b-8
Información acerca de la recolección de polvo seco...................................................................................................................... 1b-9
Radiación láser.......................................................................................................................................................................................1b-10
Símbolos y marcas................................................................................................................................................................................1b-11
Etiquetas de advertencia......................................................................................................................................................................1b-12
Section 2
Specifications.....................................................................................................................................................................2-1
System description.....................................................................................................................................................................................2-3
General...............................................................................................................................................................................................2-3
Power supply.....................................................................................................................................................................................2-3
Ignition console.................................................................................................................................................................................2-3
Gas console......................................................................................................................................................................................2-3
Off-valve.............................................................................................................................................................................................2-3
Torch...................................................................................................................................................................................................2-3
Specifications..............................................................................................................................................................................................2-4
System gas requirements...............................................................................................................................................................2-4
Power supply.....................................................................................................................................................................................2-5
Ignition console – 078172.............................................................................................................................................................2-6
Gas console – 078532..................................................................................................................................................................2-8
Off-valve – 078534.........................................................................................................................................................................2-9
Torch – 228521............................................................................................................................................................................ 2-10
IEC symbols.............................................................................................................................................................................................. 2-11
Section 3
Installation..........................................................................................................................................................................3-1
Upon receipt................................................................................................................................................................................................3-3
Claims............................................................................................................................................................................................................3-3
Installation requirements...........................................................................................................................................................................3-3
Noise levels..................................................................................................................................................................................................3-3
Placement of system components..........................................................................................................................................................3-3
Torque specifications......................................................................................................................................................................3-3
Installation requirements...........................................................................................................................................................................3-4
System components........................................................................................................................................................................3-5
Cables and hoses............................................................................................................................................................................3-5
Supply gas hoses.............................................................................................................................................................................3-5
Customer-supplied power cable..................................................................................................................................................3-5
Recommended grounding and shielding practices............................................................................................................................3-6
Introduction..................................................................................................................................................................................................3-6
Types of grounding..........................................................................................................................................................................3-6
Steps to take.....................................................................................................................................................................................3-7
Grounding diagram....................................................................................................................................................................... 3-10
Placement of the power supply............................................................................................................................................................ 3-11
Install the ignition console...................................................................................................................................................................... 3-12
Install the off-valve................................................................................................................................................................................... 3-14
Placement of the gas console............................................................................................................................................................... 3-15
Power supply to ignition console leads.............................................................................................................................................. 3-16
Pilot arc lead................................................................................................................................................................................... 3-16
Negative lead.................................................................................................................................................................................. 3-16
Ignition console power cable...................................................................................................................................................... 3-18
Ignition console coolant hoses................................................................................................................................................... 3-19
Power supply to gas console cables.................................................................................................................................................. 3-20
Control cable.................................................................................................................................................................................. 3-20
Power cable.................................................................................................................................................................................... 3-20
Gas console to off-valve connections................................................................................................................................................. 3-22
Cable and gas hose assembly................................................................................................................................................... 3-22
Power supply to CNC interface cable................................................................................................................................................ 3-24
Optional multi-system CNC interface cable........................................................................................................................... 3-24
Notes to CNC interface cable run list...................................................................................................................................... 3-25
Examples of output circuits......................................................................................................................................................... 3-26
Examples of input circuits............................................................................................................................................................ 3-27
Remote ON/OFF switch (provided by customer)............................................................................................................................ 3-28
Torch lead assembly............................................................................................................................................................................... 3-29
Work lead.................................................................................................................................................................................................. 3-30
Torch connections................................................................................................................................................................................... 3-31
Connect the torch to the torch lead assembly....................................................................................................................... 3-31
Connect the torch to the quick-disconnect............................................................................................................................ 3-35
Torch mounting and alignment............................................................................................................................................................. 3-36
Torch lifter requirement.......................................................................................................................................................................... 3-37
Hypernet.................................................................................................................................................................................................... 3-37
Power requirements................................................................................................................................................................................ 3-38
General............................................................................................................................................................................................ 3-38
Line disconnect switch................................................................................................................................................................ 3-39
Main power cable.......................................................................................................................................................................... 3-39
Connect the power.................................................................................................................................................................................. 3-40
Torch coolant requirements................................................................................................................................................................... 3-41
Premixed coolant for standard operating temperatures....................................................................................................... 3-41
Section 4
Operation...............................................................................................................................................................................4-1
Daily start-up................................................................................................................................................................................................4-3
Check torch.......................................................................................................................................................................................4-3
Controls and indicators.............................................................................................................................................................................4-4
General...............................................................................................................................................................................................4-4
Main power switch...........................................................................................................................................................................4-4
Power indicators...............................................................................................................................................................................4-4
Manual gas console operation.................................................................................................................................................................4-5
Consumable selection...............................................................................................................................................................................4-6
Standard cutting (0°).......................................................................................................................................................................4-6
Bevel cutting (0° to 45°).................................................................................................................................................................4-6
Marking...............................................................................................................................................................................................4-6
Consumables for mirror-image cutting........................................................................................................................................4-6
SilverPlus electrodes.......................................................................................................................................................................4-6
Mild steel............................................................................................................................................................................................4-7
Stainless steel...................................................................................................................................................................................4-8
Aluminum............................................................................................................................................................................................4-8
Mild steel bevel cutting...................................................................................................................................................................4-9
Mild steel, thick piercing, bevel cutting.......................................................................................................................................4-9
Stainless steel bevel cutting..........................................................................................................................................................4-9
Install and Inspect consumables.......................................................................................................................................................... 4-10
Install consumables....................................................................................................................................................................... 4-10
Inspect consumables.................................................................................................................................................................... 4-11
Torch maintenance.................................................................................................................................................................................. 4-13
Routine maintenance.................................................................................................................................................................... 4-13
Quick-disconnect maintenance................................................................................................................................................. 4-13
Maintenance kit.............................................................................................................................................................................. 4-13
Torch connections................................................................................................................................................................................... 4-14
Replace torch water tube....................................................................................................................................................................... 4-14
Common cutting faults........................................................................................................................................................................... 4-15
How to optimize cut quality................................................................................................................................................................... 4-16
Tips for table and torch................................................................................................................................................................ 4-16
Plasma set-up tips........................................................................................................................................................................ 4-16
Maximize the life of consumable parts...................................................................................................................................... 4-16
Section 5
Maintenance.........................................................................................................................................................................5-1
Introduction..................................................................................................................................................................................................5-3
Routine maintenance.................................................................................................................................................................................5-3
System description.....................................................................................................................................................................................5-4
Power and signal cables.................................................................................................................................................................5-4
Sequence of operation..............................................................................................................................................................................5-5
Gas system purge cycle............................................................................................................................................................................5-6
Gas system valve usage............................................................................................................................................................................5-6
Marking process...............................................................................................................................................................................5-8
PCB block diagram....................................................................................................................................................................................5-9
Error codes................................................................................................................................................................................................ 5-10
HyPerformance plasma system error codes........................................................................................................................... 5-10
Error code troubleshooting – error codes 000 to 018...................................................................................................... 5-11
Error code troubleshooting – error codes 020 to 028, 224 to 228............................................................................... 5-12
Error code troubleshooting – error codes 030 to 042, 231 to 234............................................................................... 5-13
Error code troubleshooting – error codes 044 to 046...................................................................................................... 5-14
Error code troubleshooting – error codes 047 to 053, 248 to 250............................................................................... 5-15
Error code troubleshooting – error codes 054 to 061...................................................................................................... 5-16
Error code troubleshooting – error codes 062 to 067, 265 to 267............................................................................... 5-17
Error code troubleshooting – error codes 071 to 075, 273 to 275............................................................................... 5-18
Error code troubleshooting – error codes 076 to 101, 276 to 301............................................................................... 5-19
Error code troubleshooting – error codes 102 to 111, 302 to 308............................................................................... 5-20
Error code troubleshooting – error codes 116 to 133, 316............................................................................................. 5-21
Error code troubleshooting – error codes 134 to 140, 334 and 338............................................................................ 5-22
Error code troubleshooting – error codes 141 to 152, 346 to 351............................................................................... 5-23
Error code troubleshooting – error codes 153 to 156, 354 to 356............................................................................... 5-24
Error code troubleshooting – error codes 157 to 159, 357 to 359............................................................................... 5-25
Error code troubleshooting – error codes 160 to 180...................................................................................................... 5-26
Error code troubleshooting – error code 181, 182, and 383.......................................................................................... 5-27
Power supply states................................................................................................................................................................................ 5-28
Plasma system operation with pump timeout.................................................................................................................................... 5-29
CNC operation with pump timeout...................................................................................................................................................... 5-30
Initial checks.............................................................................................................................................................................................. 5-31
Power measurement............................................................................................................................................................................... 5-32
Air filter element replacement............................................................................................................................................................... 5-33
Power supply coolant system servicing.............................................................................................................................................. 5-34
Draining the coolant system........................................................................................................................................................ 5-34
Coolant system filter............................................................................................................................................................................... 5-35
Section 6
Parts List...............................................................................................................................................................................6-1
Power supply...............................................................................................................................................................................................6-2
Ignition console...........................................................................................................................................................................................6-7
Gas console.................................................................................................................................................................................................6-8
Off-valve........................................................................................................................................................................................................6-9
HyPerformance torch.............................................................................................................................................................................. 6-10
Torch assembly.............................................................................................................................................................................. 6-10
Torch leads..................................................................................................................................................................................... 6-11
Ohmic contact wire....................................................................................................................................................................... 6-11
Consumable parts kits............................................................................................................................................................................ 6-12
Consumables for mirror-image cutting............................................................................................................................................... 6-14
Mild steel (straight cutting)......................................................................................................................................................... 6-14
Section 7
Wiring Diagrams................................................................................................................................................................7-1
Appendix A
Hypertherm torch coolant Safety Data......................................................................................................... a-1
1 – Identification of the substance/mixture and of the company undertaking............................................................................a-2
2 – Hazards identification.......................................................................................................................................................................a-2
3 – Composition/information on ingredients......................................................................................................................................a-3
4 – First aid measures.............................................................................................................................................................................a-3
5 – Fire-fighting measures......................................................................................................................................................................a-3
6 – Accidental release measures..........................................................................................................................................................a-3
7 – Handling and storage.......................................................................................................................................................................a-4
8 – Exposure controls/personal protection........................................................................................................................................a-4
9 – Physical and chemical properties..................................................................................................................................................a-4
10 – Stability and reactivity....................................................................................................................................................................a-5
11 – Toxicological information...............................................................................................................................................................a-5
12 – Ecological information...................................................................................................................................................................a-5
13 – Disposal considerations................................................................................................................................................................a-6
14 – Transport information.....................................................................................................................................................................a-6
15 – Ecological information...................................................................................................................................................................a-6
16 – Other information............................................................................................................................................................................a-7
Freezing Point of Propylene Glycol Solution........................................................................................................................................a-8
Appendix B
functional description of Software ............................................................................................................... b-1
Appendix C
robotic applications.................................................................................................................................................... c-1
Components for robotic applications.....................................................................................................................................................c-2
Torch leads........................................................................................................................................................................................c-2
Ohmic contact extension................................................................................................................................................................c-2
Rotational mounting sleeve (optional) – 220864...................................................................................................................c-3
Leather overwrap – 024866........................................................................................................................................................c-3
Robotic teaching torch (laser pointer) – 228394..................................................................................................................c-3
Torch and rotational mounting sleeve dimensions...................................................................................................................c-3
SAFETY
In this section
Recognize safety information...................................................................................................................................................................1-2
Follow safety instructions..........................................................................................................................................................................1-2
Electrical hazards........................................................................................................................................................................................1-2
Electric shock can kill.................................................................................................................................................................................1-3
Cutting can cause fire or explosion........................................................................................................................................................1-4
Toxic fumes can cause injury or death...................................................................................................................................................1-5
Static electricity can damage circuit boards........................................................................................................................................1-6
Compressed gas equipment safety........................................................................................................................................................1-6
Grounding safety........................................................................................................................................................................................1-6
Gas cylinders can explode if damaged..................................................................................................................................................1-6
A plasma arc can cause injury and burns..............................................................................................................................................1-7
Arc rays can burn eyes and skin..............................................................................................................................................................1-7
Noise can damage hearing.......................................................................................................................................................................1-8
Pacemaker and hearing aid operation...................................................................................................................................................1-8
A plasma arc can damage frozen pipes................................................................................................................................................1-8
Dry dust collection information................................................................................................................................................................1-9
Laser radiation.......................................................................................................................................................................................... 1-10
Symbols and marks................................................................................................................................................................................. 1-11
Additional safety information................................................................................................................................................................. 1-11
Warning labels.......................................................................................................................................................................................... 1-12
Hypertherm 1-1
03/10
Safety
Electrical hazards
• Only trained and authorized personnel may open this • The enclosure shall be closed and the proper earth
equipment. ground continuity to the enclosure verified prior to
operating the equipment after moving, opening, or
• If the equipment is permanently connected, turn it off,
servicing.
and lock out/tag out power before the enclosure is
opened. • Always follow these instructions for disconnecting
power before inspecting or changing torch
• If power is supplied to the equipment with a cord,
consumable parts.
unplug the unit before the enclosure is opened.
• Lockable disconnects or lockable plug covers must
be provided by others.
• Wait 5 minutes after removal of power before
entering the enclosure to allow stored energy to
discharge.
• If the equipment must have power when the
enclosure is open for servicing, arc flash explosion
hazards may exist. Follow ALL local requirements
(NFPA 70E in the USA) for safe work practices and
for Personal Protective Equipment when servicing
energized equipment.
1-2 Hypertherm
03/10
Safety
Touching live electrical parts can cause a fatal shock or • Install and ground this equipment according to the
severe burn. instruction manual and in accordance with national
• Operating the plasma system completes an electrical and local codes.
circuit between the torch and the workpiece. The • Inspect the input power cord frequently for damage
workpiece and anything touching the workpiece are or cracking of the cover. Replace a damaged power
part of the electrical circuit. cord immediately. Bare wiring can kill.
• Never touch the torch body, workpiece or the water in • Inspect and replace any worn or damaged torch
a water table when the plasma system is operating. leads.
• Do not pick up the workpiece, including the waste
Electric shock prevention
cutoff, while you cut. Leave the workpiece in place
All Hypertherm plasma systems use high voltage or on the workbench with the work cable attached
in the cutting process (200 to 400 VDC are during the cutting process.
common). Take the following precautions when • Before checking, cleaning or changing torch parts,
operating this system: disconnect the main power or unplug the power
• Wear insulated gloves and boots, and keep your body supply.
and clothing dry. • Never bypass or shortcut the safety interlocks.
• Do not stand, sit or lie on – or touch – any wet • Before removing any power supply or system
surface when using the plasma system. enclosure cover, disconnect electrical input power.
• Insulate yourself from work and ground using dry Wait 5 minutes after disconnecting the main power
insulating mats or covers big enough to prevent any to allow capacitors to discharge.
physical contact with the work or ground. If you must • Never operate the plasma system unless the power
work in or near a damp area, use extreme caution. supply covers are in place. Exposed power supply
• Provide a disconnect switch close to the power connections present a severe electrical hazard.
supply with properly sized fuses. This switch allows • When making input connections, attach proper
the operator to turn off the power supply quickly in grounding conductor first.
an emergency situation.
• Each Hypertherm plasma system is designed to be
• When using a water table, be sure that it is correctly used only with specific Hypertherm torches. Do not
connected to earth ground. substitute other torches which could overheat and
present a safety hazard.
Hypertherm 1-3
03/10
Safety
1-4 Hypertherm
03/10
Safety
The plasma arc by itself is the heat source used for • Duration of cutting or gouging.
cutting. Accordingly, although the plasma arc has not • Size, air volume, ventilation and filtration of the
been identified as a source of toxic fumes, the material work area.
being cut can be a source of toxic fumes or gases that
deplete oxygen. • Personal protective equipment.
• Number of welding and cutting systems in operation.
Fumes produced vary depending on the metal that is • Other site processes that may produce fumes.
cut. Metals that may release toxic fumes include, but
are not limited to, stainless steel, carbon steel, zinc If the workplace must conform to national or local
(galvanized), and copper. regulations, only monitoring or testing done at the
site can determine whether the site is above or below
In some cases, the metal may be coated with a allowable levels.
substance that could release toxic fumes. Toxic
coatings include, but are not limited to, lead (in some To reduce the risk of exposure to fumes:
paints), cadmium (in some paints and fillers), and • Remove all coatings and solvents from the metal
beryllium. before cutting.
• Use local exhaust ventilation to remove fumes from
Gases produced by plasma cutting vary based on the
the air.
material to be cut and the method of cutting, but may
include ozone, oxides of nitrogen, hexavalent chromium, • Do not inhale fumes. Wear an air-supplied respirator
hydrogen, and other substances if such are contained when cutting any metal coated with, containing, or
in or released by the material being cut. suspected to contain toxic elements.
• Assure that those using welding or cutting equipment,
Caution should be taken to minimize exposure to fumes as well as air-supplied respiration devices, are
produced by any industrial process. Depending upon qualified and trained in the proper use of such
the chemical composition and concentration of the equipment.
fumes (as well as other factors, such as ventilation),
• Never cut containers with potentially toxic materials
there may be a risk of physical illness, such as birth
inside. Empty and properly clean the container first.
defects or cancer.
• Monitor or test the air quality at the site as needed.
It is the responsibility of the equipment and site owner • Consult with a local expert to implement a site plan
to test the air quality in the area where the equipment is to ensure safe air quality.
used and to ensure that the air quality in the workplace
meets all local and national standards and regulations.
Hypertherm 1-5
03/10
Safety
Grounding safety
Work cable Attach the work cable securely to the Input power
workpiece or the work table with good metal-to-metal • Be sure to connect the power cord ground wire to
contact. Do not connect it to the piece that will fall the ground in the disconnect box.
away when the cut is complete.
• If installation of the plasma system involves
Work table Connect the work table to an earth connecting the power cord to the power supply, be
ground, in accordance with appropriate national and sure to connect the power cord ground wire properly.
local electrical codes. • Place the power cord’s ground wire on the stud
first, then place any other ground wires on top of the
power cord ground. Fasten the retaining nut tightly.
• Tighten all electrical connections to avoid excessive
heating.
1-6 Hypertherm
03/10
Safety
Instant-on torches The plasma arc will cut quickly through gloves and skin.
Plasma arc comes on immediately when the torch • Keep away from the torch tip.
switch is activated.
• Do not hold metal near the cutting path.
• Never point the torch toward yourself or others.
Eye protection Plasma arc rays produce intense • Cuffless trousers to prevent entry of sparks and slag.
visible and invisible (ultraviolet and infrared) rays that • Remove any combustibles, such as a butane lighter
can burn eyes and skin. or matches, from your pockets before cutting.
• Use eye protection in accordance with applicable
national and local codes. Cutting area Prepare the cutting area to reduce
• Wear eye protection (safety glasses or goggles with reflection and transmission of ultraviolet light:
side shields, and a welding helmet) with appropriate • Paint walls and other surfaces with dark colors to
lens shading to protect your eyes from the arc’s reduce reflection.
ultraviolet and infrared rays. • Use protective screens or barriers to protect others
from flash and glare.
Skin protection Wear protective clothing to protect
• Warn others not to watch the arc. Use placards
against burns caused by ultraviolet light, sparks, and
or signs.
hot metal.
• Gauntlet gloves, safety shoes and hat.
• Flame-retardant clothing to cover all exposed areas.
Hypertherm 1-7
03/10
Safety
Pacemaker and hearing aid operation can be affected To reduce magnetic field hazards:
by magnetic fields from high currents.
• Keep both the work cable and the torch lead to one
Pacemaker and hearing aid wearers should consult a side, away from your body.
doctor before going near any plasma arc cutting and
• Route the torch leads as close as possible to the
gouging operations.
work cable.
• Do not wrap or drape the torch lead or work cable
around your body.
• Keep as far away from the power supply as possible.
Cutting with a plasma arc can exceed acceptable noise Use ear protectors if the noise is disruptive or if there
levels as defined by local codes in many applications. is a risk of hearing damage after all other engineering
Prolonged exposure to excessive noise can damage and administrative controls have been implemented.
hearing. Always wear proper ear protection when If hearing protection is required, wear only approved
cutting or gouging, unless sound pressure level personal protective devices such as ear muffs or ear
measurements taken at the installed site have verified plugs with a noise reduction rating appropriate for the
personal hearing protection is not necessary per situation. Warn others in the area of possible noise
relevant international, regional, and local codes. hazards. In addition, ear protection can prevent hot
splatter from entering the ear.
Significant noise reduction can be obtained by adding
simple engineering controls to cutting tables such as
barriers or curtains positioned between the plasma arc
and the workstation; and/or locating the workstation
away from the plasma arc. Implement administrative
controls in the workplace to restrict access, limit
operator exposure time, screen off noisy working
areas and/or take measures to reduce reverberation
in working areas by putting up noise absorbers.
Frozen pipes may be damaged or can burst if you attempt to thaw them with a plasma torch.
1-8 Hypertherm
03/10
Safety
Hypertherm 1-9
03/10
Safety
Laser radiation
Exposure to the laser output can result in serious eye injury. Avoid direct eye exposure.
For your convenience and safety, on Hypertherm products that use a laser, one of the following laser radiation
labels has been applied on the product near where the laser beam exits the enclosure. The maximum output (mV),
wavelength emitted (nM) and, if appropriate, the pulse duration is also provided.
1-10 Hypertherm
03/10
Safety
S mark symbol
The S mark symbol indicates that the power supply and torch are suitable for operations carried out in
environments with increased hazard of electrical shock per IEC 60974-1.
CSA mark
Hypertherm products with a CSA mark meet the United States and Canadian regulations for product safety.
The products were evaluated, tested, and certified by CSA-International. Alternatively the product may have
a mark by one of the other Nationally Recognized Testing Laboratories (NRTL) accredited in both the United
States and Canada, such as Underwriters Laboratories, Incorporated (UL) or TÜV.
CE marking
he CE marking signifies the manufacturer’s declaration of conformity to applicable European directives
T
and standards. Only those versions of Hypertherm products with a CE marking located on or near the
data plate have been tested for compliance with the European Low Voltage Directive and the European
Electromagnetic Compatibility (EMC) Directive. EMC filters needed to comply with the European EMC
Directive are incorporated within versions of the product with a CE marking.
GOST-R mark
CE versions of Hypertherm products that include a GOST-R mark of conformity meet the product safety
and EMC requirements for export to the Russian Federation.
c-Tick mark
E versions of Hypertherm products with a c-Tick mark comply with the EMC regulations required for sale
C
in Australia and New Zealand.
CCC mark
The China Compulsory Certification (CCC) mark indicates that the product has been tested and found
compliant with product safety regulations required for sale in China.
Hypertherm 1-11
03/10
Safety
Warning labels
This warning label is affixed to some power supplies. It is important that the operator and maintenance technician
understand the intent of these warning symbols as described.
1. Cutting sparks can cause explosion or fire. 1. Les étincelles de coupage peuvent provoquer une explosion
1.1 Do not cut near flammables. ou un incendie.
1.2 Have a fire extinguisher nearby and ready to use. 1.1 Ne pas couper près des matières inflammables.
1.3 Do not use a drum or other closed container as a cutting table. 1.2 Un extincteur doit être à proximité et prêt à être utilisé.
1.3 Ne pas utiliser un fût ou un autre contenant fermé comme table de coupage.
2. Plasma arc can injure and burn; point the nozzle away 2. L’arc plasma peut blesser et brûler; éloigner la buse de soi.
from yourself. Arc starts instantly when triggered. Il s’allume instantanément quand on l’amorce;
2.1 Turn off power before disassembling torch. 2.1 Couper l’alimentation avant de démonter la torche.
2.2 Do not grip the workpiece near the cutting path. 2.2 Ne pas saisir la pièce à couper de la trajectoire de coupage.
2.3 Wear complete body protection. 2.3 Se protéger entièrement le corps.
3. Hazardous voltage. Risk of electric shock or burn. 3. Tension dangereuse. Risque de choc électrique ou de brûlure.
3.1 Wear insulating gloves. Replace gloves when wet or damaged. 3.1 Porter des gants isolants. Remplacer les gants quand ils sont humides ou
3.2 Protect from shock by insulating yourself from work and ground. endommagés.
3.3 Disconnect power before servicing. Do not touch live parts. 3.2 Se protéger contre les chocs en s’isolant de la pièce et de la terre.
3.3 Couper l’alimentation avant l’entretien. Ne pas toucher les pièces sous tension.
4. Plasma fumes can be hazardous. 4. Les fumées plasma peuvent être dangereuses.
4.1 Do not inhale fumes. 4.1 Ne pas inhaler les fumées
4.2 Use forced ventilation or local exhaust to remove the fumes. 4.2 Utiliser une ventilation forcée ou un extracteur local pour dissiper les fumées.
4.3 Do not operate in closed spaces. Remove fumes with ventilation. 4.3 Ne pas couper dans des espaces clos. Chasser les fumées par ventilation.
5. Arc rays can burn eyes and injure skin. 5. Les rayons d’arc peuvent brûler les yeux et blesser la peau.
5.1 Wear correct and appropriate protective equipment to protect 5.1 Porter un bon équipement de protection pour se protéger la tête, les yeux, les
head, eyes, ears, hands, and body. Button shirt collar. Protect ears oreilles, les mains et le corps. Boutonner le col de la chemise. Protéger les oreilles
from noise. Use welding helmet with the correct shade of filter. contre le bruit. Utiliser un masque de soudeur avec un filtre de nuance appropriée.
6. Become trained. Only qualified personnel should operate this 6. Suivre une formation. Seul le personnel qualifié a le droit de faire
equipment. Use torches specified in the manual. Keep non-qualified fonctionner cet équipement. Utiliser exclusivement les torches indiquées dans le
personnel and children away. manual. Le personnel non qualifié et les enfants doivent se tenir à l’écart.
7. Do not remove, destroy, or cover this label. 7. Ne pas enlever, détruire ni couvrir cette étiquette.
Replace if it is missing, damaged, or worn (PN 110584 Rev C). La remplacer si elle est absente, endommagée ou usée (PN 110584 Rev C).
1-12 Hypertherm
03/10
Safety
Hypertherm 1-13
03/10
Safety
1-14 Hypertherm
03/10
Section 1a
SÉCURITÉ
Hypertherm 1a-1
03/10
Sécurité
Risques électriques
• Seul le personnel formé et autorisé peut ouvrir cet • Vérifier que le boîtier est bien fermé et que la mise
équipement. à la terre est bien effectuée avant de faire fonctionner
l’équipement après l’avoir déplacé, ouvert ou après
• Si l’équipement est branché en permanence, mettez-le
avoir effectué un entretien.
hors tension, puis coupez l’alimentation avant d’ouvrir
le boîtier. • Toujours suivre ces instructions concernant le
débranchement de la source de courant avant
• Si l’équipement est mis sous tension à l’aide d’un
d’inspecter ou de remplacer des consommables
cordon, débranchez-le avant d’ouvrir le boîtier.
de la torche.
• Dans un cas autre, des raccords ou des capots
d’obturateurs verrouillables doivent être fournis.
• Attendre ensuite 5 minutes après la coupure de
l’alimentation électrique avant l’ouverture du capot
pour que l’énergie stockée se décharge.
• Si l’équipement doit être sous tension lorsque le capot
est ouvert pour l’entretien, le coup d’arc peut se produire.
Respecter TOUTES les exigences locales (NFPA
70E aux États-Unis) relatives aux pratiques de travail
sécuritaires et à l’équipement de protection individuelle
lors de l’entretien de l’équipement électrique.
1a-2 Hypertherm
03/10
Sécurité
Le contact avec les pièces électriques sous tension • Installer et mettre à la terre l’équipement selon les
peut entraîner une électrocution ou de brûlures graves, instructions du présent manuel et conformément
voire la mort. aux codes locaux et nationaux.
• L’utilisation d’un système plasma complète un circuit • Inspecter fréquemment le cordon de puissance
électrique entre la torche et la pièce à couper. d’entrée pour vérifier qu’il n’est pas endommagé
La pièce ainsi que tout autre élément la touchant ni fendu. Remplacer immédiatement un cordon
font partie du circuit électrique. d’alimentation endommagé. Un câble dénudé
• Ne jamais toucher le corps de la torche, la pièce peut causer la mort.
à couper ou l’eau de la table à eau lorsque • Inspecter et remplacer les câbles de la torche qui
le système plasma fonctionne. sont usés ou endommagés.
• Ne pas saisir la pièce à couper, ni les débris lors
Prévention des chocs électriques du coupage. Laisser la pièce à couper en place ou sur
Tous les systèmes plasma Hypertherm la table de travail et le câble de retour connecté lors
fonctionnent à haute tension pour le coupage du coupage.
(souvent de 200 à 400 V c.c.). Prendre les • Avant de vérifier, de nettoyer ou de remplacer
précautions suivantes lors de l’utilisation les pièces de la torche, couper l’alimentation
du système : ou débrancher la source de courant.
• Porter des bottes et des gants isolants et garder • Ne jamais contourner ou court-circuiter les verrous
le corps et les vêtements au sec. de sécurité.
• Ne pas se tenir, s’asseoir ou se coucher sur une • Avant d’enlever le capot du système ou de la source
surface mouillée, ni la toucher pendant l’utilisation de courant, couper la puissance d’entrée
du système plasma. électrique. Attendre ensuite 5 minutes pour que
• S’isoler de la surface de travail et du sol en utilisant les condensateurs se déchargent.
des tapis isolants ou des couvertures assez grandes • Ne jamais faire fonctionner le système plasma sans
pour éviter tout contact physique avec le matériel que les capots de la source de courant ne soient
de travail ou le sol. S’il s’avère nécessaire de travailler en place. Les raccords exposés de la source
dans ou près d’un endroit humide, procéder avec de courant sont extrêmement dangereux.
extrême prudence. • Lors de l’installation des connexions, attacher tout
• Installer un sectionneur avec fusibles appropriés, d’abord la prise de terre appropriée.
à proximité de la source de courant. Ce sectionneur • Chaque système plasma Hypertherm est conçu pour
permet à l’opérateur d’éteindre rapidement la source être utilisé uniquement avec des torches Hypertherm
de courant en cas d’urgence. spécifiques. Ne pas utiliser des torches inappropriées
• En cas d’utilisation d’une table à eau, s’assurer qui pourraient surchauffer et présenter des risques
que cette dernière est correctement mise à la terre. pour la sécurité.
Hypertherm 1a-3
03/10
Sécurité
1a-4 Hypertherm
03/10
Sécurité
Hypertherm 1a-5
03/10
Sécurité
Câble de retour Bien fixer le câble de retour • S’il est nécessaire de brancher le cordon d’alimentation
(ou de masse) à la pièce à couper ou à la table de travail à la source de courant lors de l’installation du système,
de façon à assurer un bon contact métal à métal. vérifier que le fil de terre est correctement branché.
Ne pas fixer le câble de retour à la partie de la pièce • Placer tout d’abord le fil de terre du cordon
qui doit se détacher. d’alimentation sur le plot de mise à la terre, puis placer
les autres fils de terre par-dessus. Bien serrer l’écrou
Table de travail Raccorder la table de travail de retenue.
à la terre, conformément aux codes de sécurité locaux
ou nationaux appropriés. • Vérifier que toutes les connexions sont bien serrées
pour éviter une surchauffe.
Puissance d’entrée
• S’assurer que le fil de terre du cordon d’alimentation
est connecté à la terre dans le coffret du sectionneur.
1a-6 Hypertherm
03/10
Sécurité
Torches à allumage instantané L’arc plasma coupe facilement les gants et la peau.
L’arc plasma s’allume immédiatement après que • Rester éloigné de l’extrémité de la torche.
la torche est activée. • Ne pas tenir de métal près de la trajectoire de coupe.
• Ne jamais pointer la torche vers soi ou d’autres personnes.
Protection de la peau Porter des vêtements de sécurité pour se protéger contre les brûlures que peuvent causer
les rayons ultraviolets, les étincelles et le métal brûlant :
• Gants à crispin, chaussures et casque de sécurité.
• Vêtements ignifuges couvrant toutes les parties exposées du corps.
• Pantalon sans revers pour éviter que des étincelles ou des scories puissent s’y loger.
• Avant le coupage, retirer de ses poches tout objet combustible comme les briquets au butane ou les allumettes.
Zone de coupage Préparer la zone de coupage afin de réduire la réverbération et la transmission de la lumière
ultraviolette :
• Peindre les murs et autres surfaces d’une couleur sombre pour réduire la réflexion de la lumière.
• Utiliser des écrans et autres dispositifs de protection afin de protéger les autres personnes de la lumière
et de la réverbération.
• Prévenir les autres personnes de ne pas regarder l’arc. Utiliser des affiches ou des panneaux.
Indice de protection
Indice de protection
Courant de l’arc suggéré pour OSHA 29CFR Europe
minimum
(A) assurer le confort 1910.133(a)(5) EN168:2002
(ANSI Z49.1:2005)
(ANSI Z49.1:2005)
Moins de 40 A 5 5 8 9
41 à 60 A 6 6 8 9
61 à 80 A 8 8 8 9
81 à 125 A 8 9 8 9
126 à 150 A 8 9 8 10
151 à 175 A 8 9 8 11
176 à 250 A 8 9 8 12
251 à 300 A 8 9 8 13
301 à 400 A 9 12 9 13
401 à 800 A 10 14 10
Hypertherm 1a-7
03/10
Sécurité
Les champs magnétiques produits par les courants • Faire passer le faisceau de torche le plus près
à haute tension peuvent affecter le fonctionnement possible du câble de retour.
des prothèses auditives et des pacemakers.
• Ne pas s’enrouler le faisceau de torche ou le câble
Les personnes portant ce type d’appareil doivent de retour autour du corps.
consulter un médecin avant de s’approcher d’un lieu
• Se tenir le plus loin possible de la source de courant.
où s’effectue le coupage ou le gougeage d’arc plasma.
Pour réduire les risques associés aux champs
magnétiques :
• Garder loin de soi et du même côté du corps le câble
de retour et le faisceau de torche.
Le coupage avec l’arc plasma peut dépasser les niveaux de l’opérateur, délimiter les zones bruyantes à l’aide
de bruits acceptables conformément aux codes locaux d’une paroi et/ou instaurer des mesures préventives
relatifs à de nombreuses applications. Une exposition visant à réduire la réverbération sur le lieu de travail
prolongée à un bruit excessif peut provoquer des en installant des dispositifs antibruits.
problèmes auditifs. Toujours porter un dispositif de
Utiliser des protecteurs d’oreille si le bruit est toujours
protection antibruit adéquat lors du coupage ou du
dérangeant ou si des problèmes auditifs peuvent
gougeage, sauf si les mesures de niveau de bruits prises
survenir après l’installation des dispositifs de sécurité
sur le site d’installation certifient que les prothèses
intégrés et l’instauration des mesures préventives.
auditives ne sont pas nécessaires, telles que spécifiées
Si des protecteurs d’oreilles s’avèrent être nécessaires,
par les codes internationaux, régionaux et locaux.
porter uniquement des articles de protection
Les bruits peuvent être considérablement réduits en personnelle approuvés, tels que des oreillères ou des
ajoutant de simples dispositifs de sécurité intégrés bouchons d’oreille avec un coefficient de réduction de
aux tables de coupe, telles que des barrières ou des bruits approprié pour la situation sur le lieu de travail.
rideaux placés entre l’arc plasma et le poste de travail; Prévenir les personnes aux alentours des risques
et/ou en éloignant le poste de travail de l’arc plasma. encourus en cas d’exposition au bruit. En outre,
Mettre sur pied des mesures administratives sur le site la protection des oreilles sert également de munition
de travail afin de limiter l’accès et la durée d’exposition contre les projections chaudes.
1a-8 Hypertherm
03/10
Sécurité
Hypertherm 1a-9
03/10
Sécurité
Radiation au laser
L’exposition à une sortie laser peut provoquer des problèmes visuels graves. Éviter un contact
direct avec les yeux.
Pour votre aisance et votre sécurité, l’une des étiquettes de radiation au laser suivantes a été installée sur les
produits Hypertherm près de la sortie du faisceau laser du boîtier. Ont également été fournies la sortie maximale
(mV), la longueur d’onde émise (nM) et au besoin, la durée d’impulsion.
1a-10 Hypertherm
03/10
Sécurité
Symboles et marquage
Votre produit Hypertherm peut comporter une ou plusieurs des marques suivantes sur sa plaque signalétique
ou à proximité. En raison des différends et des conflits relatifs aux règlements nationaux, toutes les marques ne sont
pas appliquées à chaque version d’un produit.
Symbole de marque S
Le symbole de marque S indique que la source de courant et la torche conviennent pour les travaux
effectués dans les milieux à risque accru de choc électrique selon l’IEC 60974-1.
Marque CSA
Les produits Hypertherm portant la marque CSA sont conformes aux réglementations des États-Unis
et du Canada pour la sécurité des produits. Les produits ont été évalués, testés et certifiés par
CSA-International. Le produit peut autrement porter la marque d’autres laboratoires d’essais reconnus
à l’échelle nationale (NRTL) agréés à la fois aux États-Unis et au Canada, par exemple : Underwriters
Laboratories, Incorporated (UL) ou TÜV.
Marque CE
e marquage CE signifie : déclaration de conformité du fabricant aux directives et normes européennes
L
applicables. Seules les versions des produits Hypertherm portant la marque CE située sur ou à proximité
de la plaque signalétique ont été testées pour conformité à la directive européenne « basse tension »
et la directive européenne « compatibilité électromagnétique » (CEM). Les filtres CEM devant être
en conformité avec la directive européenne CEM sont intégrés dans les produits portant la marque CE.
Marque GOST-R
Les versions CE des produits Hypertherm qui portent la marque de conformité GOST-R répondent aux
exigences de sécurité du produit et de CEM en vue de l’exportation à la Fédération russe.
Marque c-Tick
es versions CE des produits Hypertherm portant la marque c-Tick sont conformes aux règlements CEM
L
prescrits pour la vente en Australie et en Nouvelle-Zélande.
Marque CCC
La marque de certification obligatoire en Chine (CCC) indique que le produit a été mis à l’essai et déclaré
conforme aux règlements de sécurité du produit prescrits pour la vente en Chine.
Hypertherm 1a-11
03/10
Sécurité
Étiquettes de sécurtité
Cette étiquette est affichée sur certaines sources de courant. Il est important que l’opérateur et le technicien d’entretien
comprennent la signification des symboles de sécurité.
1. Cutting sparks can cause explosion or fire. 1. Les étincelles de coupage peuvent provoquer une explosion
1.1 Do not cut near flammables. ou un incendie.
1.2 Have a fire extinguisher nearby and ready to use. 1.1 Ne pas couper près des matières inflammables.
1.3 Do not use a drum or other closed container as a cutting table. 1.2 Un extincteur doit être à proximité et prêt à être utilisé.
1.3 Ne pas utiliser un fût ou un autre contenant fermé comme table de coupage.
2. Plasma arc can injure and burn; point the nozzle away 2. L’arc plasma peut blesser et brûler; éloigner la buse de soi.
from yourself. Arc starts instantly when triggered. Il s’allume instantanément quand on l’amorce;
2.1 Turn off power before disassembling torch. 2.1 Couper l’alimentation avant de démonter la torche.
2.2 Do not grip the workpiece near the cutting path. 2.2 Ne pas saisir la pièce à couper de la trajectoire de coupage.
2.3 Wear complete body protection. 2.3 Se protéger entièrement le corps.
3. Hazardous voltage. Risk of electric shock or burn. 3. Tension dangereuse. Risque de choc électrique ou de brûlure.
3.1 Wear insulating gloves. Replace gloves when wet or damaged. 3.1 Porter des gants isolants. Remplacer les gants quand ils sont humides ou
3.2 Protect from shock by insulating yourself from work and ground. endommagés.
3.3 Disconnect power before servicing. Do not touch live parts. 3.2 Se protéger contre les chocs en s’isolant de la pièce et de la terre.
3.3 Couper l’alimentation avant l’entretien. Ne pas toucher les pièces sous tension.
4. Plasma fumes can be hazardous. 4. Les fumées plasma peuvent être dangereuses.
4.1 Do not inhale fumes. 4.1 Ne pas inhaler les fumées
4.2 Use forced ventilation or local exhaust to remove the fumes. 4.2 Utiliser une ventilation forcée ou un extracteur local pour dissiper les fumées.
4.3 Do not operate in closed spaces. Remove fumes with ventilation. 4.3 Ne pas couper dans des espaces clos. Chasser les fumées par ventilation.
5. Arc rays can burn eyes and injure skin. 5. Les rayons d’arc peuvent brûler les yeux et blesser la peau.
5.1 Wear correct and appropriate protective equipment to protect 5.1 Porter un bon équipement de protection pour se protéger la tête, les yeux, les
head, eyes, ears, hands, and body. Button shirt collar. Protect ears oreilles, les mains et le corps. Boutonner le col de la chemise. Protéger les oreilles
from noise. Use welding helmet with the correct shade of filter. contre le bruit. Utiliser un masque de soudeur avec un filtre de nuance appropriée.
6. Become trained. Only qualified personnel should operate this 6. Suivre une formation. Seul le personnel qualifié a le droit de faire
equipment. Use torches specified in the manual. Keep non-qualified fonctionner cet équipement. Utiliser exclusivement les torches indiquées dans le
personnel and children away. manual. Le personnel non qualifié et les enfants doivent se tenir à l’écart.
7. Do not remove, destroy, or cover this label. 7. Ne pas enlever, détruire ni couvrir cette étiquette.
Replace if it is missing, damaged, or worn (PN 110584 Rev C). La remplacer si elle est absente, endommagée ou usée (PN 110584 Rev C).
1a-12 Hypertherm
03/10
Sécurité
1a-14 Hypertherm
03/10
Sección 1b
SEGURIDAD
En esta sección:
Reconocimiento de información de seguridad................................................................................................................................. 1b-2
Cumplimiento de instrucciones de seguridad.................................................................................................................................. 1b-2
Riesgos de electrocución...................................................................................................................................................................... 1b-2
Las descargas eléctricas pueden matar............................................................................................................................................. 1b-3
Los cortes pueden producir incendios o explosiones..................................................................................................................... 1b-4
Los vapores tóxicos pueden producir lesiones o la muerte........................................................................................................... 1b-5
Seguridad de equipos de gas comprimido....................................................................................................................................... 1b-6
Seguridad de toma a tierra.................................................................................................................................................................... 1b-6
La electricidad estática puede dañar las placas de circuitos........................................................................................................ 1b-6
Los cilindros de gas pueden explotar si están dañados................................................................................................................ 1b-6
El arco de plasma puede producir lesiones y quemaduras........................................................................................................... 1b-7
Los rayos del arco pueden quemar los ojos y la piel....................................................................................................................... 1b-7
Los ruidos pueden dañar la audición.................................................................................................................................................. 1b-8
Funcionamiento de marcapasos y audífonos.................................................................................................................................... 1b-8
El arco de plasma puede dañar las tuberías congeladas............................................................................................................... 1b-8
Información acerca de la recolección de polvo seco...................................................................................................................... 1b-9
Radiación láser....................................................................................................................................................................................... 1b-10
Símbolos y marcas................................................................................................................................................................................1b-11
Etiquetas de advertencia......................................................................................................................................................................1b-12
Hypertherm 1b-1
03/10
Seguridad
Riesgos de electrocución
• Sólo el personal capacitado y autorizado puede abrir • Si no se puede cortar el suministro de energía del
este equipo. equipo mientras se abre el armazón para realizar
reparaciones, es posible que se produzcan peligros
• Si el equipo está conectado en forma permanente,
de explosión de arco eléctrico. Siga TODOS los
apáguelo e implemente un cierre “con llave y etiqueta”
requisitos locales (NFPA 70E en los EE. UU.) en
de la energía antes de abrir el armazón.
relación con las practicas de trabajo seguro y con el
• Si el suministro de energía se realiza a través de un equipo de protección personal al realizar reparaciones
cable, desenchufe la unidad antes de abrir el armazón. en equipos energizados.
• Otras personas deberán suministrar las cubiertas para • El armazón debe permanecer cerrado y se debe
enchufes bloqueables y los elementos de desconexión verificar que la continuidad a tierra física al armazón
bloqueables. sea la adecuada antes de operar el equipo y luego
de moverlo, abrirlo o realizarle reparaciones.
• Espere 5 minutos luego de cortar la energía y antes
de ingresar en el armazón, a fin de permitir que • Siempre siga estas instrucciones para desconectar
la energía almacenada se descargue. la energía antes de inspeccionar o cambiar las piezas
consumibles de la antorcha.
1b-2 Hypertherm
03/10
Seguridad
El contacto con piezas eléctricas con corriente puede • Instale y ponga a tierra el equipo respetando el manual
causar una descarga mortal o quemaduras graves. de instrucciones y los códigos nacionales y locales.
• Cuando el sistema de plasma está en funcionamiento, • Inspeccione con frecuencia el cable de potencia
se completa un circuito eléctrico entre la antorcha y la de alimentación para detectar daños o rajaduras
pieza a cortar. La pieza a cortar y cualquier objeto que en la cubierta. Reemplace los cables dañados
la esté tocando pasan a formar parte de este circuito. de inmediato. Los cables pelados pueden ser
• Nunca toque el cuerpo de antorcha, la pieza a cortar mortales.
ni el agua de la mesa de agua cuando el sistema • Inspeccione las mangueras de la antorcha y reemplace
de plasma esté en funcionamiento. las que estén dañadas.
• No levante la pieza a cortar ni los residuos de corte
Prevención de descargas eléctricas
durante la tarea. Deje la pieza a cortar en su lugar
Todos los sistemas de plasma Hypertherm o en la mesa de trabajo con el cable de trabajo
usan voltajes altos en el proceso de corte colocado durante el proceso de corte.
(suelen ser de 200 a 400 VCD). Tome las • Antes de controlar, limpiar o reemplazar piezas de
siguientes precauciones al operar el sistema: la antorcha, desconecte la alimentación principal
• Use botas y guantes aislados, y mantenga su cuerpo o desenchufe la fuente de energía.
y su vestimenta secos. • Nunca anule ni puentee los bloqueos de seguridad.
• Asegúrese de que ninguna parte de su cuerpo esté • Antes de quitarle la cubierta a una fuente de energía
en contacto con una superficie mojada mientras usa o recinto del sistema, desconecte la potencia
el sistema de plasma. de alimentación eléctrica. Espere 5 minutos antes
• Aíslese de la pieza de trabajo y la tierra con una de desconectar la alimentación principal, para permitir
alfombra o cubierta aislante de tamaño suficiente la descarga de los condensadores.
para prevenir cualquier contacto físico con la pieza • Nunca opere el sistema de plasma sin las cubiertas
de trabajo o la tierra. Tenga mucha precaución si de la fuente de energía en su lugar. Si las conexiones
el lugar de trabajo o los alrededores están húmedos. de la fuente de energía están expuestas, presentan
• Instale un interruptor de desconexión con fusibles un alto riesgo de electrocución.
de tamaño apropiado cerca de la fuente de energía. • Al hacer las conexiones de entrada, una primero
Este interruptor permitirá al operador cortar la fuente el conductor de puesta a tierra correspondiente.
de energía rápidamente ante una emergencia.
• Cada sistema de plasma Hypertherm está diseñado
• Al usar una mesa de agua, asegúrese de que esté para usarse únicamente con antorchas Hypertherm
bien puesta a tierra. específicas. No utilice otras antorchas, ya que
podrían sobrecalentarse y presentar un riesgo para
la seguridad.
Hypertherm 1b-3
03/10
Seguridad
ADVERTENCIA
Explosión de hidrógeno
al cortar aluminio
• No realice cortes bajo el agua con gases
combustibles que contengan hidrógeno.
• Realizar cortes bajo el agua con gases combustibles
que contienen hidrógeno puede provocar una situación
explosiva que podría detonarse durante operaciones
de corte por plasma.
1b-4 Hypertherm
03/10
Seguridad
Hypertherm 1b-5
03/10
Seguridad
Cable de trabajo Sujete el cable de trabajo firmemente • Si la instalación del sistema de plasma implica
a la pieza a cortar o la mesa de trabajo, estableciendo un la conexión del cable de alimentación a la fuente
buen contacto metal con metal. No lo conecte a la pieza de energía, asegúrese de conectar adecuadamente
que se caerá cuando se termine el corte. el conductor de puesta a tierra del cable de
alimentación.
Mesa de trabajo Ponga a tierra la mesa de trabajo, • Coloque el conductor de puesta a tierra del cable
en cumplimiento con los códigos eléctricos locales de alimentación en el borne antes que los demás;
y nacionales. los otros conductores de puesta a tierra deben ir
encima del conductor del cable de alimentación.
Potencia de alimentación (entrada) Ajuste bien la tuerca de retención.
• Asegúrese de conectar el conductor de puesta • Ajuste todas las conexiones eléctricas para evitar
a tierra del cable de alimentación con la puesta el calentamiento excesivo.
a tierra de la caja de desconexión.
1b-6 Hypertherm
03/10
Seguridad
Protección cutánea Use vestimenta de protección para evitar las quemaduras producidas por la luz ultravioleta,
las chispas y el metal caliente.
• Guantes de seguridad, calzado de seguridad y casco.
• Vestimenta ignífuga para cubrir todas las áreas expuestas.
• Pantalones sin dobladillo, para evitar el ingreso de chispas y escoria.
• Antes del corte, sáquese de los bolsillos todo material combustible, como los encendedores con butano o los fósforos.
Área de corte Prepare el área de corte para reducir el reflejo y la emisión de luz ultravioleta:
• Pinte las paredes y otras superficies de colores oscuros, para reducir el reflejo.
• Use pantallas o barreras protectoras para resguardar a los demás del centelleo y el resplandor.
• Advierta a las demás personas que no deben mirar el arco. Coloque carteles o anuncios.
Número mínimo Número de sombra
Corriente
de sombra de sugerido para OSHA 29CFR Europa
del arco
protección confort 1910.133(a)(5) EN168:2002
(amperios)
(ANSI Z49.1:2005) (ANSI Z49.1:2005)
Inferior a 40 A 5 5 8 9
41 a 60 A 6 6 8 9
61 a 80 A 8 8 8 9
81 a 125 A 8 9 8 9
126 a 150 A 8 9 8 10
151 a 175 A 8 9 8 11
176 a 250 A 8 9 8 12
251 a 300 A 8 9 8 13
301 a 400 A 9 12 9 13
401 a 800 A 10 14 10
Hypertherm 1b-7
03/10
Seguridad
El funcionamiento de marcapasos y audífonos puede • Haga pasar las mangueras de la antorcha lo más
verse afectado por los campos magnéticos de las altas cerca posible del cable de trabajo.
corrientes.
• No se enrosque ni apoye los conductos de antorcha
Las personas que usan marcapasos o audífonos deben ni el cable de trabajo en el cuerpo.
consultar a un médico antes de acercarse a una operación
• Manténgase lo más alejado de la fuente de energía
de corte o ranurado por arco de plasma.
como sea posible.
Para reducir el riesgo que presentan los campos
magnéticos:
• Mantenga el cable de trabajo y los conductos
de antorcha a un costado, alejados del cuerpo.
Realizar cortes con un arco de plasma puede superar administrativos en el lugar de trabajo para restringir
los niveles de ruido aceptables, según se definen el acceso, limitar el tiempo de exposición del operador,
en los códigos locales en muchas aplicaciones. La cubrir áreas de trabajo ruidosas o tomar las medidas
exposición prolongada a ruidos excesivos puede dañar necesarias para reducir la reverberación en áreas de
la audición. Siempre use una protección apropiada para trabajo al colocar mecanismos de absorción de ruidos.
los oídos al realizar cortes o ranurados, a menos que
Se debe utilizar una protección auditiva si el ruido es
se haya verificado que, en función de las mediciones
perjudicial o si existe el riesgo de que se produzcan
de los niveles de presión de sonido tomadas en el sitio
daños a la audición una vez implementados todos los
instalado, no sea necesario utilizar protección auditiva
demás controles administrativos y de ingeniería. Si es
personal, de acuerdo con los códigos internacionales,
necesario utilizar una protección auditiva, utilice sólo los
regionales y locales correspondientes.
dispositivos de protección personal aprobados, como
Se puede obtener una reducción significativa de protectores para las orejas o tapones para los oídos
los ruidos mediante la incorporación de controles con una calificación de reducción de ruidos adecuada
de ingeniería simples a las mesas de corte, como para la situación. Advierta a las demás personas que
barreras o cortinas ubicadas entre el arco de trabajan en el área sobre los posibles riesgos que
plasma y la estación de trabajo; además, se puede presentan los ruidos. Además, la protección para los
ubicar la estación de trabajo en un lugar alejado oídos puede evitar que salpicaduras calientes ingresen
del arco de plasma. Se deben implementar controles en la oreja.
1b-8 Hypertherm
03/10
Seguridad
Hypertherm 1b-9
03/10
Seguridad
Radiación láser
La exposición a la salida del láser puede provocar graves daños oculares. Evite la exposición
ocular directa.
Para su conveniencia y seguridad, en todos los productos Hypertherm que usan un láser, se ha aplicado una
de las siguientes etiquetas de radiación láser en el producto, cerca de lugar donde el haz láser sale del bastidor.
También se proporcionan los valores de salida máxima (mV), la longitud de onda emitida (nM) y, si corresponde,
la duración de pulso.
1b-10 Hypertherm
03/10
Seguridad
Símbolos y marcas
Su producto Hypertherm puede contener alguna de las siguientes marcas en la placa de datos o cerca de ella. Debido
a las diferencias y los conflictos con las regulaciones nacionales, no todas las marcas se aplican a todas las versiones
de un producto.
Marca símbolo S
La marca símbolo S indica que la fuente de energía y la antorcha son aptas para operaciones llevadas a cabo
en entornos en los que existe un alto peligro de descargas eléctricas, de acuerdo con la norma IEC 60974-1.
Marca CSA
Los productos de Hypertherm que tienen la marca CSA cumplen con los reglamentos de seguridad de los
productos de los Estados Unidos y Canadá. Estos productos han sido evaluados, probados y certificados
por CSA-International. De manera alternativa, es posible que el producto tenga una marca colocada por otro
Laboratorio de pruebas reconocido a nivel nacional (NRTL, por sus siglas en inglés) autorizado en los Estados
Unidos y en Canadá, por ejemplo, Underwriters Laboratories, Incorporated (UL) o TÜV.
Marca CE
La marca CE indica la declaración de cumplimiento del fabricante con las normas y las directivas europeas
aplicables. Sólo se considerarán probadas para cumplimiento con las Directivas europeas de baja tensión
y con las Directivas europeas de compatibilidad electromagnética (EMC) aquellas versiones de los productos
Hypertherm que tengan la marca CE colocada sobre la placa de datos o cerca de ésta. Aquellos filtros de
EMC que deban cumplir con las Directivas europeas de EMC se han incorporado a las versiones de los
productos con la marca CE.
Marca GOST-R
Las versiones CE de los productos de Hypertherm que incluyen una marca de conformidad GOST-R cumplen
los requisitos de compatibilidad electromagnética (EMC) y de seguridad del producto para exportación
a la Federación Rusa.
Marca c-Tick
Las versiones CE de los productos de Hypertherm que incluyen una marca c-Tick cumplen las regulaciones de
EMC para la venta del producto en Australia y Nueva Zelanda.
Marca CCC
La marca China Compulsory Certification (CCC) indica que se ha evaluado el producto y que este cumple
las regulaciones de seguridad .del producto requeridas para su venta en China.
Hypertherm 1b-11
03/10
Seguridad
Etiquetas de advertencia
Esta etiqueta de advertencia se coloca en ciertas fuentes de energía. Es importante que el operador y el técnico
de mantenimiento entiendan las ideas que transmiten estos símbolos de advertencia.
1. Cutting sparks can cause explosion or fire. 1. Les étincelles de coupage peuvent provoquer une explosion
1.1 Do not cut near flammables. ou un incendie.
1.2 Have a fire extinguisher nearby and ready to use. 1.1 Ne pas couper près des matières inflammables.
1.3 Do not use a drum or other closed container as a cutting table. 1.2 Un extincteur doit être à proximité et prêt à être utilisé.
1.3 Ne pas utiliser un fût ou un autre contenant fermé comme table de coupage.
2. Plasma arc can injure and burn; point the nozzle away 2. L’arc plasma peut blesser et brûler; éloigner la buse de soi.
from yourself. Arc starts instantly when triggered. Il s’allume instantanément quand on l’amorce;
2.1 Turn off power before disassembling torch. 2.1 Couper l’alimentation avant de démonter la torche.
2.2 Do not grip the workpiece near the cutting path. 2.2 Ne pas saisir la pièce à couper de la trajectoire de coupage.
2.3 Wear complete body protection. 2.3 Se protéger entièrement le corps.
3. Hazardous voltage. Risk of electric shock or burn. 3. Tension dangereuse. Risque de choc électrique ou de brûlure.
3.1 Wear insulating gloves. Replace gloves when wet or damaged. 3.1 Porter des gants isolants. Remplacer les gants quand ils sont humides ou
3.2 Protect from shock by insulating yourself from work and ground. endommagés.
3.3 Disconnect power before servicing. Do not touch live parts. 3.2 Se protéger contre les chocs en s’isolant de la pièce et de la terre.
3.3 Couper l’alimentation avant l’entretien. Ne pas toucher les pièces sous tension.
4. Plasma fumes can be hazardous. 4. Les fumées plasma peuvent être dangereuses.
4.1 Do not inhale fumes. 4.1 Ne pas inhaler les fumées
4.2 Use forced ventilation or local exhaust to remove the fumes. 4.2 Utiliser une ventilation forcée ou un extracteur local pour dissiper les fumées.
4.3 Do not operate in closed spaces. Remove fumes with ventilation. 4.3 Ne pas couper dans des espaces clos. Chasser les fumées par ventilation.
5. Arc rays can burn eyes and injure skin. 5. Les rayons d’arc peuvent brûler les yeux et blesser la peau.
5.1 Wear correct and appropriate protective equipment to protect 5.1 Porter un bon équipement de protection pour se protéger la tête, les yeux, les
head, eyes, ears, hands, and body. Button shirt collar. Protect ears oreilles, les mains et le corps. Boutonner le col de la chemise. Protéger les oreilles
from noise. Use welding helmet with the correct shade of filter. contre le bruit. Utiliser un masque de soudeur avec un filtre de nuance appropriée.
6. Become trained. Only qualified personnel should operate this 6. Suivre une formation. Seul le personnel qualifié a le droit de faire
equipment. Use torches specified in the manual. Keep non-qualified fonctionner cet équipement. Utiliser exclusivement les torches indiquées dans le
personnel and children away. manual. Le personnel non qualifié et les enfants doivent se tenir à l’écart.
7. Do not remove, destroy, or cover this label. 7. Ne pas enlever, détruire ni couvrir cette étiquette.
Replace if it is missing, damaged, or worn (PN 110584 Rev C). La remplacer si elle est absente, endommagée ou usée (PN 110584 Rev C).
1b-12 Hypertherm
03/10
Seguridad
1b-14 Hypertherm
03/10
Section 2
Specifications
In this section:
System description.....................................................................................................................................................................................2-3
General...............................................................................................................................................................................................2-3
Power supply.....................................................................................................................................................................................2-3
Ignition console.................................................................................................................................................................................2-3
Gas console......................................................................................................................................................................................2-3
Off-valve.............................................................................................................................................................................................2-3
Torch...................................................................................................................................................................................................2-3
Specifications..............................................................................................................................................................................................2-4
System gas requirements...............................................................................................................................................................2-4
Power supply.....................................................................................................................................................................................2-5
Ignition console – 078172.............................................................................................................................................................2-6
Gas console – 078532..................................................................................................................................................................2-8
Off-valve – 078534.........................................................................................................................................................................2-9
Torch – 228521............................................................................................................................................................................ 2-10
IEC symbols.............................................................................................................................................................................................. 2-11
System description
General
HyPerformance plasma systems are designed to cut a wide range of thicknesses of mild steel, stainless steel
and aluminum.
Power supply
The power supply is a 260-amp, 150-VDC constant-current supply. It contains the circuitry to ignite a torch, a heat
exchanger and pump to cool the torch. The power supply has a serial interface to provide communication with a CNC
controller.
Ignition console
The ignition console uses a spark-gap assembly. The ignition console converts 120 VAC control voltage from the power
supply into high-frequency and high-voltage pulses (9-10 kV) to break over the torch electrode-nozzle gap. The high-
voltage, high-frequency signal is coupled to the cathode lead and pilot arc lead.
Gas console
The power switch located on the gas console is the main power switch for the system. Power may be present at all
other components when it is in the ON (l) position. The gas console manages the selection and flow rate of all incoming
gases. The gas console includes motor valves, solenoid valves, check valves and pressure transducers. The gas console
also houses a relay PC board and a control PC board.
Off-valve
The off-valve consists of 5 solenoid valves, a manifold block and a wiring harness with connector. The assembly
interfaces with the machine torch, the ignition console and the gas console.
Torch
The virtually dross-free cutting capacity of the torch is 38 mm (1.5 in) for HyDefinition cutting. The production pierce
capacity is 38 mm (1.5 in) for mild steel, 32 mm (1.25 in) stainless steel and 25 mm (1 in) for aluminum. The maximum
cutting capability (edge start) is 64 mm (2.5 in) for mild steel and stainless steel and 50 mm (2 in) for aluminum.
Specifications
System gas requirements
Gas types Plasma gas Shield gas Plasma gas Shield gas Plasma gas Shield gas
Cutting 30 to 50 A O2 O2 N2 & F5 N2 Air Air
Cutting 80 A O2 Air F5 N2 – –
Cutting 130 A O2 Air N2 & H35 N2 H35 & Air N2 & Air
Cutting 200 A O2 Air N2 & H35 N2 N2 & H35 N2
Cutting 260 A O2 Air N2 & H35 N2 & Air N2 & H35 N2 & Air
Power supply
General
Maximum OCV (U0) 311 VDC
Maximum output current (I2) 260 Amps
Output voltage (U2) 50 – 175 VDC
Duty cycle rating (X) 100% @ 45.5 kw, 40° C (104° F)
Power supplies will operate between -10° C and +40° C
Ambient temperature/Duty cycle
(+14° and 104° F)
Power factor (cosϕ) 0.98 @ 260 ADC output
Cooling Forced air (Class F)
Insulation Class H
Power supply
part numbers AC Voltage Frequency Amperage Power kVA
Phase Regulatory (+/- 10%)
Without With (U1) (Hz) (I1) approval (U1 x I1 x 1.73)
Hypernet Hypernet
078554 078562 200/208 3 50/60 149/144 CSA 51.6
078555 078563 220 3 50/60 136 CSA 51.6
078556 078564 240 3 60 124 CSA 51.6
078557 078565 380* 3 50/60 79 CCC 51.6
078558 078566 400 3 50/60 75 CE/GOST-R 51.6
078605 078606 415 3 50/60 75 CE/GOST-R 51.6
078559 078567 440 3 50/60 68 CSA 51.6
078560 078568 480 3 60 62 CSA 51.6
078561 078569 600 3 60 50 CSA 51.6
133.4 mm
5.3 in
1181.1 mm
46.5 in
554.7 kg
1223 lb
1143.0 mm
45.0 in
803.3 mm
31.6 in
• Maximum cable length from the ignition console to the torch lifter station is 20 m (65 ft). Allow room to remove
the top for servicing.
283 mm
11.125 in
219 mm
8.625 in
194 mm 9.1 kg
7.625 in 20 lb
216 mm
8.5 in
152 mm
6 in
Mounted on table
Horizontal mounting
Vertical mounting
• Maximum cable length from the gas console to the off-valve assembly is 20 m (65 ft).
• Mount the gas console on top of the power supply or near the CNC on the cutting table. Allow room to open the
top for servicing.
292 mm 359 mm
11.5 in 14.125 in
317 mm
12.5 in
14 kg
31 lb
276 mm
10.88 in
178 mm
7 in
Off-valve – 078534
• 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 to a
bracket just above the bridge.
• The vent hole on the manifold must be kept clear at all times.
70 mm
A
2.75 in
Vent hole:
19 mm
Do not block
0.75 in
157 mm 1.1 kg
6.18 in 2.5 lb
4.7 mm
0.187 in
92 mm
3.62 in 30 mm
1.18 in
165 mm
6.5 in
A-A
Torch – 228521
• The outside diameter of the torch mounting sleeve is 50.8 mm (2.0 in).
• The minimum bend radius for the torch leads is 152.4 mm (6.0 in).
1.8 m
6’
49 mm
193 mm 1.91 in
7.59 in
104 mm
4.10 in
51 mm 51 mm 57 mm
2.00 in 2 in 2.25 in
95 mm
3.74 in
43 °
345 mm
13.60 in
1.9 kg
4.2 lb
IEC symbols
The following symbols may appear on the power supply data plate, control labels, switches, LEDs, and LCD screen.
1~ f 1
f2
An inverter-based power
Plasma torch cutting source, either 1-phase or
3-phase
Installation
In this section:
Upon receipt................................................................................................................................................................................................3-3
Claims............................................................................................................................................................................................................3-3
Installation requirements...........................................................................................................................................................................3-3
Noise levels..................................................................................................................................................................................................3-3
Placement of system components..........................................................................................................................................................3-3
Torque specifications......................................................................................................................................................................3-3
Installation requirements...........................................................................................................................................................................3-4
System components........................................................................................................................................................................3-5
Cables and hoses............................................................................................................................................................................3-5
Supply gas hoses.............................................................................................................................................................................3-5
Customer-supplied power cable..................................................................................................................................................3-5
Recommended grounding and shielding practices............................................................................................................................3-6
Introduction..................................................................................................................................................................................................3-6
Types of grounding..........................................................................................................................................................................3-6
Steps to take.....................................................................................................................................................................................3-7
Grounding diagram....................................................................................................................................................................... 3-10
Placement of the power supply............................................................................................................................................................ 3-11
Install the ignition console...................................................................................................................................................................... 3-12
Install the off-valve................................................................................................................................................................................... 3-14
Placement of the gas console............................................................................................................................................................... 3-15
Power supply to ignition console leads.............................................................................................................................................. 3-16
Pilot arc lead................................................................................................................................................................................... 3-16
Negative lead.................................................................................................................................................................................. 3-16
Ignition console power cable...................................................................................................................................................... 3-18
Ignition console coolant hoses................................................................................................................................................... 3-19
Power supply to gas console cables.................................................................................................................................................. 3-20
Control cable.................................................................................................................................................................................. 3-20
Power cable.................................................................................................................................................................................... 3-20
Gas console to off-valve connections................................................................................................................................................. 3-22
Cable and gas hose assembly................................................................................................................................................... 3-22
Power supply to CNC interface cable................................................................................................................................................ 3-24
Optional multi-system CNC interface cable........................................................................................................................... 3-24
Notes to CNC interface cable run list...................................................................................................................................... 3-25
Upon receipt
• Verify that all system components on your order have been received. Contact your supplier if any items
are missing.
• Inspect the system components for any physical damage that may have occurred during shipping. If there is
evidence of damage, refer to Claims. All communications regarding claims must include the model number and
serial number located on the rear of the power supply.
Claims
Claims for damage during shipment – If your unit was damaged during shipment, you must file a claim with the
carrier. Hypertherm will furnish you with a copy of the bill of lading upon request. If you need additional assistance, call
Customer Service listed in the front of this manual, or your authorized Hypertherm distributor.
Claims for defective or missing merchandise – If any of the merchandise is defective or missing, contact your
supplier. If you need additional assistance, call Customer Service listed in the front of this manual, or your authorized
Hypertherm distributor.
Installation requirements
All installation and service of the electrical and plumbing systems must conform to national and local
electrical and plumbing codes. This work should be performed only by qualified, licensed personnel.
Direct any technical questions to the nearest Hypertherm Technical Service Department listed in the front of this manual,
or your authorized Hypertherm distributor.
Noise levels
Acceptable noise levels as defined by national and local codes may be exceeded by this plasma system. Always
wear proper ear protection when cutting or gouging. Any noise measurements taken are dependant on the specific
environment in which the system is used. See also Noise can damage hearing in the Safety section of this manual.
Specific information by product can be found in the Hypertherm downloads library at:
https://www.hypertherm.com/Xnet/library/DocumentLibrary.jsp
Select the product you are looking for from the Product Type drop down menu, choose “Regulatory” from the Category
drop down menu, and choose “Acoustical Noise Data Sheets” from the Sub Category drop down menu. Hit Submit.
Torque specifications
Gas or water hose
size kgf-cm lbf-in lbf-ft
Installation requirements
16
A
B
4 3
7 11
D
15 10
14
5 13
12
6
8 9
System components
A Power supply
B Ignition console
C Off-valve assembly
D Gas console
E Torch
2 Negative lead
3 Ignition console power cable
4 Ignition console coolant hoses
9 Optional CNC interface cable for systems with multiple power supplies
10 Torch lead assembly
11 Work lead
12 Oxygen
13 Nitrogen or argon
14 Air
DANgER
ElEctRIc SHock cAN kIll
Introduction
This document describes the grounding and shielding necessary to protect a plasma cutting system installation against
radio frequency interference (RFI) and electromagnetic interference (EMI) noise. It addresses the three grounding
systems described below. There is a diagram on page 3-10 for reference.
Note: These procedures and practices are not known to succeed in every case to eliminate RFI/EMI noise
issues. The practices listed here have been used on many installations with excellent results, and we
recommend that these practices be a routine part of the installation process. The actual methods
used to implement these practices may vary from system to system, but should remain as consistent
as possible across the product line.
types of grounding
A. The safety (PE) or service ground. This is the grounding system that applies to the incoming line voltage. It prevents
a shock hazard to any personnel from any of the equipment, or the work table. It includes the service ground coming
into the plasma power supply and other systems such as the CNC controller and the motor drivers, as well as the
supplemental ground rod connected to the work table. In the plasma circuits, the ground is carried from the plasma
power supply chassis to the chassis of each separate console through the interconnecting cables.
B. The DC power or cutting current ground. This is the grounding system that completes the path of the cutting current
from the torch back to the power supply. It requires that the positive lead from the power supply be firmly connected
to the work table ground bus with a properly sized cable. It also requires that the slats, on which the workpiece rests,
make good contact with the table and the workpiece.
C. RFI and EMI grounding and shielding. This is the grounding system that limits the amount of electrical “noise”
emitted by the plasma and motor drive systems. It also limits the amount of noise that is received by the CNC and
other control and measurement circuits. This grounding/shielding process is the main target of this document.
11-08
Steps to take
1. Unless noted, use only 6 AWG (16 mm2) welding cable (Hypertherm part no. 047040) for the EMI ground cables
shown on the diagram.
2. The cutting table is used for the common, or star, EMI ground point and should have threaded studs welded to the
table with a copper bus bar mounted on them. A separate bus bar should be mounted on the gantry as close to
each drive motor as possible. If there are drive motors at each end of the gantry, run a separate EMI ground cable
from the far drive motor to the gantry bus bar. The gantry bus bar should have a separate, heavy EMI ground cable
(4 AWG (21,2 mm2) part no. 047031) to the table bus bar. The EMI ground cables for the torch lifter and the RHF
console must each run separately to the table ground bus.
3. A ground rod that meets all applicable local and national electrical codes must be installed within 6 m (20 ft)
of the table. This is a PE ground and should be connected to the ground bus on the cutting table with 6 AWG
(16 mm2) green/yellow grounding cable (Hypertherm part number 047121) or equivalent. All PE grounds are shown
on the diagram in green.
4. For the most effective shielding, use the Hypertherm CNC interface cables for I/O signals, serial communication
signals, power supply-to-power supply multi-drop connections, and interconnections between all parts of the
Hypertherm system.
5. All hardware used in the ground system must be brass or copper. The only exception is that the studs welded to the
table for mounting the ground bus can be steel. Under no circumstances should aluminum or steel hardware be used.
6. AC power, PE, and service grounds must be connected to all equipment according to local and national codes.
7. * The positive, negative, and pilot arc leads should be bundled together for as long a distance as possible.
The torch lead, work lead, and the pilot arc (nozzle) leads may only be run parallel to other wires or cables if they
are separated by at least 150 mm (6 in). If possible, run power and signal cables in separate cable tracks.
8. * The ignition console should be mounted as close as possible to the torch, and must have a separate ground cable
to the bus bar on the cutting table.
9. Each Hypertherm component, as well as any other CNC or motor-drive cabinet or enclosure, must have a separate
ground cable to the common (star) point on the table. This includes the ignition console, even if it is bolted to the
power supply or to the cutting machine.
10. The metal braided shield on the torch leads must be connected firmly to the ignition console and to the torch.
It must be electrically insulated from any metal and from any contact with the floor or building. The leads can be
run in a plastic cable tray (track) or covered with a plastic or leather sheath.
11. The torch holder and the torch breakaway mechanism – the part mounted to the lifter, not the part mounted on
the torch – must be connected to the stationary part of the lifter with copper braid at least 12.7 mm (1/2 in) wide.
A separate cable must run from the lifter to the bus bar on the gantry. The valve assembly should also have a
separate ground connection to the gantry bus bar.
11-08
12. If the gantry runs on rails that are not welded to the table, then the rails need to be connected with a ground cable
from each end of both rails to the table. These need not go to the common (star) point, but could take the shortest
path to the table.
13. If the OEM is installing a voltage divider to process arc voltage for use in the control system, the voltage divider
board should be mounted as close as possible to the point where the arc voltage is sampled. One acceptable
location is inside the plasma power supply. If the Hypertherm voltage divider board is used, the output signal is
isolated from all other circuits. The processed signal should be run in twisted, shielded cable (Belden type 1800F
or equivalent). The cable used must have a braided shield, not a foil shield. The shield should be connected to the
chassis of the power supply and left unconnected at the other end.
14. All other signals (analog, digital, serial, encoder) should run in twisted pairs inside a shielded cable. Connectors on
these cables should have a metal housing and the shield, not the drain, should be connected to the metal housing
of the connectors at each end of the cable. Never run the shield or the drain through the connector on any of the
pins.
Power
supply Remote
Ground rod lead (+) high frequency
(RHF) console
Gantry
CNC enclosure
Torch holder
Power supply
chassis
Example of a good cutting table ground bus. The picture above shows the connection from the
gantry ground bus, the connection from the ground rod, the power supply positive lead, the RHF
console*, the CNC enclosure, the torch holder, and the power supply chassis.
Cable to ground
bus on the Component
cutting table ground cables
Example of a good gantry ground bus. It is bolted to the gantry, close to the motor. All of the individual
ground cables from the components mounted on the gantry go to the bus except those from the RHF
console* and the torch holder. A single heavy cable then goes from the gantry ground bus to the
ground bus bolted to the table.
3-10
THC console console console console
Bus bar
Installation
Gantry
Command
THC
**
Ground rod
Cutting table
Positive DC
Plasma
power supply
grounding diagram (some systems will not include all the components shown)
** The lifter assembly and the RHF console each
require a separate path to the cutting table
AC earth/service ground Chassis and RFI ground ground bus bar.
DANGER
Electric Shock Can Kill
Remove all electrical connections to the power supply before moving or positioning. Transporting the
unit can cause personal injury and equipment damage.
The power supply can be moved by forklift but the forks must be long enough to extend the entire length of the base.
Take care when lifting so that the underside of the power supply is not damaged. The forks must also be centered front
to back and side to side to prevent tipping while moving. Fork lift speeds should be kept to a minimum, especially when
making a turn or going around a corner.
• Place the power supply in an area that is free of excessive moisture, has proper ventilation and is relatively clean.
Allow 1 m (3 ft) of space on all sides of the power supply for ventilation and service.
• Cooling air is drawn in through the front panel and is exhausted through the rear of the unit by a cooling
fan. Do not place any filter device over the air intake locations, which reduces cooling efficiency and VOIDS
THE WARRANTY.
• Do not place the power supply on an incline greater than 10° to prevent it from toppling.
• Mount the ignition console on the power supply for the LHF configuration.
32 mm 184 mm
1.25 in 7.25 in
216 mm
8.50 in
32 mm
1.25 in
248 mm
9.75 in
279 mm
11.00 in
7 mm
0.28 in
(4 places)
LHF mounting
Off-valve grounding
A
A-A
70 mm
A 157 mm
6.18 in
2.75 in
4.7 mm
0.187 in
92 mm
Vent hole: 19 mm 3.62 in 30 mm
Do not block 0.75 in 1.18 in
165 mm
6.5 in
50.8 mm 228.6 mm
2.0 in 9.0 in
314.5 mm
12.38 in
38.1 mm
1.5 in
7 mm
0.28 in
(4 places)
2 Negative lead
* Cable numbers 123683 and 123829 are for use with systems that have the ignition console mounted on the power supply
Negative lead
Work lead 2 1
Negative lead Pilot arc lead
1
Pilot arc lead
2
Negative lead
2
* Cable number 123865 is for use with systems that have the ignition console mounted on the power supply
Red
Green
* Hose set number 228031 is for use with systems that have the ignition console mounted on the power supply
Green
Red
5 Control cable
6 Power cable
* Cable numbers 123784 and 123785 are for use with systems that have the gas console mounted on the power supply
1X1
J300
J103
Male
Female
5
6
3X3 3X1
3X2
Green
Black
Blue
Red
Green
Black
Blue
Red
9 Optional multi-system CNC interface cable (see schematics for installation information)
Power supply
end CNC end
Red 12 Input Corner (–) The CNC Notifies the plasma system that a corner is approaching Output
and to reduce cut current (Cut current is CNC selectable or 1
Orange 31 Input Corner (+) defaults to 50% of cut current) Output
Green 13 Input Pierce (–) The CNC Notifies the plasma system to maintain the shield preflow Output
1
White 32 Input Pierce (+) until the CNC releases the signal
Green 14 Input Hold (–) Not required without CommandTHC. CommandTHC requires Output
1
Blue 33 Input Hold (+) signal to preflow gases during IHS
Green 15 Input Start (–) Output
The CNC initiates the plasma arc 1
Yellow 34 Input Start (+) Output
Green 16 None Not used
Brown 35 None Not used
Green 17 None Not used
Orange 36 Power ground Ground
White 18 Power ground Ground
4
Black 37 CNC +24 VDC Available 24 VDC (200 milliamps maximum) see notes
19 CNC +24 VDC Not connected
Note 2. Outputs are optically isolated, open collector, transistors. The maximum rating is 24 VDC at 10 mA.
Note 3. Machine motion is selectable and is used for configurations with multiple plasma systems.
Note 4.* CNC +24 VDC provides 24 VDC at 200 mA maximum. A jumper is required on J304 to use 24 V power.
Caution: The CNC cable must be constructed using cable with 360 degree shielding and
metal housing connectors at each end. The shielding must be terminated to the
metal housings at each end to ensure proper grounding and to provide the best
shielding.
HPR CNC/PLC
C
+
-
E High-impedance (≤10 mA)
3. Relay interface
CNC +24 V
+24 VDC CNC +24 V
Install a °t
Jumper
J304 HPR
108056 C
+ CNC/PLC
-
E High-current
contact closure
inputs (AC or DC)
External relay
24 VDC low-power coil
≤10 mA or ≥2400 ohms
All relay coils require a freewheeling diode
Power across the relay coil
ground
+24 VDC
Output from
HPR
CNC/PLC
External relay
(AC or DC)
Power
ground
2. Optocoupler interface
+24 VDC
CNC/PLC
HPR
Transistor-output
optocoupler
Power
ground
3. Amplified-output interface
HPR
Power
Active-high drive ground Power
ground
DANGER
Electric Shock Can Kill
TB2 location
2. Remove wire 1 as shown and connect it to terminal 2.
1 3
TB2 1 2 3
1 3
1 3
TB2 1 2 3
Note: Use a switch, relay or solid-state relay that is
1 3 compatible with 24 VAC @ 100 mA. It must be
a maintained-contact switch, not a momentary-
contact switch.
Note: The main power switch on the gas console must be in the ON position for the remote switch to function.
Blue
Black Plasma-gas vent hose
(white)
Caution: The length of the hoses Caution: Locate the exposed end
from the torch to the 10 of the plasma-gas vent
metering console are hose away from sparks
critical to cut quality caused by piercing
and consumable life. to avoid ignition and
possible damage to the
Do not alter the length
torch leads.
of the hoses.
11 Work lead
Work table Power supply
Work lead
Work lead
E Torch connections
Connect the torch to the torch lead assembly
1. Uncoil the first 2 meters (6.5 ft) of the leads on a flat surface.
2. Hold the torch assembly in place with the spanner wrench (104269) and remove the mounting sleeve from the torch
assembly.
3. Push back the braided cover and slide the sleeve over the leads. Align the torch with the hoses in the lead assembly.
The hoses must not be twisted. They are taped together to help prevent twisting.
Sleeve
Braided cover
2WRENCHES
5. Connect the pilot arc lead (yellow). Insert the connector into the torch receptacle and turn it by hand until it is tight.
6a. Route the ohmic contact wire through the opening in the braided cover and the torch sleeve.
Sleeve
Braided cover
6b. Insert the connector into the torch receptacle and turn it by hand until it is tight.
Ohmic contact wire part numbers (Not part of the HPR260XD system. Shown for reference only)
connector-collar
11. Slide the torch sleeve over the connections and screw it onto the torch assembly.
12. Slide the braided cover up to the torch sleeve. Make sure that the plasma, shield and vent hoses are routed through
the hole in the braided cover. Loosen the hose clamp on the braided cover, slide the braided cover and clamp over
the sleeve and tighten the clamp.
Installation note
Align the torch body to the torch leads and secure by
screwing completely together. Be certain that there is no
space between the torch body and the o-ring on the torch
leads. See also Torch connections earlier in this section for
torch lead connections to ignition console.
Installation
1. Install the torch (with torch leads
attached) in the torch mounting bracket.
Upper torch sleeve
2. Position the torch below the mounting
bracket, so that the bracket is around the
lower portion of the torch sleeve but not
Lower torch sleeve Torch mounting touching the torch quick-disconnect.
bracket
(customer supplied) 3. Tighten the securing screws.
Torch alignment
To align the torch at right angles to the workpiece, use a square. See figure above.
Hypernet
Hypernet is only used to connect certain Hypertherm components to each other. An HPRXD system can be connected
to the ArcGlide® torch height control, and an EDGE® Pro or MicroEDGE® Pro CNC using an ethernet hub and cable.
The Hypernet PCB provides communication between components and is the source for the arc voltage needed for the
torch height control. See the ArcGlide instruction manual (806450), the EDGE Pro instruction manual (806360) or the
MicroEDGE Pro CNC instruction manual (807290) for more information.
Note: The HPR130XD power supply is shown below, but the Hypernet interface board is in the same location in
the HPR260XD power supply.
Power requirements
General
All switches, slow-blow fuses and power cables are customer-supplied and must be chosen as outlined by applicable
national and local electrical codes. Installation must be performed by a licensed electrician. Use a separate, primary, line
disconnect switch for the power supply. Recommendations on fuse and circuit breaker sizing are listed below, however
actual sizes required will vary based on individual site electrical line conditions (including but not limited to source
impedance, line impedance, and line voltage fluctuation), product inrush characteristics, and regulatory requirements.
The main feed protection device (Circuit Breaker or Fuse) must be sized to handle all branch-feed loads for both inrush
and steady-state current. The power supply must be wired into one of the branch-feed circuits. The power supply has a
steady-state current listed in the table below.
Use a motor-start circuit breaker or equivalent if time delay high inrush fuses are not permitted by local and national
codes. Time delay fuses and circuit breakers must be capable of withstanding inrush current that is up to 30 times the
rated input current (FLA) for 0.01 seconds and up to 12 times the rated input current (FLA) for 0.1 seconds.
Note: Cable AWG recommendations taken from table 310-16 of the National Electric Code handbook (USA).
Installation must be performed by a licensed electrician and according to applicable national and local codes.
DANGER
Electric Shock Can Kill
The line disconnect switch must be in the OFF position before making the power cable
connections. In the U.S., use a “lock-out/tag-out” procedure until installation is complete. In other
countries, follow appropriate national and local safety procedures.
1. Insert the power cable through the strain relief at the rear of the power supply.
2. Connect the ground lead (PE) to the GROUND terminal ( ) of TB1 as shown below.
4. Verify that the line disconnect switch is in the OFF position and remains in the OFF position for the
remainder of the installation of the system.
5. Connect the power cord leads to the line disconnect switch following national and local electrical codes.
North American wire colors European wire colors
U = Black U = Black
V = White V = Blue
W = Red W = Brown
(PE) Earth ground = Green/Yellow (PE) Earth ground = Green/Yellow
Line
disconnect
switch
GND
W
V
U
Power
cable
TB1
Observe the warning and cautions below. Refer to the Material Safety Data Sheets appendix for data on safety,
handling and storage of propylene glycol and benzotriazole.
DANgER
coolANt cAN bE IRRItAtINg to SkIN AND EyES AND
HARMFUl oR FAtAl IF SwAllowED
Propylene glycol and benzotriazole are irritating to skin and eyes, and harmful or fatal if
swallowed. Upon contact, flush skin or eyes with water. If swallowed, seek immediate medical
attention.
Always use purified water in the coolant mixture in order to prevent damage
to the pump and corrosion in the torch coolant system.
Hypertherm premixed coolant consists of 69.8% water, 30% propylene glycol, and 0.2% benzotriazole.
10/16/08
custom coolant mix for cold operating temperatures (below -12° c / 10° F)
caution: For operating temperatures colder than the temperature stated above,
the percentage of propylene glycol must be increased. Failure to do so
could result in a cracked torch head, hoses or other damage to the torch
coolant system due to freezing.
Use the chart below to determine what percentage of propylene glycol to use in the mixture.
Mix 100% glycol (028873) with the premixed Hypertherm coolant (028872) to increase the percentage of glycol. The
100% glycol solution can also be mixed with purified water (see next page for water purity requirements) to achieve the
required protection from freezing.
°c °F
4 40
-1 30
-12 10
-18 0
temperature
-23 -10
-29 -20
Maximum glycol percentage
-34 -30
-40 -40
-46 -50
-51 -60
-57 -70
0 10 20 30 40 50 60
% of Propylene glycol
10/16/08
custom coolant mix for hot operating temperatures (above 38° c / 100° F)
Treated water (with no propylene glycol) can only be used as coolant when operating temperatures are never below
0° C (32° F). For operations in very warm temperatures treated water will provide the best cooling properties.
Treated water refers to a mixture of purified water, that meets the specifications below, and 1 part benzotriazole (BZT)
to 300 parts of water. BZT (128020) acts as a corrosion inhibitor for the copper based coolant system contained in the
plasma system.
Conductivity Resistivity
μS/cm mΩ-cm Dissolved solids Grains per gallon
water purity at 25° C (77° F) at 25° C (77° F) (ppm of NaCl) (gpg of CaCO2)
10/16/08
Caution: sing the wrong coolant can cause damage to the system. Refer to torch
U
coolant requirements in this section for more information.
1. Add coolant to the power supply until the 2. Press and hold the current selection knob
tank is full. (8) and press power switch on the gas
console. The pump will run continuously
while (8) is pressed.
3. The current display shows the flow rate. 4. Add coolant to the power supply until
When the flow rate is constant and greater the tank is full and replace the filler cap.
than 22.7 lpm (0.6 gpm), release the knob.
The display will show the current again. The
pump will continue to run.
Gas requirements
The customer must furnish all gases and gas-supply regulators for the system. Use a high-quality, 2-stage pressure
regulator located within 3 m (10 ft) of the gas console. See gas regulators in this section for recommendations.
See the Specification section for gas and flow specifications. See Supply gas hoses at the end of this section for
recommendations.
Caution: Gas supply pressures not within the specifications in Section 2 can cause
poor cut quality, poor consumable life and operational problems.
If the purity level of the gas is too low or if there are leaks in the supply
hoses or connections,
1. Turn OFF the power to the system. Set all gas regulator pressures to 8 bar (115 psi).
3. After the purge cycle stops, move switch (7) on the gas console to SET PREFLOW.
4. While gas is flowing adjust the supply regulator for the shield gas pressure to
8 bar (115 psi).
7. While gas is flowing adjust the supply regulator for the plasma gas to 8 bar (115 psi).
Gas regulators
Low-quality gas regulators do not provide consistent supply pressures and can result in poor cut quality and system
operation problems. Use a high-quality, 1-stage, gas regulator to maintain consistent gas supply pressure, if using liquid
cryogenic or bulk storage. Use a high-quality, 2-stage, gas regulator to maintain consistent gas supply pressure from
high pressure gas cylinders.
The high-quality gas regulators listed below are available from Hypertherm and meet U.S. Compressed Gas Association
(CGA) specifications. In other countries, select gas regulators that conform to national or local codes.
Part
Number Description Qty.
128544 Kit: Oxygen, 2-stage * 1
128545 Kit: Inert Gas, 2-stage 1
128546 Kit: Hydrogen (H5, H35 and methane) 2-stage 1
128547 Kit: Air, 2-stage 1
128548 Kit: 1-stage (for use with cryogenic liquid nitrogen or oxygen) 1
022037 Oxygen, 2-stage 1
022038 Inert gas, 2-stage 1
022039 Hydrogen/methane, 2-stage 3
022040 Air, 2-stage 1
022041 Line regulator, 1-stage 1
For flexible-hose systems, use a hose designed for inert gas to carry air, nitrogen or argon-hydrogen. See the last page
of this section for hose part numbers.
Caution: When connecting the selection console to the supply gases, make sure that
all hoses, hose connections and fittings are acceptable for use with oxygen
and argon-hydrogen. Installation must be made in accordance with national
and local codes.
Note: When cutting with oxygen as the plasma gas, air must also be connected to the selection console to
achieve the proper mixtures in the preflow and cutflow modes.
WARNING
CUTTING WITH OXYGEN CAN CAUSE FIRE OR EXPLOSION
Cutting with oxygen as the plasma gas can cause a potential fire hazard due to the oxygen-enriched
atmosphere that it creates. As a precaution, Hypertherm recommends that an exhaust ventilation
system be installed when cutting with oxygen.
Flashback arrestors are required (unless not available for specific gases or required pressures)
to prevent fire from propagating back to supply gas.
Fitting Size
Caution: Replacing the fittings on the gas console may cause the internal valves to
malfunction, because particulates can migrate into the valves.
12 Oxygen hose
Caution: Never use teflon
tape on any joint
preparation.
14 Air hose
Operation
In this section:
Daily start-up................................................................................................................................................................................................4-3
Check torch.......................................................................................................................................................................................4-3
Controls and indicators.............................................................................................................................................................................4-4
General...............................................................................................................................................................................................4-4
Main power switch...........................................................................................................................................................................4-4
Power indicators...............................................................................................................................................................................4-4
Manual gas console operation.................................................................................................................................................................4-5
Consumable selection...............................................................................................................................................................................4-6
Standard cutting (0°).......................................................................................................................................................................4-6
Bevel cutting (0° to 45°).................................................................................................................................................................4-6
Marking...............................................................................................................................................................................................4-6
Consumables for mirror-image cutting........................................................................................................................................4-6
SilverPlus electrodes.......................................................................................................................................................................4-6
Mild steel............................................................................................................................................................................................4-7
Stainless steel...................................................................................................................................................................................4-8
Aluminum............................................................................................................................................................................................4-8
Mild steel bevel cutting...................................................................................................................................................................4-9
Mild steel, thick piercing, bevel cutting.......................................................................................................................................4-9
Stainless steel bevel cutting..........................................................................................................................................................4-9
Install and Inspect consumables.......................................................................................................................................................... 4-10
Install consumables....................................................................................................................................................................... 4-10
Inspect consumables.................................................................................................................................................................... 4-11
Torch maintenance.................................................................................................................................................................................. 4-13
Routine maintenance.................................................................................................................................................................... 4-13
Quick-disconnect maintenance.................................................................................................................................................. 4-13
Maintenance kit.............................................................................................................................................................................. 4-13
Torch connections................................................................................................................................................................................... 4-14
Replace torch water tube....................................................................................................................................................................... 4-14
Common cutting faults........................................................................................................................................................................... 4-15
How to optimize cut quality................................................................................................................................................................... 4-16
Tips for table and torch................................................................................................................................................................ 4-16
Plasma set-up tips......................................................................................................................................................................... 4-16
Daily start-up
Prior to start-up, ensure that your cutting environment and that your clothing meet the safety requirements outlined in the
Safety section of this manual.
Check torch
DANGER
Electric Shock Can Kill
Before operating this system, you must read the Safety section thoroughly. Turn OFF the power
supply’s main disconnect switch before proceeding with the following steps.
2. Remove the consumables from the torch and check for worn or damaged parts. Always place the consumables
on a clean, dry, oil-free surface after removing. Dirty consumables can cause the torch to malfunction.
• Refer to Install and inspect consumables later in this section for details and for parts inspection tables.
• Refer to the Cut charts to choose the correct consumables for your cutting needs.
3. Replace consumable parts. Refer to Install and inspect consumables parts later in this section for details.
Shield cap Shield Nozzle retaining cap Nozzle Swirl ring Electrode Current ring Torch
On Position (I)
AC power is sent to the control transformer, to
turn on the power supply.
Power indicators
AC Green Indicator:
Illuminates when the power switch is in the on
position.
3-digit display*
Position number
2. Follow instructions below using the settings provided in the Cut charts.
Position # Instruction
1 Select PLASMA GAS.
2 Select SHIELD GAS.
3, 4 & 7 Position switch (7) to SET PREFLOW (3-4). Set plasma preflow (3). Set shield preflow (4)
5, 6 & 7 Position switch (7) to SET CUTFLOW (5-6). Set plasma cutflow (5). Set shield cutflow (6).
7 Position switch (7) to RUN.
8 Position switch (8) to SET AMPS. Set amperage using knob above switch (8). Switch 8 can be in any
position while operating.
System is ready to cut.
* The 3-digit display is for reference. The current shown during cutting may vary by +/- 2 amps from the current shown
when the amperage is set.
Consumable selection
Standard cutting (0°)
Most of the consumables on the following pages are designed for standard (straight) cutting, when the torch is
perpendicular to the workpiece.
Marking
Any of the consumable sets can also be used for marking with argon or nitrogen. Marking parameters are shown at the
bottom of each cut chart. The quality of the marks will vary depending on the marking process, cut process, material
type, material thickness, and material surface finish. For best mark quality, use the argon marking process settings. For
all marking processes the depth of the mark can be increased by reducing the marking speed, or the depth can be
decreased by increasing the marking speed. Argon marking currents can be increased by up to 30% to increase the
depth of the mark. When marking with an argon process at 25 amps or greater, the process will start with air before
changing to argon, and a thicker, darker mark will be seen at the start of the mark. When using the argon marking
processes, mark and cut individual parts. Marking the entire nest prior to cutting may lead to reduced consumable life.
For better results intersperse cuts and marks. Poor quality marking or burn-through may occur with material less than
1.5 mm (0.06 in. or 16 gauge).
SilverPlus electrodes
SilverPlus electrodes provide increased life when the average cut duration is short (< 60 seconds), and cut quality is not
the most critical requirement. SilverPlus electrodes are available for 130 amp, 200 amp, and 260 amp mild steel O2 / Air
cutting. Part numbers can be found on the following page.
Mild steel
Nozzle Water
Shield cap Shield retaining cap Nozzle Swirl ring Electrode tube
30A
50A
220747 80A
130A
200A
220637 260A
Stainless steel
Nozzle Water
Shield cap Shield retaining cap Nozzle Swirl ring Electrode tube
45A
80A
130A
220340
220198 220755 (H35) 220197 220179 220307
220756 (N2)
200A
220637 260A
Aluminum
Nozzle Water
Shield cap Shield retaining cap Nozzle Swirl ring Electrode tube
45A
220747 130A
200A
220637
260A
80 A
130 A
260 A
260 A
130 A
260 A
WARNING
The system is designed to go into an idle mode if the retaining cap is removed. However,
DO NOT CHANGE CONSUMABLE PARTS WHILE IN THE IDLE MODE. Always disconnect power to
the power supply before inspecting or changing torch consumable parts. Use gloves when removing
consumables. The torch might be hot.
Install consumables
Check the consumable parts daily for wear before cutting. Before removing consumables, bring the torch to the edge of
the cutting table, with the torch lifter raised to its highest point to prevent the consumables from dropping into the water
of the water table.
Note: Do not overtighten parts! Only tighten until mating parts are seated.
Apply a thin film of silicone lubricant on each o-ring. Wipe the internal and external surfaces of the
The o-ring should look shiny, but there should not be torch with a clean cloth or paper towel.
any excess or built-up grease.
Tool: 104119
1. Install the 2. Install the 3. Install the 4. Install the 5. Install the 6. Install the
electrode swirl ring nozzle and nozzle shield shield cap
swirl ring retaining cap
Inspect consumables
Shield cap
Erosion, missing material Replace shield cap
Shield General:
Erosion or missing material Replace shield
Molten material attached Replace shield
Blocked gas holes Replace shield
Center hole:
Must be round Replace the shield when the hole is no longer round
O-rings:
Damage Replace shield
Lubricant Apply a thin film of silicone lubricant if the o-rings
are dry
General:
Damage to insulating ring Replace nozzle retaining cap
Insulating ring
Nozzle General:
Always replace the nozzle and Erosion or missing material Replace nozzle
electrode as a set.
Blocked gas holes Replace nozzle
Center hole:
Must be round Replace the nozzle when the hole is no longer round
Signs of arcing Replace nozzle
O-rings:
Damage Replace nozzle
Lubricant Apply a thin film of silicone lubricant if the o-rings
are dry
Torch maintenance
Poor cut quality and premature failure may occur if the HPR torch is not maintained properly.
The torch is manufactured to very tight tolerances to maximize cut quality. The torch should not be subjected to hard
impacts that can cause critical features to become misaligned.
The torch should be stored in a clean location when not in use, to avoid contamination of critical surfaces and passages.
Routine maintenance
The following steps should be completed each time consumables are changed: External
o-rings (2)
1. Use a clean cloth to wipe off the torch inside and outside. A cotton swab can be
used to access hard-to-reach internal surfaces.
2. Use compressed air to blow away any remaining dirt and debris from internal
and external surfaces.
3. Apply a thin film of silicone lubricant on each external o-ring. The o-rings should
look shiny, but there should not be any excess or built-up grease.
4. If consumables will be reused, use a clean cloth to wipe them off, and use Front view of the torch
compressed air to blow them off before they are installed again. This is especially
critical for the nozzle retaining cap.
Quick-disconnect maintenance
The following steps should be completed every 5-10 times
consumables are changed:
Torch connections
Plasma vent
Shield gas
Note: The coolant in and the coolant return lines in the quick-disconnect are in opposite positions from the torch
coolant lines. This helps reduce the coolant temperature.
WARNING
The system is designed to go into an idle mode if the retaining cap is removed. However,
DO NOT CHANGE CONSUMABLE PARTS WHILE IN THE IDLE MODE. Always disconnect power to
the power supply before inspecting or changing torch consumable parts. Use gloves when removing
consumables. The torch might be hot.
Note: The water tube may seem loose when correctly inserted, but any side-to-side looseness will disappear
after the electrode is installed.
1. Work cable connection on the cutting table is not making good contact.
• The workpiece is not totally penetrated, and there is excessive sparking on top of the workpiece.
Causes can be:
1. Arc current, arc voltage, travel speed, motion delay, gas flow rates, or initial torch height not set as specified
in the Cut charts.
2. Attempting to cut highly magnetic metal plate, such as armor plate with a high nickel content, will shorten
consumable life. Long consumable life is difficult to achieve when cutting plate that is magnetized or
becomes magnetized easily.
3. Beginning or ending the cut off the plate surface. To achieve consumable long life, all cuts must begin
and end on the plate surface.
• The torch may travel more smoothly if you clean, check and “tune” the rails and drive system on the cutting table.
Unsteady machine motion can cause a regular, wavy pattern on the cut surface.
• The torch must not touch the workpiece during cutting. Contact can damage the shield and nozzle, and affect
the cut surface.
• Each cut should end with the arc still attached to the workpiece, to avoid arc blow-outs (ramp-down errors).
– When cutting drop parts (small parts that drop down after being cut from the workpiece), check that the arc
stays attached to the edge of the workpiece, for proper ramp-down.
cut 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 determine whether a cut-angle problem is being caused by the plasma system or the drive
system, make a test cut and measure the angle of each side. Next, rotate the torch 90° in its
holder and repeat the process. If the angles are the same in both tests, the problem is in the
drive system.
If a cut-angle problem persists after “mechanical causes” have been eliminated (see Tips for table and torch, previous
page), check the torch-to-work distance, especially if cut angles are all positive or all negative.
• A positive cut angle results when more material is removed from the top of the cut than from the bottom.
• A negative cut angle results when more material is removed from the bottom of the cut.
Square cut
Dross
Low-speed dross forms when the torch’s cutting speed is too slow and the arc shoots ahead. It forms as a heavy,
bubbly deposit at the bottom of the cut and can be removed easily. Increase the speed to reduce the dross.
High-speed dross forms when the cutting speed is too fast and the arc lags behind. It forms as a thin, linear bead of
solid metal attached very close to the cut. It is welded to the bottom of the cut and is difficult to remove. To reduce
high-speed dross:
The cut surface may become more concave, or convex. Correct torch height is required to keep the cut
surface acceptably close to straight.
A strongly concave cut surface occurs when the torch-to-work distance is too low. Increase the arc voltage
to increase the torch-to-work distance and straighten the cut surface.
A convex cut surface occurs when the torch-to-work distance is too great or the cutting current is too high.
First, reduce the arc voltage, then reduce the cutting current. If there is overlap between different cutting
currents for that thickness, try the consumables designed for the lower current.
additional improvements
Some of these improvements involve trade-offs, as described.
piercing
The pierce delay should allow sufficient time to penetrate the full thickness of the material, but not so long that it allows
the arc to “wander” while trying to find the edge of a large pierce hole. As consumables wear, this delay time may need
to be increased. Pierce delay times given in the cut charts are based on average delay times throughout the life of the
consumables.
Using the “pierce complete” signal during piercing maintains the shield-gas pressure at the higher preflow pressure,
which provides additional protection for the consumables (for example: 30 amp O2/O2 and 50 amp O2/O2 processes).
The pierce complete signal must be turned off for processes with shield gas preflow pressures that are lower than the
cutflow pressures (for example: 600 amp and 800 amp processes).
When piercing materials close to the maximum thickness for a specific process, there are several important factors to
consider:
• Allow a lead-in distance that is about the same as the thickness of the material being pierced. 50 mm (2 in)
material requires a 50 mm lead-in.
• To avoid damage to the shield from the build up of molten material created by the pierce, do not allow the torch
to descend to cut height until it has cleared the puddle of molten material.
• Different material chemistries can have an adverse effect on the pierce capability of the system. In particular,
high-strength steel and steel with a high manganese or silicon content can reduce the maximum pierce
capability. Hypertherm calculates mild steel pierce parameters with certified A-36 plate.
• If the system has difficulty piercing a specific material or thickness, increasing the shield preflow pressure can
help in some cases.
Trade-off: This may reduce starting reliability.
• Using a “moving pierce” or “flying pierce” (starting torch motion immediately after transfer and during the pierce
process) can extend the piercing capability of the system in some cases. Because this can be a complex
process that can damage the torch, lifter, or other components, an edge start is recommended unless the
operator is experienced with this technique.
Note: The torch must not touch the workpiece while piercing or cutting.
Cut charts
The following Cut charts show the consumable parts, cutting speeds and the gas and torch settings required for each
process.
The numbers shown in the Cut charts are recommended to provide high-quality cuts with minimal dross. Because of
differences between installations and material composition, adjustments may be required to obtain desired results.
Equivalent thicknesses and the arc voltages will vary depending on the angle of the cut. The angle for bevel cutting can
range from 0° to 45°.
See Bevel cutting definitions on the next page for more detailed information.
Torch
center-line
0°
Bevel angle
Torch-to-work
distance
Clearance
Nominal
thickness
Equivalent
thickness
Metric
Thickness (mm)
Process 1.5 3 5 6 8 10 12 15 20 25 32 38 50
Mild steel
260A O2 / Air N/A N/A N/A 2.54 2.54 2.54 2.79 3.43 3.56 3.91 4.32 4.45 5.72
200A O2 / Air N/A N/A 1.93 1.98 2.09 2.20 2.26 2.61 2.95 3.16 4.19 4.87 5.45
130A O2 / Air N/A 1.64 1.77 1.81 1.92 2.04 2.11 2.22 2.65 3.43 4.26 4.59 N/A
80A O2 / Air N/A 1.37 1.53 1.73 1.79 1.91 2.00 2.11 2.72 N/A N/A N/A N/A
50A O2 / O2 1.52 1.74 1.86 1.86 2.09 N/A N/A N/A N/A N/A N/A N/A N/A
30A O2 / O2 1.35 1.45 1.54 1.56 N/A N/A N/A N/A N/A N/A N/A N/A N/A
Stainless steel
260A N2 / Air N/A N/A N/A 2.31 2.39 2.46 2.54 2.76 3.08 3.30 3.64 4.43 4.16
260A H35 / N2 N/A N/A N/A N/A 3.84 3.83 3.81 3.81 4.06 4.32 4.53 4.70 7.46
200A N2 / N2 N/A N/A N/A N/A 2.10 2.16 2.29 2.47 2.92 N/A N/A N/A N/A
200A H35 / N2 N/A N/A N/A N/A 3.66 3.68 3.81 3.68 3.94 N/A N/A N/A N/A
130A H35 / N2 N/A N/A N/A N/A 2.69 2.72 2.77 3.03 2.90 3.25 N/A N/A N/A
130A N2 / N2 N/A N/A N/A 1.83 1.89 1.88 2.42 2.51 3.00 N/A N/A N/A N/A
80A F5 / N2 N/A N/A 1.02 1.20 1.05 0.96 N/A N/A N/A N/A N/A N/A N/A
45A F5 / N2 0.59 0.38 0.52 0.54 N/A N/A N/A N/A N/A N/A N/A N/A N/A
45A N2 / N2 0.49 0.23 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A
Aluminum
260A N2 / Air N/A N/A N/A 2.49 2.73 2.97 3.05 2.91 3.05 3.30 2.87 3.99 5.66
260A H35 / N2 N/A N/A N/A 2.64 2.64 2.62 2.79 3.09 3.30 3.56 3.29 3.60 5.37
200A N2 / N2 N/A N/A N/A N/A 1.78 2.03 2.58 2.54 3.01 N/A N/A N/A N/A
200A H35 / N2 N/A N/A N/A N/A 2.44 2.67 2.92 3.18 3.30 N/A N/A N/A N/A
130A H35 / N2 N/A N/A N/A N/A 2.70 2.72 2.77 2.36 2.90 1.72 N/A N/A N/A
130A Air / Air N/A N/A N/A 2.09 2.09 2.10 2.19 1.91 1.87 2.23 N/A N/A N/A
45A Air / Air 1.07 1.10 1.25 1.25 N/A N/A N/A N/A N/A N/A N/A N/A N/A
English
Thickness (in)
Process 0.060 0.135 1/4 5/16 3/8 1/2 5/8 3/4 1.0 1-1/4 1-1/2 1-3/4 2.0 2-1/4 2-1/2
Mild steel
260A O2 / Air N/A N/A 0.100 0.100 0.100 0.110 0.115 0.135 0.150 0.170 0.175 0.220 0.225 0.240 0.260
200A O2 / Air N/A N/A 0.078 0.082 0.086 0.089 0.108 0.116 0.125 0.164 0.192 N/A 0.216 N/A N/A
130A O2 / Air N/A 0.066 0.071 0.076 0.080 0.083 0.089 0.104 0.135 0.167 0.181 N/A N/A N/A N/A
80A O2 / Air N/A 0.054 0.068 0.070 0.075 0.080 0.084 0.102 N/A N/A N/A N/A N/A N/A N/A
50A O2 / O2 0.060 0.063 0.073 0.082 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A
30A O2 / O2 0.053 0.057 0.067 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A
Stainless steel
260A N2 / Air N/A N/A 0.091 0.094 0.100 0.100 0.120 0.120 0.130 0.142 0.175 0.223 0.155 N/A N/A
260A H35 / N2 N/A N/A N/A 0.150 0.151 0.165 0.170 0.177 0.182 0.184 0.185 0.202 0.307 N/A N/A
200A N2 / N2 N/A N/A N/A 0.083 0.085 0.090 0.100 0.115 N/A N/A N/A N/A N/A N/A N/A
200A H35 / N2 N/A N/A N/A 0.144 0.145 0.150 0.152 0.155 N/A N/A N/A N/A N/A N/A N/A
130A H35 / N2 N/A N/A N/A 0.115 0.121 0.123 0.124 0.125 0.129 N/A N/A N/A N/A N/A N/A
130A N2 / N2 N/A N/A 0.072 0.074 0.083 0.095 0.100 0.118 N/A N/A N/A N/A N/A N/A N/A
80A F5 / N2 N/A 0.032 0.047 0.050 0.052 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A
45A F5 / N2 0.023 0.015 0.021 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A
45A N2 / N2 0.019 0.009 0.006 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A
Aluminum
260A N2 / Air N/A N/A 0.098 0.107 0.120 0.120 0.120 0.120 0.130 0.145 0.158 0.193 0.227 N/A N/A
260A H35 / N2 N/A N/A 0.104 0.104 0.105 0.110 0.126 0.130 0.140 0.141 0.142 0.222 0.210 N/A N/A
200A N2 / N2 N/A N/A N/A 0.070 0.080 0.090 0.100 0.105 N/A N/A N/A N/A N/A N/A N/A
200A H35 / N2 N/A N/A N/A 0.096 0.105 0.115 0.125 0.130 N/A N/A N/A N/A N/A N/A N/A
130A H35 / N2 N/A N/A N/A 0.106 0.107 0.109 0.112 0.114 0.120 N/A N/A N/A N/A N/A N/A
130A Air / Air N/A N/A 0.082 0.082 0.082 0.086 0.071 0.071 0.089 N/A N/A N/A N/A N/A N/A
45A Air / Air 0.042 0.043 0.049 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A
English
Select Set Set Material Arc Torch-to-Work Cutting Initial Pierce Pierce Delay
Gases Preflow Cutflow Thickness Voltage Distance Speed Height Time
Plasma Shield Plasma Shield Plasma Shield
in Volts in ipm in factor % seconds
gas gas gas gas gas gas
0.018 215
114 0.1
0.024 200
0.030 115 170 0.2
15 15 0.05 0.09
0.036 116 155
0.048 117 110 0.3
O2 O2 80 92 0.060 119 85 180
0.075 120 60
35 0.4
0.105 122 50
5 0.135* 123 0.06 40 0.11 0.5
75 3/16* 30 0.7
128
1/4* 25 1.0
Marking
Torch-to-Work Marking Arc
Select Set Set Amperage
Distance Speed Voltage
Gases Preflow Cutflow
Amps mm in mm/m ipm Volts
N2 N2 10 10 10 10 15 2.5 0.10 6350 250 105
Ar Air 90 10 90 10 9 2.5 0.10 2540 100 80
* Pierce complete is recommended for these thicknesses.
4-24 HPR260XD Manual Gas – 806340 Revision 2
Operation
Marking
Torch-to-Work Marking Arc
Select Set Set Amperage
Distance Speed Voltage
Gases Preflow Cutflow
Amps mm in mm/m ipm Volts
N2 N2 10 10 10 10 15 2.5 0.10 6350 250 130
Ar Air 50 10 50 10 15 3.0 0.12 2540 100 78
Metric
Equivalent
Select Set Set Minimum Torch-to-Work Cutting Initial Pierce Pierce Delay
Material
Gases Preflow Cutflow Clearance Distance Speed Height Time
Thickness
Plasma Shield Plasma Shield Plasma Shield
mm mm Range (mm) mm/m mm factor % seconds
gas gas gas gas gas gas
2 9810
0.1
2.5 2.5 – 8.6 7980 3.8 150
3 6145
0.2
4 4300
48
5 3670
0.3
O2 Air 50 48 72 2.0 6 3045 4.0 200
8 2.0 – 8.6 2430 0.4
10 1810 0.5
12 1410 0.7
5.0
24 15 1030 250 0.8
20 2.5 – 8.6 545 6.3 0.9
English
Equivalent
Select Set Set Minimum Torch-to-Work Cutting Initial Pierce Pierce Delay
Material
Gases Preflow Cutflow Clearance Distance Speed Height Time
Thickness
Plasma Shield Plasma Shield Plasma Shield
in in Range (in) ipm in factor % seconds
gas gas gas gas gas gas
0.075 400
0.1
0.105 0.1 – 0.34 290 0.15 150
0.135 180
0.2
48 3/16 155
1/4 110 0.3
O2 Air 50 48 72 0.08 0.16 200
5/16 96 0.4
0.08 – 0.34
3/8 75 0.5
1/2 50 0.7
0.20
24 5/8 37 250 0.8
3/4 0.1 – 0.34 25 0.25 0.9
Marking
Torch-to-Work Marking Arc
Select Set Set Amperage
Distance Speed Voltage
Gases Preflow Cutflow
Amps mm in mm/m ipm Volts
N2 N2 10 10 10 10 15 2.5 0.10 6350 250 130
Ar Air 50 10 50 10 15 3.0 0.12 2540 100 78
English
Equivalent
Select Set Set Minimum Torch-to-Work Cutting Initial Pierce Pierce Delay
Material
Gases Preflow Cutflow Clearance Distance Speed Height Time
Thickness
Plasma Shield Plasma Shield Plasma Shield
in in Range (in) ipm in factor % seconds
gas gas gas gas gas gas
0.135 0.100 – 0.34 240 0.200 0.1
30 3/16 190 0.2
0.110 – 0.34 0.220
1/4 150
5/16 132 0.3
0.120 – 0.34 0.240 200
33 3/8 110
O2 Air 15 80 0.08 1/2 0.130 – 0.34 80 0.260 0.5
5/8 60 0.7
23 0.150 – 0.34
3/4 45 0.300 1.0
1 0.160 – 0.34 20 190 1.8
1-1/4* 15 0.4 220 4.0
49 0.180 – 0.34
1-1/2 10 Edge start
Marking
Torch-to-Work Marking Arc
Select Set Set Amperage
Distance Speed Voltage
Gases Preflow Cutflow
Amps mm in mm/m ipm Volts
N2 N2 10 10 10 10 15 2.5 0.10 6350 250 130
Ar Air 50 10 50 10 15 3.0 0.12 2540 100 75
* Suggestions for piercing 32 mm (1-1/4 in) mild steel: 1. Turn preflow on during IHS, 2. Use ohmic contact during IHS,
3. Use pierce complete when piercing.
Metric
Select Set Set Material Arc Torch-to-Work Cutting Initial Pierce Pierce Delay
Gases Preflow Cutflow Thickness Voltage Distance Speed Height Time
Plasma Shield Plasma Shield Plasma Shield
mm Volts mm mm/m mm factor % seconds
gas gas gas gas gas gas
5 123 5700
0.2
6 124 5250
8 125 3.3 4355 6.6
0.3
10 126 3460
12 128 3060 0.5
O2 Air 24 65 69 28 15 131 2275 200 0.6
4.1 8.2
20 133 1575 0.8
25 143 1165 1.0
32 145 750
5.1 10.2
38 152 510 Edge start
50 163 255
English
Select Set Set Material Arc Torch-to-Work Cutting Initial Pierce Pierce Delay
Gases Preflow Cutflow Thickness Voltage Distance Speed Height Time
Plasma Shield Plasma Shield Plasma Shield
in Volts in ipm in factor % seconds
gas gas gas gas gas gas
3/16 230
124 0.2
1/4 200
5/16 125 0.13 171 0.26
0.3
3/8 126 140
1/2 128 115 0.5
O2 Air 24 65 69 28 5/8 131 80 200 0.6
0.16 0.32
3/4 133 65 0.8
1 143 45 1.0
1-1/4 145 30
0.20 0.40
1-1/2 152 20 Edge start
2 163 10
Marking
Torch-to-Work Marking Arc
Select Set Set Amperage
Distance Speed Voltage
Gases Preflow Cutflow
Amps mm in mm/m ipm Volts
N2 N2 10 10 10 10 15 2.5 0.10 6350 250 130
Ar Air 30 10 30 10 20 3.0 0.12 2540 100 63
Marking
Torch-to-Work Marking Arc
Select Set Set Amperage
Distance Speed Voltage
Gases Preflow Cutflow
Amps mm in mm/m ipm Volts
N2 N2 10 10 10 10 18 2.5 0.10 6350 250 122
Ar Air 30 20 30 20 24 3.0 0.12 2540 100 62
The consumables on this page are designed for thick metal piercing. They are only recommended for use if you have
a problem with excessive slag on the shield, or problems with the torch misfiring, when using the standard bevel
consumables.
Using the thick metal piercing process may result in a 20% decrease in the life of the consumables.
* Suggestions for piercing 38 mm (1-1/2 in) mild steel:
1. Turn preflow on during IHS
2. Use stall force during IHS
3. Use pierce complete when piercing
Metric
Select Set Set Material Arc Torch-to-Work Cutting Initial Pierce Pierce Delay
Gases Preflow Cutflow Thickness Voltage Distance Speed Height Time
Plasma Shield Plasma Shield Plasma Shield
mm Volts mm mm/m mm factor % seconds
gas gas gas gas gas gas
0.8 6380 0.0
1 94 5880 0.1
1.2 5380
1.5 95 4630
N2 N2 35 5 55 60 2.5 3.8 150 0.2
2 97 3935
2.5 101 3270
3 2550
103 0.3
4 1580
English
Select Set Set Material Arc Torch-to-Work Cutting Initial Pierce Pierce Delay
Gases Preflow Cutflow Thickness Voltage Distance Speed Height Time
Plasma Shield Plasma Shield Plasma Shield
in Volts in ipm in factor % seconds
gas gas gas gas gas gas
0.036 240 0.0
94
0.048 210 0.1
0.060 95 180
N2 N2 35 5 55 60 0.10 0.150 150
0.075 97 160 0.2
0.105 101 120
0.135 103 75 0.3
Marking
Torch-to-Work Marking Arc
Select Set Set Amperage
Distance Speed Voltage
Gases Preflow Cutflow
Amps mm in mm/m ipm Volts
N2 N2 10 10 10 10 15 2.5 0.10 6350 250 85
Ar Air 90 10 90 10 12 2.5 0.10 2540 100 65
Note: This process produces a darker cut edge than the 45 A, F5/N2 stainless steel process.
Metric
Select Set Set Material Arc Torch-to-Work Cutting Initial Pierce Pierce Delay
Gases Preflow Cutflow Thickness Voltage Distance Speed Height Time
Plasma Shield Plasma Shield Plasma Shield
mm Volts mm mm/m mm factor % seconds
gas gas gas gas gas gas
0.8 6570
1 5740
99
1.2 4905
0.2
1.5 3890
60 2.5 150
F5 N2 35 25 55 2 101 3175 3.8
2.5 102 2510
3 103 2010
0.3
4 104 1435
15 6 110 2.0 845 190 0.5
English
Select Set Set Material Arc Torch-to-Work Cutting Initial Pierce Pierce Delay
Gases Preflow Cutflow Thickness Voltage Distance Speed Height Time
Plasma Shield Plasma Shield Plasma Shield
in Volts in ipm in factor % seconds
gas gas gas gas gas gas
0.036 240
0.048 99 190
0.060 150 0.2
60 0.10 150
0.075 100 130
F5 N2 35 25 55 0.150
0.105 102 90
0.135 104 65 0.3
3/16 108 45 0.4
15 0.08 190
1/4 110 30 0.5
Marking
Torch-to-Work Marking Arc
Select Set Set Amperage
Distance Speed Voltage
Gases Preflow Cutflow
Amps mm in mm/m ipm Volts
N2 N2 10 10 10 10 15 2.5 0.10 6350 250 85
Ar Air 90 10 90 10 12 2.5 0.10 2540 100 65
Note: This process produces a shinier cut edge than the 45 A, N2/N2 stainless steel process.
Metric
Select Set Set Material Arc Torch-to-Work Cutting Initial Pierce Pierce Delay
Gases Preflow Cutflow Thickness Voltage Distance Speed Height Time
Plasma Shield Plasma Shield Plasma Shield
mm Volts mm mm/m mm factor % seconds
gas gas gas gas gas gas
4 108 3.0 2180 4.5 0.2
5 110 2.7 1700 4.1
0.3
F5 N2 35 30 60 75 6 112 2.5 1225 3.8 150
8 116 895 0.4
3.0 4.5
10 120 560 0.5
English
Select Set Set Material Arc Torch-to-Work Cutting Initial Pierce Pierce Delay
Gases Preflow Cutflow Thickness Voltage Distance Speed Height Time
Plasma Shield Plasma Shield Plasma Shield
in Volts in ipm in factor % seconds
gas gas gas gas gas gas
0.135 108 0.120 105 0.180 0.2
3/16 110 0.110 60 0.170
0.3
F5 N2 35 30 60 75 1/4 112 0.100 45 0.150 150
5/16 116 35 0.4
0.120 0.180
3/8 120 25 0.5
Marking
Torch-to-Work Marking Arc
Select Set Set Amperage
Distance Speed Voltage
Gases Preflow Cutflow
Amps mm in mm/m ipm Volts
N2 N2 10 10 10 10 15 2.5 0.10 6350 250 95
Ar Air 50 10 50 10 12 3.0 0.12 2540 100 60
Metric
Select Set Set Material Arc Torch-to-Work Cutting Initial Pierce Pierce Delay
Gases Preflow Cutflow Thickness Voltage Distance Speed Height Time
Plasma Shield Plasma Shield Plasma Shield
mm Volts mm mm/m mm factor % seconds
gas gas gas gas gas gas
6 153 1960 0.3
8 155 3.0 1630 6.0 0.4
200
10 156 1300 0.5
N2 N2 20 65 70 30
12 162 3.5 900 7.0 0.8
15 167 3.8 670
Edge start
20 176 4.3 305
English
Select Set Set Material Arc Torch-to-Work Cutting Initial Pierce Pierce Delay
Gases Preflow Cutflow Thickness Voltage Distance Speed Height Time
Plasma Shield Plasma Shield Plasma Shield
in Volts in ipm in factor % seconds
gas gas gas gas gas gas
1/4 153 75 0.3
5/16 155 0.120 64 0.240 0.4
200
3/8 156 55 0.5
N2 N2 20 65 70 30
1/2 162 0.140 30 0.280 0.8
5/8 167 0.150 25
Edge start
3/4 176 0.170 15
Marking
Torch-to-Work Marking Arc
Select Set Set Amperage
Distance Speed Voltage
Gases Preflow Cutflow
Amps mm in mm/m ipm Volts
N2 N2 10 10 10 10 18 2.5 0.10 6350 250 140
Ar Air 50 10 50 10 15 3.0 0.12 2540 100 75
Note: This process produces a rougher, darker cut edge with more dross, and the cut edges are closer to
perpendicular than the 130 A, H35/N2 process.
Metric
Select Set Set Material Arc Torch-to-Work Cutting Initial Pierce Pierce Delay
Gases Preflow Cutflow Thickness Voltage Distance Speed Height Time
Plasma Shield Plasma Shield Plasma
Shield mm Volts mm mm/m mm factor % seconds
gas gas gas gas gas
8 150 1140
60 0.3
10 154 980
45 12 158 820 7.7 170 0.5
H35 N2 20 40 70 4.5
15 162 580 0.8
30
20 165 360 1.3
20 25 172 260 Edge start
English
Select Set Set Material Arc Torch-to-Work Cutting Initial Pierce Pierce Delay
Gases Preflow Cutflow Thickness Voltage Distance Speed Height Time
Plasma Shield Plasma Shield Plasma Shield
in Volts in ipm in factor % seconds
gas gas gas gas gas gas
5/16 150 45
60 0.3
3/8 154 40
45 1/2 158 30 0.310 170 0.5
H35 N2 20 40 70 0.180
5/8 162 20 0.8
30
3/4 165 15 1.3
20 1 172 10 Edge start
Marking
Torch-to-Work Marking Arc
Select Set Set Amperage
Distance Speed Voltage
Gases Preflow Cutflow
Amps mm in mm/m ipm Volts
N2 N2 10 10 10 10 18 2.5 0.10 6350 250 130
Ar Air 50 10 50 10 15 3.0 0.12 2540 100 75
Note: This process produces a smoother, shinier cut edge with less dross, and the cut edges are less
perpendicular than the 130 A, N2/N2 process.
Metric
Equivalent
Select Set Set Minimum Torch-to-Work Cutting Initial Pierce Pierce Delay
Material
Gases Preflow Cutflow Clearance Distance Speed Height Time
Thickness
Plasma Shield Plasma Shield Plasma Shield
mm mm Range (mm) mm/m mm factor % seconds
gas gas gas gas gas gas
6 1960 0.3
8 3.0 – 10.0 1630 6.0 0.4
200
10 1300 0.5
N2 N2 20 65 70 80 2.0
12 3.5 – 10.0 900 7.0 0.8
15 3.8 – 10.0 670
Edge start
20 4.3 – 10.0 305
English
Equivalent
Select Set Set Minimum Torch-to-Work Cutting Initial Pierce Pierce Delay
Material
Gases Preflow Cutflow Clearance Distance Speed Height Time
Thickness
Plasma Shield Plasma Shield Plasma Shield
in in Range (in) ipm in factor % seconds
gas gas gas gas gas gas
1/4 75 0.3
5/16 0.12 – 0.40 64 0.240 0.4
200
3/8 55 0.5
N2 N2 20 65 70 80 0.08
1/2 0.14 – 0.40 30 0.280 0.8
5/8 0.15 – 0.40 25
Edge start
3/4 0.17 – 0.40 15
Marking
Torch-to-Work Marking Arc
Select Set Set Amperage
Distance Speed Voltage
Gases Preflow Cutflow
Amps mm in mm/m ipm Volts
N2 N2 10 10 10 10 18 2.5 0.10 6350 250 140
Ar Air 50 10 50 10 15 3.0 0.12 2540 100 75
Metric
Equivalent
Select Set Set Minimum Torch-to-Work Cutting Initial Pierce Pierce Delay
Material
Gases Preflow Cutflow Clearance Distance Speed Height Time
Thickness
Plasma Shield Plasma Shield Plasma Shield
mm mm Range (mm) mm/m mm factor % seconds
gas gas gas gas gas gas
8 1140
0.3
10 980
12 820 7.7 170 0.5
H35 N2 20 40 70 80 2.0 4.5 – 10.0
15 580 0.8
20 360 1.3
25 260 Edge start
English
Equivalent
Select Set Set Minimum Torch-to-Work Cutting Initial Pierce Pierce Delay
Material
Gases Preflow Cutflow Clearance Distance Speed Height Time
Thickness
Plasma Shield Plasma Shield Plasma Shield
in in Range (in) ipm in factor % seconds
gas gas gas gas gas gas
5/16 45
0.3
3/8 40
1/2 30 0.310 170 0.5
H35 N2 20 40 70 80 0.08 0.180 – 0.40
5/8 20 0.8
3/4 15 1.3
1 10 Edge start
Marking
Torch-to-Work Marking Arc
Select Set Set Amperage
Distance Speed Voltage
Gases Preflow Cutflow
Amps mm in mm/m ipm Volts
N2 N2 10 10 10 10 18 2.5 0.10 6350 250 130
Ar Air 50 10 50 10 15 3.0 0.12 2540 100 75
Metric
Select Set Set Material Arc Torch-to-Work Cutting Initial Pierce Pierce Delay
Gases Preflow Cutflow Thickness Voltage Distance Speed Height Time
Plasma Shield Plasma Shield Plasma Shield
mm Volts mm mm/m mm factor % seconds
gas gas gas gas gas gas
8 159 3000 0.4
10 160 2700 0.5
N2 N2 21 65 82 65 12 161 3.8 2400 7.6 200 0.6
15 163 1800 0.8
20 167 1000 1.0
English
Select Set Set Material Arc Torch-to-Work Cutting Initial Pierce Pierce Delay
Gases Preflow Cutflow Thickness Voltage Distance Speed Height Time
Plasma Shield Plasma Shield Plasma Shield
in Volts in ipm in factor % seconds
gas gas gas gas gas gas
5/16 159 118 0.4
3/8 160 110 0.5
N2 N2 21 65 82 65 1/2 161 0.15 90 0.300 200 0.6
5/8 163 65 0.8
3/4 167 45 1.0
Marking
Torch-to-Work Marking Arc
Select Set Set Amperage
Distance Speed Voltage
Gases Preflow Cutflow
Amps mm in mm/m ipm Volts
N2 N2 10 10 10 10 18 2.5 0.10 6350 250 140
Ar Air 30 10 30 10 20 3.0 0.12 2540 100 66
Metric
Select Set Set Material Arc Torch-to-Work Cutting Initial Pierce Pierce Delay
Gases Preflow Cutflow Thickness Voltage Distance Speed Height Time
Plasma Shield Plasma Shield Plasma Shield
mm Volts mm mm/m mm factor % seconds
gas gas gas gas gas gas
8 1790 0.4
175 9.0 9.0
10 1620 0.5
H35 N2 21 65 82 75 12 170 1450 100 0.6
15 173 7.5 1200 7.5 0.7
20 177 820 0.8
English
Select Set Set Material Arc Torch-to-Work Cutting Initial Pierce Pierce Delay
Gases Preflow Cutflow Thickness Voltage Distance Speed Height Time
Plasma Shield Plasma Shield Plasma Shield
in Volts in ipm in factor % seconds
gas gas gas gas gas gas
5/16 70 0.4
175 0.350 0.350
3/8 65 0.5
H35 N2 21 65 82 75 1/2 170 55 100 0.6
5/8 173 0.300 45 0.300 0.7
3/4 177 35 0.8
Marking
Torch-to-Work Marking Arc
Select Set Set Amperage
Distance Speed Voltage
Gases Preflow Cutflow
Amps mm in mm/m ipm Volts
N2 N2 10 10 10 10 18 2.5 0.10 6350 250 140
Ar Air 30 10 30 10 20 3.0 0.12 2540 100 66
Marking
Torch-to-Work Marking Arc
Select Set Set Amperage
Distance Speed Voltage
Gases Preflow Cutflow
Amps mm in mm/m ipm Volts
N2 N2 10 10 10 10 18 2.5 0.10 6350 250 120
Ar Air 30 10 30 10 20 3.0 0.12 2540 100 63
Metric
Select Set Set Material Arc Torch-to-Work Cutting Initial Pierce Pierce Delay
Gases Preflow Cutflow Thickness Voltage Distance Speed Height Time
Plasma Shield Plasma Shield Plasma Shield
mm Volts mm mm/m mm factor % seconds
gas gas gas gas gas gas
8 188 2030
11.0 11.0 0.3
10 185 1870 100
12 173 9.0 1710 0.4
15 171 1465 0.5
20 175 1085 9.0 0.6
H35 N2 11 75 80 88 120
25 180 785 0.7
32 185 7.5 630 1.0
38 186 510
44 189 390 Edge start
50 200 270
English
Select Set Set Material Arc Torch-to-Work Cutting Initial Pierce Pierce Delay
Gases Preflow Cutflow Thickness Voltage Distance Speed Height Time
Plasma Shield Plasma Shield Plasma Shield
in Volts in ipm in factor % seconds
gas gas gas gas gas gas
5/16 188 80
0.45 0.45 0.3
3/8 185 75 100
1/2 173 0.35 65 0.35 0.4
5/8 171 55 0.5
3/4 175 45 0.6
H35 N2 11 75 80 88 0.36 120
1 180 30 0.7
1-1/4 185 0.30 25 1.0
1-1/2 186 20
1-3/4 189 15 Edge start
2 200 10
Marking
Torch-to-Work Marking Arc
Select Set Set Amperage
Distance Speed Voltage
Gases Preflow Cutflow
Amps mm in mm/m ipm Volts
N2 N2 10 10 10 10 18 2.5 0.10 6350 250 120
Ar Air 30 10 30 10 20 3.0 0.12 2540 100 63
English
Equivalent
Select Set Set Minimum Torch-to-Work Cutting Initial Pierce Pierce Delay
Material
Gases Preflow Cutflow Clearance Distance Speed Height Time
Thickness
Plasma Shield Plasma Shield Plasma Shield
in in Range (in) ipm in factor % seconds
gas gas gas gas gas gas
1/4 240
5/16 193 0.3
3/8 140
1/2 110 0.4
0.30 200
5/8 95 0.5
N2 Air 11 75 75 82 0.08 3/4 0.15 – 0.40 70 0.6
1 50 0.8
1-1/4 35 1.0
1-1/2 20
1-3/4 14 Edge start
2 6
Marking
Torch-to-Work Marking Arc
Select Set Set Amperage
Distance Speed Voltage
Gases Preflow Cutflow
Amps mm in mm/m ipm Volts
N2 N2 10 10 10 10 18 2.5 0.10 6350 250 120
Ar Air 30 10 30 10 20 3.0 0.12 2540 100 63
Metric
Select Set Set Material Arc Torch-to-Work Cutting Initial Pierce Pierce Delay
Gases Preflow Cutflow Thickness Voltage Distance Speed Height Time
Plasma Shield Plasma Shield Plasma Shield
mm Volts mm mm/m mm factor % seconds
gas gas gas gas gas gas
1.2 130 4750
1.5 115 4160
60 2 113 2.5 3865 3.8 0.2
Air Air 35 25 55 2.5 110 3675 150
3 107 2850
4 102 1.8 2660 2.7 0.3
40
6 117 3.0 1695 4.5 0.6
English
Select Set Set Material Arc Torch-to-Work Cutting Initial Pierce Pierce Delay
Gases Preflow Cutflow Thickness Voltage Distance Speed Height Time
Plasma Shield Plasma Shield Plasma Shield
in Volts in ipm in factor % seconds
gas gas gas gas gas gas
0.040 130 220
0.051 115 170
60 0.100 0.150 0.2
0.064 113 160
Air Air 35 25 55 0.102 110 140 150
0.125 102 0.070 110 0.110 0.3
40 3/16 114 90 0.4
0.120 0.180
1/4 117 60 0.6
Marking
Torch-to-Work Marking Arc
Select Set Set Amperage
Distance Speed Voltage
Gases Preflow Cutflow
Amps mm in mm/m ipm Volts
N2 N2 10 10 10 10 15 2.5 0.10 6350 250 85
Ar Air 90 10 90 10 12 2.5 0.10 2540 100 75
Metric
Select Set Set Material Arc Torch-to-Work Cutting Initial Pierce Pierce Delay
Gases Preflow Cutflow Thickness Voltage Distance Speed Height Time
Plasma Shield Plasma Shield Plasma Shield
mm Volts mm mm/m mm factor % seconds
gas gas gas gas gas gas
6 153 2.8 2370 5.6 0.2
8 154 1920
0.3
10 154 3.0 1465 6.0
200
Air Air 20 40 70 30 12 156 1225 0.5
15 158 3.3 1050 6.6 0.8
20 162 3.5 725 7.0 1.3
25 172 4.0 525 N/A
English
Select Set Set Material Arc Torch-to-Work Cutting Initial Pierce Pierce Delay
Gases Preflow Cutflow Thickness Voltage Distance Speed Height Time
Plasma Shield Plasma Shield Plasma Shield
in Volts in ipm in factor % seconds
gas gas gas gas gas gas
1/4 153 0.110 90 0.220 0.2
5/16 154 76
0.3
3/8 154 0.120 60 0.240
200
Air Air 20 40 70 30 1/2 156 45 0.5
5/8 158 0.130 40 0.260 0.8
3/4 162 0.140 30 0.280 1.3
1 172 0.160 20 N/A
Marking
Torch-to-Work Marking Arc
Select Set Set Amperage
Distance Speed Voltage
Gases Preflow Cutflow
Amps mm in mm/m ipm Volts
N2 N2 10 10 10 10 18 2.5 0.10 6350 250 120
Ar Air 50 10 50 10 15 3.0 0.12 2540 100 82
Note: This process produces a rougher cut edge that is less perpendicular than the 130 A, H35/N2 process.
Metric
Select Set Set Material Arc Torch-to-Work Cutting Initial Pierce Pierce Delay
Gases Preflow Cutflow Thickness Voltage Distance Speed Height Time
Plasma Shield Plasma Shield Plasma Shield
mm Volts mm mm/m mm factor % seconds
gas gas gas gas gas gas
8 1775
60 158 5.0 6.5 130 0.3
10 1615
45 12 1455 0.5
H35 N2 20 40 70 156
15 1305 7.7 170 0.8
30 4.5
20 157 940 1.3
20 25 176 540 Edge start
English
Select Set Set Material Arc Torch-to-Work Cutting Initial Pierce Pierce Delay
Gases Preflow Cutflow Thickness Voltage Distance Speed Height Time
Plasma Shield Plasma Shield Plasma Shield
in Volts in ipm in factor % seconds
gas gas gas gas gas gas
5/16 70
60 158 0.200 0.260 130 0.3
3/8 65
45 1/2 55 0.5
H35 N2 20 40 70 156
5/8 50 0.310 170 0.8
30 0.180
3/4 157 40 1.3
20 1 176 20 Edge start
Marking
Torch-to-Work Marking Arc
Select Set Set Amperage
Distance Speed Voltage
Gases Preflow Cutflow
Amps mm in mm/m ipm Volts
N2 N2 10 10 10 10 18 2.5 0.10 6350 250 130
Ar Air 50 10 50 10 15 3.0 0.12 2540 100 75
Note: This process produces a smoother cut edge that is more perpendicular than the 130 A, Air/Air process.
Metric
Select Set Set Material Arc Torch-to-Work Cutting Initial Pierce Pierce Delay
Gases Preflow Cutflow Thickness Voltage Distance Speed Height Time
Plasma Shield Plasma Shield Plasma Shield
mm Volts mm mm/m mm factor % seconds
gas gas gas gas gas gas
8 6000 0.3
10 158 4750 0.4
N2 N2 21 65 70 65 12 6.4 3500 9.0 140 0.5
15 166 2350 0.6
20 165 1000 0.8
English
Select Set Set Material Arc Torch-to-Work Cutting Initial Pierce Pierce Delay
Gases Preflow Cutflow Thickness Voltage Distance Speed Height Time
Plasma Shield Plasma Shield Plasma Shield
in Volts in ipm in factor % seconds
gas gas gas gas gas gas
5/16 236 0.3
3/8 158 200 0.4
N2 N2 21 65 70 65 1/2 0.250 120 0.350 140 0.5
5/8 166 80 0.6
3/4 165 50 0.8
Marking
Torch-to-Work Marking Arc
Select Set Set Amperage
Distance Speed Voltage
Gases Preflow Cutflow
Amps mm in mm/m ipm Volts
N2 N2 10 10 10 10 18 2.5 0.10 6350 250 140
Ar Air 30 10 30 10 20 3.0 0.12 2540 100 66
Metric
Select Set Set Material Arc Torch-to-Work Cutting Initial Pierce Pierce Delay
Gases Preflow Cutflow Thickness Voltage Distance Speed Height Time
Plasma Shield Plasma Shield Plasma Shield
mm Volts mm mm/m mm factor % seconds
gas gas gas gas gas gas
8 5000
152 0.3
10 4400
H35 N2 21 65 70 65 12 6.4 3800 9.0 140 0.4
150
15 3000 0.5
20 159 1450 0.6
English
Select Set Set Material Arc Torch-to-Work Cutting Initial Pierce Pierce Delay
Gases Preflow Cutflow Thickness Voltage Distance Speed Height Time
Plasma Shield Plasma Shield Plasma Shield
in Volts in ipm in factor % seconds
gas gas gas gas gas gas
5/16 197
152 0.3
3/8 180
H35 N2 21 65 70 65 1/2 0.250 140 0.350 140 0.4
150
5/8 110 0.5
3/4 159 70 0.6
Marking
Torch-to-Work Marking Arc
Select Set Set Amperage
Distance Speed Voltage
Gases Preflow Cutflow
Amps mm in mm/m ipm Volts
N2 N2 10 10 10 10 18 2.5 0.10 6350 250 140
Ar Air 30 10 30 10 20 3.0 0.12 2540 100 66
Marking
Torch-to-Work Marking Arc
Select Set Set Amperage
Distance Speed Voltage
Gases Preflow Cutflow
Amps mm in mm/m ipm Volts
N2 N2 10 10 10 10 18 2.5 0.10 6350 250 120
Ar Air 30 10 30 10 20 3.0 0.12 2540 100 63
Maintenance
In this section:
Introduction..................................................................................................................................................................................................5-3
Routine maintenance.................................................................................................................................................................................5-3
System description.....................................................................................................................................................................................5-4
Power and signal cables.................................................................................................................................................................5-4
Sequence of operation..............................................................................................................................................................................5-5
Gas system purge cycle............................................................................................................................................................................5-6
Gas system valve usage............................................................................................................................................................................5-6
Marking process...............................................................................................................................................................................5-8
PCB block diagram....................................................................................................................................................................................5-9
Error codes................................................................................................................................................................................................ 5-10
HyPerformance plasma system error codes........................................................................................................................... 5-10
Error code troubleshooting – error codes 000 to 018...................................................................................................... 5-11
Error code troubleshooting – error codes 020 to 028, 224 to 228............................................................................... 5-12
Error code troubleshooting – error codes 030 to 042, 231 to 234............................................................................... 5-13
Error code troubleshooting – error codes 044 to 046...................................................................................................... 5-14
Error code troubleshooting – error codes 047 to 053, 248 to 250............................................................................... 5-15
Error code troubleshooting – error codes 054 to 061...................................................................................................... 5-16
Error code troubleshooting – error codes 062 to 067, 265 to 267............................................................................... 5-17
Error code troubleshooting – error codes 071 to 075, 273 to 275............................................................................... 5-18
Error code troubleshooting – error codes 076 to 101, 276 to 301............................................................................... 5-19
Error code troubleshooting – error codes 102 to 111, 302 to 308............................................................................... 5-20
Error code troubleshooting – error codes 116 to 133, 316............................................................................................. 5-21
Error code troubleshooting – error codes 134 to 140, 334 and 338............................................................................ 5-22
Error code troubleshooting – error codes 141 to 152, 346 to 351............................................................................... 5-23
Error code troubleshooting – error codes 153 to 156, 354 to 356............................................................................... 5-24
Error code troubleshooting – error codes 157 to 159, 357 to 359............................................................................... 5-25
Error code troubleshooting – error codes 160 to 180...................................................................................................... 5-26
Error code troubleshooting – error code 181, 182, and 383.......................................................................................... 5-27
Power supply states................................................................................................................................................................................ 5-28
Plasma system operation with pump timeout.................................................................................................................................... 5-29
CNC operation with pump timeout...................................................................................................................................................... 5-30
Initial checks.............................................................................................................................................................................................. 5-31
Power measurement............................................................................................................................................................................... 5-32
Introduction
Hypertherm assumes that the service personnel performing the troubleshooting testing are high-level
electronic service technicians who have worked with high-voltage electro-mechanical systems. Knowledge
of final isolation troubleshooting techniques is also assumed.
In addition to being technically qualified, maintenance personnel must perform all testing with safety in
mind. Refer to the Safety section for operating precautions and warning formats.
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.
Routine maintenance
For a complete list of routine maintenance recommendations, see the Preventive Maintenance Schedule, located at
the end of this section. Contact the Technical Services department listed at the front of this manual with any questions
regarding the maintenance schedule or procedures.
System description
Power and signal cables
Sequence of operation
1. Power-up – The system verifies that all of these signals are off at power-up
Coolant flow off
Chopper current off
Transfer off
Phase Loss off
Chopper 1 over-temp off
Magnetics over-temp off
Coolant over-temp off
Plasma start off
3. Idle
Gas pressure ok
Coolant flow on
Chopper current off
Line voltage ok
7. Ramp-up – Chopper current increases to set point and gas switches to cutflow
Coolant flow on
Gas pressure ok
Phase loss on
Line voltage ok
9. Ramp-down – Current and gas flow decreases after plasma start has been removed
Cutflow gas off
The preflow purge gas is turned on for 8 seconds with an auto gas console, or 12 seconds with a manual gas console.
The cutflow purge gas is turned on for 8 seconds with an auto gas console, or 12 seconds with a manual gas console.
Exception 2 – no purge process will occur if the operator changes from any process to a nitrogen marking process.
O2/O2
Gas console AC valve driver board – LEDs
process
Valve
Gas console Off-valve
location
LED
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
number
Preflow SV1 SV2 SV4 SV7 SV10 SV17 SV18
O2/Air
Gas console AC valve driver board – LEDs
process
Valve
Gas console Off-valve
location
LED
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
number
Preflow SV1 SV2 SV5 SV7 SV10 SV17 SV18
N2/N2
Gas console AC valve driver board – LEDs
process
Valve
Gas console Off-valve
location
LED
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
number
Preflow SV6 SV8 SV11 SV17 SV18
F5/N2
Gas console AC valve driver board – LEDs
process
Valve
Gas console Off-valve
location
LED
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
number
Preflow SV3 SV6 SV8 SV12 SV17 SV18
H35/N2
Gas console AC valve driver board – LEDs
process
Valve
Gas console Off-valve
location
LED
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
number
Preflow SV3 SV6 SV8 SV12 SV17 SV18
N2/Air
Gas console AC valve driver board – LEDs
process
Valve
Gas console Off-valve
location
LED
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
number
Preflow SV1 SV5 SV8 SV11 SV17 SV18
Air/Air
Gas console AC valve driver board – LEDs
process
Valve
Gas console Off-valve
location
LED
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
number
Preflow SV1 SV5 SV7 SV9 SV17 SV18
Marking process
The valves that are active when marking are represented by the tables below. The active valves in the gas console will
differ, depending on what process was used before marking.
Valves active when changing from a process that does not use a fuel gas
N2/N2
Gas console AC valve driver board – LEDs
process
Valve
Gas console Off-valve
location
LED
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
number
Preflow SV6 SV8 SV11 SV17 SV18
Cutflow SV6 SV8 SV11 SV14 SV16 SV19
Valves active when changing from a process that does use a fuel gas
N2/N2
Gas console AC valve driver board – LEDs
process
Valve
Gas console Off-valve
location
LED
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
number
Preflow SV6 SV8 SV11 SV17 SV18
Cutflow SV6 SV8 SV11 SV14 SV16 SV19
Ar/Ar
Gas console AC valve driver board – LEDs
process
Valve
Gas console Off-valve
location
LED
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
number
Preflow SV6 SV8 SV11 SV17 SV18
Cutflow SV6 SV8 SV11 SV14 SV16 SV19
Ar/Air
< 25 or Gas console AC valve driver board – LEDs
> 35
amps Gas console Off-valve
LED
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
number
Preflow SV1 SV5 SV8 SV11 SV17 SV18
Cutflow SV1 SV5 SV8 SV11 SV14 SV16 SV19
Control board
Chopper
Cutting table controler Duty cycle –
Chopper current sensor
CAN DC Total Chopper temp
sensor +
communication power in current
AC power
Start circuit
Control signals
to outputs
Gas console
DC power in
5-9
Maintenance
Maintenance
Error codes
HyPerformance plasma system error codes
Error codes are displayed in the 3-digit LED display on the gas console.
Error code
Name Description Corrective action
number
000 No error System is ready to run. None needed.
The flow switch is tested
when the pump restarts
after a pump timeout
Flow switch (30 minutes without a
009 Wait 10 seconds for the flow rate to stabilize.
test start signal). The test
ensures that the coolant
flow is correct before
firing the torch.
Error code
Name Description Corrective action
number
1. Verify that the consumable parts are in good condition.
2. Verify proper preflow and cut-flow settings.
3. Perform gas leak tests (see Maintenance section).
No current detected from
4. Verify spark across spark gap.
020 No pilot arc chopper at ignition and
5. Inspect CON1 and pilot arc relay for excessive wear.
before 1-second timeout.
6. Perform gas flow test (see Maintenance section).
7. Perform torch lead test (see Maintenance section).
8. Perform start circuit test (see Maintenance section).
No current detected
1. Verify proper pierce height.
No arc on work lead 500 milli-
021 2. Verify proper preflow and cut-flow settings.
transfer seconds after pilot arc
3. Inspect work lead for damage or loose connections.
current was established.
Lost current 1. Verify that the consumable parts are in good condition.
025
Chopper 2 2. Verify proper cut-flow gas settings.
Primary Lost the current signal from
HPR260XD 3. Verify pierce delay time.
225 Chopper 2 after transfer.
HPR400XD 4. Verify arc did not lose contact with plate while cutting
Secondary Only (hole cutting, scrap cutting, etc).
Error code
Name Description Corrective action
number
1. Verify that cable number 5 (power supply-to-gas console
control cable) is not damaged and is properly connected to
PCB3 and to the rear of the gas console.
2. Verify that cable number 6 (power supply-to-gas console
power cable) is not damaged and is properly connected
Gas system
inside the power supply and to the rear of the gas console.
error A failure has occurred in
030 3. Verify that D1 (+5 VDC) and D2 (+3.3 VDC) are
Auto Gas the gas system.
illuminated on PCB2 inside the gas console. These LEDs
Only
indicate power to PCB2.
4. If power is present at PCB2 and PCB3 and both gas
console cables are good, then PCB2 or PCB3 has failed.
Use the CAN tester to verify which board needs to be
replaced.
1. Check the interface cable for damage. The hold wires may
be short-circuiting inside.
Hold signal was active for 2. The CNC is maintaining this input, it could be waiting for an
032 Hold timeout
longer than 60 seconds. IHS complete input from another torch.
3. If CNC interface cable is good and it is a 1-torch system,
change PCB3.
Precharge
Selection console was not This is a warning for a possible gas restriction in the leads.
time-out
033 able to charge the lines to Verify that there are no restrictions in the plasma and shield
Auto Gas
the correct value. hoses, or low inlet-gas pressure.
Only
Error code
Name Description Corrective action
number
Error code
Name Description Corrective action
number
1. Verify input–line voltage at PCB2 in the power supply and
PCB1 in the cooler (HPR400XD only). Voltage needs to be
within 10% of nominal (120 VAC).
2. Verify fuses on PCB2 in the power supply.
3. Verify 120 VAC voltage on plug J2.4, pins 3 and 4 on PCB2
in the power supply.
4. Verify the voltage on PCB1 in the cooler (HPR400XD
Line voltage is close to or only) with a DC volt meter. It should be about 0.415 VDC
greater than the upper limit between TP23 and TP2 on PCB1.
of 138 VAC 5. If AC voltage on PCB2, J2.4, pins 3 and 4, is less than
High line
047 (120 VAC +15%). 132 VAC and DC voltage between TP23 and TP2 on PCB1
voltage
The normal upper limit for is greater than 0.44 VDC, verify maximum 132 VAC voltage
operation is 132 VAC on plug J4, pins 1 and 2 on PCB1. Verify wiring between
(120 VAC +10%). PCB2 in the power supply and J4 on PCB1. If the voltage
on plug J4 is less than 132 VAC, but the DC voltage on
TP23 and TP2 is greater than 0.44, replace PCB1.
6. If the AC voltage on PCB2 in the power supply on plug
J2.4, pins 3 and 4, is less than 132 VAC and the DC voltage
between TP23 and TP2 on PCB1 in the cooler (HPR400XD
only) is also less than 0.44 VDC, verify the CAN link
between PCB3 in the power supply and PCB1 in the cooler.
1. Verify that cable number 5 (power supply-to-gas console
control cable) is not damaged and is properly connected to
PCB3 and to the rear of the gas console.
2. Verify that cable number 6 (power supply-to-gas console
048 power cable) is not damaged and is properly connected
An error occurred with
Primary inside the power supply and to the rear of the gas console.
the CAN communications
CAN error 3. Verify that D1 (+5 VDC) and D2 (+3.3 VDC) are illuminated
248 between the power supply
on PCB2 inside the gas console. These LEDs indicate
Secondary and the gas console.
power to PCB2.
4. If power is present at PCB2 and PCB3 and both gas
console cables are good, then PCB2 or PCB3 has failed.
Use the CAN tester to verify which board needs to be
replaced.
1. Stop or clear the cutting program. The plasma start signal to
the plasma was not dropped after the last cut.
050 2. Verify that the CNC interface cable is not damaged.
Start signal Plasma start signal input is 3. Remove CNC interface cable from PCB3 and look for an
Primary
is on at active during power-up of open circuit between pins 15 and 34.
250 power-up power supply. 4. If the circuit is closed either the CNC is issuing a plasma
Secondary
start or the CNC interface cable is damaged.
5. If circuit is open, and LEDN300J is illuminated with CNC
Interface cable removed from PCB3, replace PCB3.
Error code
Name Description Corrective action
number
Coolant flow is less than the 1. Verify that the correct consumables are properly installed.
Low coolant
060 required 2.3 lpm 2. Perform the coolant flow test procedure in the
flow
(0.6 gpm). Maintenance section of the manual.
Error code
Name Description Corrective action
number
1. A
uto gas – The process parameters may not have been
downloaded. Verify that the process information can be
Manual gas – The gas viewed on the CNC screen.
console control board is 2. M
anual gas – The selector knob (2) may be set between
not receiving signals from positions. Reset the knob.
No shield gas the gas selector knob.
062 3. V
erify that there is power to the console by looking to see
type
Auto gas – The selection if any LED on any board in the selection console (auto)
console is not receiving or gas console (manual) is illuminated. If no LEDs are
the shield gas type signal. illuminated, verify that the fuse on the power distribution
PCB is in proper working condition.
4. If the problem still exists, replace the control board.
1. Verify that all chopper fans are operating properly.
Spinning fan blades should be difficult to see.
2. Blow dust out of system, especially from fans and heat
sink of chopper.
065
3. Verify that the voltage on rear side of J3.202, pins 2 and 3
Primary Chopper 1 Chopper 1 has
on PCB3, is less than or equal to 2.9 VDC.
265 overtemp overheated.
4. If the voltage is low, verify correct wiring between chopper
Secondary temperature sensor and J3.202 pins 1 and 2.
5. If wiring is good and overtemp error does not clear after
30 minutes of the power supply idling with the fans
running, replace the chopper.
1. Verify that all chopper fans are operating properly.
Spinning fan blades should be difficult to see.
2. Blow dust out of system, especially from fans and heat
066 Chopper 2 sink of chopper.
Primary overtemp 3. Verify that the voltage on rear side of J3.202, pins 5 and 6
Chopper 2 has
HPR260XD on PCB3, is less than or equal to 2.9 VDC.
266 overheated.
HPR400XD 4. If the voltage is low, verify correct wiring between chopper
Secondary
Only temperature sensor and J3.202 pins 4 and 5.
5. If wiring is good and overtemp error does not clear after
30 minutes of the power supply idling with the fans
running, replace the chopper.
Error code
Name Description Corrective action
number
1. Verify that the large fan in the cooler (HPR400XD only) is
running.
2. Blow dust out of the coolerr (HPR400XD only), especially
from the heat exchanger.
3. Verify that the voltage on the rear side of J1.5
pins 6 and 8, is equal to or lower than 2.8 VDC.
Coolant Torch coolant has
071 4. If voltage is low, inspect wiring between coolant
overtemp overheated.
temperature sensor and J1.5, pins 5 and 6, for shorts to
wires or ground.
5. If wiring is good, the coolant has overheated; let system
idle with the fans running for 30 minutes to cool.
6. Replace the coolant temperature sensor if it is open or
shorted. Sensor part number is 229224.
Auto gas,
control board
Control board has
072 overtemp Verify that the airflow to the gas console is not restricted.
exceeded 90° C (194° F).
Auto Gas
Only
1. Verify that all chopper fans are operating properly.
Spinning fan blades should be difficult to see.
2. Blow dust out of system, especially from fans and heat
sink of chopper.
073 Chopper 3
3. Verify that the voltage on rear side of J3.202, pins 8 and 9
Primary overtemp Chopper 3 has
on PCB3, is less than or equal to 2.9 VDC.
273 HPR400XD overheated.
4. If the voltage is low, verify correct wiring between chopper
Secondary Only
temperature sensor and J3.202 pins 7 and 8.
5. If wiring is good and overtemp error does not clear after
30 minutes of the power supply idling with the fans
running, replace the chopper.
1. Verify that all chopper fans are operating properly.
Spinning fan blades should be difficult to see.
2. Blow dust out of system, especially from fans and heat
074 sink of chopper.
Chopper 4
Primary 3. Verify that the voltage on rear side of J3.202, pins 11 and
overtemp Chopper 4 has
12 on PCB3, is less than or equal to 2.9 VDC.
274 HPR400XD overheated.
4. If the voltage is low, verify correct wiring between chopper
Secondaryy Only
temperature sensor and J3.202 pins 10 and 11.
5. If wiring is good and overtemp error does not clear after
30 minutes of the power supply idling with the fans
running, replace the chopper.
075 Low current A current less than
Primary on CS3 10 amps has been
See the chopper test later in this section.
275 HPR400XD detected by
Secondary Only current sensor 3.
Error code
Name Description Corrective action
number
099 1. Verify that the temperature sensor for the chopper has not
Chopper 1 been bypassed or that the wires to the temperature switch
Primary Chopper 1 is indicating
overtemp at are shorted out in the harness, or that the sensor is open.
299 an overtemp at power-up.
power-up 2. If no jumper is present, the chopper is overheated and
Secondary
needs time to cool to 83° C (181.4° F).
Chopper 2
100 1. Verify that the temperature sensor for the chopper has not
overtemp at
Primary been bypassed or that the wires to the temperature switch
power-up Chopper 2 is indicating
are shorted out in the harness, or that the sensor is open.
300 HPR260XD an overtemp at power-up.
2. If no jumper is present, the chopper is overheated and
Secondary HPR400XD
needs time to cool to 83° C (181.4° F).
Only
1. V
erify that the transformer temperature sensor has not been
101 bypassed or the wires to the temperature sensor are not
Magnetics Main transformer is
Primary shorted out in the harness.
overtemp at indicating an overtemp at
301 2. Verify that the sensor is not open or shorted, if it is not
power-up power-up.
Secondary open or shorted, the main transformer is overheated and
needs time to cool to 150° C (302° F).
Error code
Name Description Corrective action
number
See wiring diagrams in section 7
102 1. Verify that the voltage at CS1 is correct.
Chopper 1
Primary Chopper 1 current signal 2. Verify that the wiring between CS1 and PCB3 is correct
current at
302 is active at power-up. and not damaged.
power-up
Secondary 3. Swap CS1 with CS2. If the error code changes to 156,
replace the original CS1.
High current
104 A current greater
on CS2
Primary than 35 amps has
HPR260XD See the chopper test later in this section.
304 been detected by
HPR400XD
Secondary current sensor 2.
Only
Error code
Name Description Corrective action
number
1. Verify that cable number 5 (power supply-to-gas console
control cable) is not damaged and is properly connected
to PCB3 and the rear of the gas console.
2. Verify that cable number 6 (power supply-to-gas console
power cable) is not damaged and is properly connected
inside the power supply and to the rear of the gas
console.
3a. (Manual gas console) Verify that D1 (+5 VDC) and
116 D2 (+3.3 VDC) are illuminated on PCB2 inside the gas
An error occurred with
Primary Watchdog console. These LEDs indicate power to PCB2.
the CAN communication
316 interlock 3b. (Auto gas console) Verify that D17 (+5 VDC) and
system.
Secondary D18 (+3.3 VDC) are illuminated on PCB2 inside the gas
console. These LEDs indicate power to PCB2.
4. If power is present at PCB2 and PCB3 and both gas
console cables are good, then PCB2 or PCB3 has failed.
Use the CAN tester to verify which board needs to be
replaced.
5. Verify that the gas console control PCB and power
distribution PCBs are securely mounted to the chassis at
all four corners.
Error code troubleshooting – error codes 134 to 140, 334 and 338
Error code
Name Description Corrective action
number
Error code
Name Description Corrective action
number
1. Verify that transducer P2 in the selection console is
Pressure
Faulty transducer or working properly. Replace if necessary.
transducer
control board in the 2. Verify that transducer P7 in the metering console is
141 2 or 7 error
metering console or the working properly. Replace if necessary.
Auto Gas
selection console. 3. Verify that the control boards in the metering and selection
Only
consoles are working properly. Replace if necessary.
1. Verify that transducer P3 in the selection console is
Pressure
Faulty transducer or working properly. Replace if necessary.
transducer
control board in the 2. Verify that transducer P5 in the metering console is
142 3 or 5 error
metering console or the working properly. Replace if necessary.
Auto Gas
selection console. 3. Verify that the control boards in the metering and selection
Only
consoles are working properly. Replace if necessary.
1. Verify that transducer P4 in the selection console is
Pressure
Faulty transducer or working properly. Replace if necessary.
transducer
control board in the 2. Verify that transducer P6 in the metering console is
143 4 or 6 error
metering console or the working properly. Replace if necessary.
Auto Gas
selection console. 3. Verify that the control boards in the metering and selection
Only
consoles are working properly. Replace if necessary.
Internal flash Communication problem
error to the flash chip on
144 Replace the control board.
Manual Gas the gas console control
Only board.
Internal flash Communication problem
error to the flash chip on
145 Replace the control board.
Auto Gas the selection console
Only control board.
146 Chopper 3 1. Verify that the temperature sensor for the chopper has not
Primary overtemp at been bypassed or that the wires to the temperature switch
Chopper 3 is indicating
power-up are shorted out in the harness, or that the sensor is open.
346 an overtemp at power-up.
HPR400XD 2. If no jumper is present, the chopper is overheated and
Secondary
Only needs time to cool to 83° C (181.4° F).
Chopper 4 1. Verify that the temperature sensor for the chopper has not
147
Primary overtemp at been bypassed or that the wires to the temperature switch
Chopper 4 is indicating
power-up are shorted out in the harness, or that the sensor is open.
347 an overtemp at power-up.
HPR400XD 2. If no jumper is present, the chopper is overheated and
Secondary
Only needs time to cool to 83° C (181.4° F).
151
Software has detected
Primary
Software fail an incorrect state or Replace power supply control board.
351 condition.
Secondary
Communication problem
Internal flash to the flash chip on
152 Replace the control board.
error the power supply control
board.
Error code
Name Description Corrective action
number
EEPROM memory on
PS EEPROM
153 power supply control Replace the control board.
error
board not working.
Error code
Name Description Corrective action
number
Communication between
the control board (PCB3 1. Verify that the cable connections from the power supply to
HPR cooler’s
in the power supply) and the cooler are good.
CAN fault
160 the cooler sensor board 2. Verify that D1 (+ 5 VDC) and D2 (+3.3 VDC) are
HPR400XD
(PCB1 in the cooler) was illuminated on PCB1 inside the cooler.
Only
interrupted for more than 3. Verify that the CAN bus LEDs, D7 and D8 are blinking.
1 second.
Error code
Name Description Corrective action
number
Secondary
The secondary power 1. The primary power supply to secondary power supply CAN
power supply
supply fails before communication cable was disconnected after power-up.
182 time-out
transmitting the error to 2. The cable has electrical interference (noise) or the cable
HPR800XD
the primary power supply. shielding has been compromised.
Only
State
Name
code
00 Power -up (idle)
02 Purge
04 Preflow
05 Pilot arc
06 Transfer
07 Ramp-up
08 Steady state
09 Ramp-down
10 Final ramp-down
12 Test cutflow
14 Shutdown
15 Reset
16 Maintenance
20 Test preflow
PLASMA START
signal active Yes
No
Yes Yes
No
No
Complete the
cut cycle
Initial checks
Before troubleshooting, do a visual check and verify that proper voltages are present at the power source, transformers
and power distribution board.
DANGER
Shock Hazard
Always use caution when servicing a power supply when plugged in and the covers are removed.
Dangerous voltages exist within the power supply which could cause injury or death.
2. Remove the power supply’s top panel and two side panels.
3. Inspect interior of power supply for discoloration on PC boards, or other apparent damage. If a component or module
is obviously defective, remove and replace it before doing any testing. Refer to the Parts List section to identify parts
and part numbers.
4. If no damage is apparent, connect power to the power supply, and turn the main disconnect switch ON.
5. Measure the voltage between the W, V and U terminals of TB1 located on the right side of the power supply. See
figure on next page. Also refer to the wiring diagram in Section 7, if required. The voltage between any 2 of the 3
terminals should be equal to the supply voltage. If there is a problem at this point, disconnect main power and check
connections, power cable, and fuses at line disconnect switch. Repair or replace any defective component.
Power measurement
DANGER
Shock Hazard
There is line voltage at the contactor and the power distribution board (PCB2) when the line
disconnect switch is on. Use extreme care when measuring primary power in these areas. Voltages
present at the terminal block and contactors can cause injury or death.
Main power in
W V U
PE
3. Pull the clear filter housing down firmly to remove it. The filter housing has an o-ring around the top. Apply a thin film
of silicone lubricant on the o-ring to extend it’s life. The o-ring should look shiny, but there should not be any excess
or built-up grease.
Filter bowl
4. Use a screwdriver to remove the filter element from the filter housing. Then install the new filter element.
Note: Do not allow the filter element to turn when loosening the screw.
1. Turn OFF the power, and remove the return coolant hose (red tape) from the pump and put it in a
20 liter (5 gallon) container.
2. Press and hold the current selection knob (8) and turn ON the power switch. The pump will run continuously while
(8) is pressed.
3. Run the pump until the coolant stops flowing and immediately release the current selection knob (8).
Caution: Coolant will flow from the filter when its housing is removed. Drain coolant
before servicing the filter.
2 3 4 5
5-36
Replace the pump, and inspect
the shaft for damage
Coolant error
(093) or (060)
Flow
Maintenance
rate from
bucket test
Go to “steps to take before testing” on the next page < 0.9 gpm
Flow Flow
Go to “pump/motor rate from rate from
No flow Go to test 1 flow tube Go to test 2 bucket test Go to test 6
troubleshooting”
< 0.8 gpm < 0.9 gpm
Flow
Replace the torch
rate from Go to test 3 Check your power supply outlet hose for
Go to test 7 If the flow shown
CNC kinks. If there are no kinks, replace the
On the CNC is
> 0.8 gpm bypass valve and the hose set
> 0.9 gpm
between the power supply and the
Flow
Flow high frequency console.
rate from
rate from CNC
Order a replacement CNC
Check valve or your < 0.9 gpm
< 0.8 gpm
Coolant will drain out at
Each consumable change
Go to test 4
Replace the flow switch
Before testing
Note: Coolant must be drained from the system before the in-line filter is cleaned (step 1 below). The coolant in
the system will drain out as soon as the in-line filter is removed.
In-line filter
2.0
1.8
1.6
1.4
1.2
1.0
1.0 .2
Flow
direction
1. Turn ON the power. Press and hold the current selection knob (8) to turn on the pump manually, and allow the
coolant to flow for 60 seconds.
2. Write down the coolant flow rate shown on the gas console’s LED display. The recorded flow rate will be used for
comparison during some of the tests. Coolant flow must be greater than 2.3 lpm (0.6 gpm) for the system to operate.
3. Release the current selection knob (8) and then turn OFF the power.
1. Turn OFF the power. Remove the return coolant line (blue hose with red tape),
and connect the flow meter to measure the flow rate.
2. Measure the flow rate on the flow meter. Turn ON the power. Turn ON the
pump manually (see step 1 under “Manual pump operation”). Write down the
flow rate from the flow meter.
3. Reconnect the return coolant line (blue hose with red tape).
1. Turn OFF the power. Remove the supply coolant line (blue hose with
green tape) from the RHF/LHF console, and place it in a 3.8 liter
(1 gallon) container. A Hypertherm coolant container works well.
2. Measure how long it takes to fill the container. Turn ON the power.
Turn ON the pump manually (see step 1 under “Manual pump
operation”). Write down how long it takes to fill the container.
3. Reconnect the coolant lines.
If the flow rate shown on the LED display is 0.9 gpm or more, replace the torch.
If the flow rate is still less than 0.9 gpm, go to test 4.
2. Measure how long it takes to fill the container. Turn ON the power. Turn ON the pump manually (see step 1 under
“Manual pump operation”). Write down how long it takes to fill the container.
3. Reconnect the coolant supply line to the torch receptacle.
If it takes more than 65 seconds to fill the container, look for an obstruction or kink in the coolant hose between the
torch and the LHF/RHF console. If there is no obstruction or kink, replace the torch leads.
If the container is full in 65 seconds or less, go to test 5.
Test 5 – return line from the torch receptacle (remove at the ignition console)
1. Turn OFF the power. Remove the return coolant line (blue hose with
red tape) from the RHF/LHF console, and place it in a 3.8 liter
(1 gallon) container. A Hypertherm coolant container works well.
2. Measure how long it takes to fill the container. Turn ON the power.
Turn ON the pump manually (see step 1 under “Manual pump
operation”). Write down how long it takes to fill the container.
3. Reconnect the return coolant line.
1. Turn OFF the power. Remove the hose from the relief
valve.
Test 7 – continued
5. Turn ON the power supply, and note the coolant flow rate shown on the LED display on the gas console.
If the flow shown on the LED display is more than 0.8 gpm, replace the check valve. Coolant will drain out of the torch
during every consumable change if the check valve is bypassed.
If the flow shown on the LED display is less than 0.8 gpm, replace the flow switch.
Note: The check valve must be oriented correctly. The arrow points up, as shown.
If you are still not getting flow from the pump, verify that the solenoid valve and check valve are working correctly.
TP 206 TP 210
041993
The inlet valves within the gas console will close and the off-valves will open to allow any trapped gas to escape. After
20 seconds all the off-valves will close. At this point there should be no pressure between the gas console and off-valve,
and the pressure displays should read zero.
This test is intended to identify a problem with any inlet supply valve that does not close properly in the gas console, in
which case pressure will build at the off-valve and be displayed on the gas console. This test also checks for leaks in the
supply lines.
The inlet valves will open and pressurize the gas lines between the off-valve and the gas console. After 20 seconds all
inlet valves are turned off. The pressures displayed should remain constant.
This test is intended to identify a leak between the gas console and the off-valve.
Leak test 1
1. Turn ON power to the HPR260.
2. After initial gas purge switch shield selector switch (2) to TEST.
3. Select SET PREFLOW on switch 7. The off-valve opens and exhausts gas between the gas console and torch.
The inlet valves in gas console will remain closed.
6. Monitor the pressure displays and the gas supply pressure gauges for 20 minutes. The pressure displays should
remain at or close to zero while inlet pressures remain constant.
7. If any pressure display increases, then one or more inlet valves in the gas console are not closing properly.
8. If a gas supply pressure gauge decreases but no pressure is displayed on gas console, then there is a leak in the
supply hoses between the shut-off and the gas console.
Leak test 2
1. After performing leak test 1, turn on gas supply valves again and move switch 7 to SET CUTFLOW. The inlet valves
in the gas console will open for 20 seconds and then close, while the off-valve remains closed. This traps pressure
between the gas console and the off-valve.
3. Monitor the pressure displays on the gas console and the gas supply pressure gauges for 20 minutes. Pressure
displays and gas supply gauges should remain constant.
4. If any pressure displays decrease, then there is a leak in a gas line between the gas console and the off-valve.
5. If a gas supply pressure gauge decreases then there is a leak in the supply hoses between the shut-off and the gas
console.
041993
= HPR130
= HPR260
Note: See wiring
diagrams for other
dipswitch settings
D1
D2
D5
D7
D25
D33
D32
D3
D31
D35
D26
D12
D23
Start-circuit PCB1
Operation
The start circuit is a high-speed switch that quickly transfers the pilot arc current from the pilot arc lead to the work lead.
The start circuit performs 2 functions:
1. It allows the initial pilot arc current to flow through the pilot arc lead quickly, with little impedance.
2. After initial pilot arc current is established, the start circuit introduces impedance to the pilot arc lead to aid in
transferring the arc to the workpiece. See schematic below.
Chopper
Choke
Power
resistor
ALEL Caps
Cutting
IGBT arc
Control
logic Diode
DANGER
Shock Hazard
Always use caution when servicing a power supply when plugged in and the covers are removed.
Dangerous voltages exist within the power supply which could cause injury or death.
D2
15kΩ
or
H8
WORK + –
H9
NOZZLE 5.5kΩ
R1
1Ω
Transfer current
Plasma gas 30-amps 45-amps 50-amps 80-amps 130-amps 200-amps 260-amps
O2 10 10 10 10 15 20 20
N2 10 10 10 10 15 20 20
H35 10 10 10 10 15 20 20
F5 10 10 10 10 15 20 20
Air 10 10 10 10 15 20 20
Gas console control board LEDN list Gas console control board LED list
LEDN Signal name Color LED Signal name Color
LEDN1 Plasma preflow, left digit Red D1 + 5 VDC Green
LEDN2 Plasma preflow, right digit Red D2 + 3.3 VDC Green
LEDN3 Plasma cutflow, left digit Red D4 Coolant error Yellow
LEDN4 Plasma cutflow, right digit Red D6 Pressure error Yellow
LEDN5 Shield preflow, left digit Red D8 CAN– TX Green
LEDN6 Shield preflow, right digit Red D9 CAN– RX Green
LEDN7 Shield cutflow, left digit Red D10 Voltage error Yellow
LEDN8 Shield cutflow, right digit Red D11 Temperature error Yellow
LEDN9 Current, left digit Red
LEDN10 Current, center digit Red
LEDN11 Current, right digit Red
P1 P2
P3
P4
SV14
SV13
SV12 SV3
SV19
SV18
SV10 SV20
SV16
SV17
SV4
SV6
SV2
SV11
SV9
SV8 Off-valve
SV7
SV5
SV1
Chopper tests
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.
I/O board
(PCB6)
Troubleshooting low-current error codes 105 and 106
1. Verify that the current sensors (CS1 and CS2) and
cables are not damaged.
CS3
2. Exchange CS1 and CS2. Replace the faulty sensor if CS2
the error code is not displayed again. CS1
2. Exchange CS1 and CS2. Replace the faulty sensor if the error the code is not displayed again.
3. Look at the surge capacitor to ensure that it is not short-circuited. Replace PCB6 if the surge capacitor is shorted.
4. Check for short circuits from the work terminal to the negative terminal on PCB6. Resistance should be about 100K
ohm from the work terminal to the negative terminal. Resistance will vary if you have a voltage divider for a height
control system.
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. If the error remains, perform the following steps.
OK Excessive wear
D2
D5
D7
D33
D32
D3
D31
D35
D26
D12
D23
4. Remove J2.8 from PCB2 and place a jumper between pins 1 and 2 on the cable connector.
a. Make a test cut. If the phase-loss error continues, verify wiring between J2.8 on PCB2 and J3.302 on PCB3 by
verifying the continuity between
– J2.8 pin1 to J3.302 pin14
– J2.8 pin2 to J3.302 pin15.
b. If the wiring is ok replace PCB3. If any wiring is damaged repair or replace damaged wires.
c. If the phase-loss error goes away while the jumper is on J2.8, make another cut and measure the phase-
to-phase voltage across the fuses, F5, F6, and F7. The voltage should be 220 VAC +/-15%. If one of the
3 voltage readings is less than 187 VAC, check the contacts to the contactor, and check for loose connections
between the power cord – contactor – power transformer – and the chopper.
WARNING
Shock Hazard
Always use caution when servicing a power supply when plugged in and the covers are removed.
Dangerous voltages exist within the power supply which could cause injury or death.
D1
between H8 (work) and H9 H8
D2
(nozzle) on the start circuit WORK
PCB1.
H8
WORK + –
H9
NOZZLE
H9
NOZZLE
4. Locate the pilot arc relay (CR1) and remove the dust cover. Have a second person close the contact.
5. Measure the ohm value between the nozzle and the plate. The reading should be less than 3 ohms. A measurement
of greater than 3 ohms indicates a faulty connection between the torch and ignition console or between the ignition
console and the power supply.
6. Verify that the pilot arc wire on the torch lead is not damaged. If it is damaged replace the lead. If it is not damaged
replace the torch head.
Preventive maintenance
Introduction
Deteriorating consumable parts life is one of the first indications that something is wrong with a plasma system.
Reduced parts life increases operating costs in two ways: the operator must use more electrodes and nozzles to cut the
same amount of metal, and the work of cutting must stop more often to change consumables.
Proper maintenance often eliminates the problems that shorten the life of consumable parts. Since labor and overhead
can account for 80% of the cost of cutting, improved productivity can reduce cutting costs dramatically.
If inspection suggests that a component is worn and might require replacement, and you would like confirmation of your
decision, please contact Hypertherm’s Technical Service department.
DANGER
Electric Shock Can Kill
Turn off all electrical power before removing the power supply cover and
set the line disconnect switch to OFF. In the U.S., use a “lock-out and
tag-out” procedure until the service or maintenance is complete. In other
countries, follow appropriate local and national safety procedures.
1. With power to the power supply turned off, remove all side panels. Use compressed air to blow out any accumulation
of dust and particulates.
2. Inspect wiring harnesses and connections for wear, damage or loose connections. If you see any discoloration that
might indicate overheating, contact Hypertherm Technical Service.
3. Inspect the main contactor for excessive pitting on the contacts, characterized by a blackened, rough surface on any
of the contacts. If this condition exists, replacement is recommended.
4. Inspect the pilot arc relay (CR1) for excessive pitting on the contacts, characterized by a r oughened, black surface.
Replace if necessary.
Cooling system
5. Inspect the coolant-circulating system’s filter element at the rear of the power supply. If the filter is a brownish color,
replace it. Consult the Parts List in this manual for part numbers.
6. Perform a coolant flow test as described in this manual, then check for coolant leaks. Primary locations to inspect
are these:
A. The back of the power supply;
B. At the ignition console; and
C. At the torch main body.
Also, check the coolant tank for dirt and particulates. Verify that proper Hypertherm coolant is being used. Proper
Hypertherm coolant (028872) is a red liquid.
8. Inspect the current ring inside the torch main body. The current ring should be smooth and not pitted. If no pitting is
observed, clean the current ring with a clean cotton swab and hydrogen peroxide. Do not use alcohol. Pitting on the
current ring generally indicates improper maintenance (i.e. lack of regular cleaning).
9. Clean all threads on the front end of the torch head with hydrogen peroxide and a cotton swab, pipe cleaner or
clean cloth. Do not use alcohol. Damage to the threads usually results from not cleaning the torch and retaining cap
threads properly, so that dirt and particulates accumulate in the threads.
10. Inspect the torch insulator for cracks. Replace the torch if you find cracks.
11. Inspect all o-rings on the torch body and consumables. Make sure that the correct amount of lubricant – a thin film –
is applied to these o-rings. Too much lubricant may obstruct gas flows.
12. Check that the retaining or shield cap is tightened securely to the torch main body.
13. Inspect all hose fittings at the rear of the torch for wear. Damage to the fitting threads mayindicate that
overtightening has occurred.
14. Check that all connections between the torch and torch leads are tight, but do not overtighten. See torque specs in
the Installation section of this manual.
When removing consumables, always place them on a clean, dry, oil-free surface, since dirty consumables may cause
the torch to malfunction.
Gas flows
15. Check each gas line from the gas supply, as follows:
A. Remove and plug the inlet gas fitting at the gas console.
B. Pressurize the gas line to 8.3 bar (120 psi).
C. Close the gas supply valve at the source. Watch for a pressure drop. If the gas supply line is a hose, there may
be a 0.3 to 0.5 bar (5 to 7 psi) drop due to hose-stretch.
D. Repeat for each line from a gas supply source. If any pressure continues to drop, find the leak within the system.
16. If the gas line pressures hold steady, perform a system gas leak test as specified in this manual.
Cable connections
18. All cables should be checked for chafing or unusual wear. If the outside insulation has been cut or otherwise
damaged, replace the cable.
Ignition console
19. Open the cover and use compressed air to blow out any accumulation of dust and particulates. If moisture is present,
dry the inside of the console with a cloth and try to identify the source of the moisture.
20. Inspect the spark gap assembly. Ensure that the wiring connections to the spark gap assembly are secure. Check
that the console doors close properly.
21. Inspect the torch leads. Ensure that they are fastened tightly to the outside of the ignition console.
System grounding
22. Verify that all components of the system are individually grounded to a driven earth ground, as described in the
Installation and Grounding sections of this manual.
A. All metal enclosures, such as the power supply, ignition console and gas console, should be connected
individually to a ground point. These connections should be made with 10 mm2 (#8 AWG) wire (USA), or
equivalent-size wire.
23. Check the work lead (+) connection, particularly where the work lead (+) connects to the cutting table. This must
be a good, clean c
onnection because a poor connection may cause arc-transfer problems.
24. Complete the Preventive Maintenance worksheet on the next page, for future reference.
Daily:
• Verify proper inlet gas pressure.
• Verify proper gas flow settings. – Mandatory at every consumable change.
• Inspect torch and replace consumables as needed.
Weekly:
Week Jan Feb March April May June July Aug Sept Oct Nov Dec
1
2
3
4
5
• Clean power supply with dry, oil free compressed air, or a vacuum cleaner.
• Verify cooling fans are working properly.
• Clean torch threads and current ring.
• Verify proper coolant level.
Semi-Annually:
Year 1st service 2nd service
Annually:
Year
6.5 Years or 3900 arc hours Repeat schedule starting at 6 months or 300 arc hours
Parts List
In this section
Power supply...............................................................................................................................................................................................6-2
Ignition console...........................................................................................................................................................................................6-7
Gas console.................................................................................................................................................................................................6-8
Off-valve........................................................................................................................................................................................................6-9
HyPerformance torch.............................................................................................................................................................................. 6-10
Torch assembly.............................................................................................................................................................................. 6-10
Torch leads..................................................................................................................................................................................... 6-11
Ohmic contact wire....................................................................................................................................................................... 6-11
Consumable parts kits............................................................................................................................................................................ 6-12
Consumables for mirror-image cutting................................................................................................................................................ 6-14
Mild steel (straight cutting).......................................................................................................................................................... 6-14
Mild steel (bevel cutting).............................................................................................................................................................. 6-15
Recommended spare parts................................................................................................................................................................... 6-16
Power supply
Power supplies Note: The Hypernet option is currently used with the
ArcGlide® torch height control. See the ArcGlide
Without With Voltage instruction manual (806450) for more information.
Hypernet Hypernet (AC)
078554 078562 200/208
078555 078563 220
078556 078564 240
078557 078565 380 2
078558 078566 400
078605 078606 415 1
078559 078567 440
078560 078568 480
078561 078569 600
3
4
6
Part
Item Number Description Designator Qty.
1 See table above Power supply
2 228332 Panel: Top, with label 1
3 075241 Sheet metal screws 1
4 228535 Panel: Right or left side, with label 1
5 228534 Panel: Front, with label 1
6 129633 Green power lamp assembly 1
8 228611 Kit: Hypernet upgrade (not shown) 1
Power supply
2
5
Part
Item Number Description Designator Qty.
1 027634 Filter housing 1
027664 Filter element 1
2 127014 Cap: Coolant reservoir 1
3 229034* EMI filter: 80 amp, 50-60 HZ 1
4 129792 Chopper assembly CH1, CH2 2
5 127039 6” fan: 230 CFM, 115 VAC 50-60 HZ 4
6 027079 10” fan: 450-550 CFM, 120 VAC 50-60 HZ 3
7 014295 200 volt main transformer: 45.5 KW, 3 ph, 50 HZ T2 1
014296 220 volt main transformer: 45.5 KW, 3 ph, 50-60HZ 1
014297 240 volt main transformer: 45.5 KW, 3 ph, 60 HZ 1
014302 380 volt main transformer: 45.5 KW, 3 ph, 50 HZ 1
014295 400 volt main transformer: 45.5 KW, 3 ph, 50 HZ 1
014295 415 volt main transformer: 45.5 KW, 3 ph, 50 HZ 1
014296 440 volt main transformer: 45.5 KW, 3 ph, 50-60 HZ 1
014297 480 volt main transformer: 45.5 KW, 3 ph, 60 HZ 1
014298 600 volt main transformer: 45.5 KW, 3 ph, 60 HZ 1
228309 Kit: Thermistor replacement for main transformer 1
Power supply
4
5
3
6a
6b
Part
Item Number Description Designator Qty.
1 003149 Relay: Pilot arc, 120 VAC CR1 1
2 041837 PCB: I/O PCB6 1
3 003217 Contactor (200 VAC - 240 VAC) CON1 1
003233 Contactor (380 VAC - 600 VAC) CON1 1
4 229238 Start circuit assembly PCB1 1
5 109483 Current sensor: Hall 200 amp, 4 volt CS3 1
6a 109004 Current sensor: Hall 100 amp, 4 volt CS2 1
6b 109004 Current sensor: Hall 100 amp, 4 volt CS1 1
7 014280 Inductor: 4 MH 2
Power supply
4
3
5
2
6
1
Part
Item Number Description Designator Qty.
1 008551* Fuse: 7.5 amp, 600 volt F1, F2 2
008709** Fuse: 20 amp, 500 volt F1, F2 2
2 228548 Control PCB PCB3 1
3 041802 Power distribution PCB PCB2 1
108028 Fuse: 3 amp 1
108075 Fuse: 6.3 amp 1
108709 Fuse: 10 amp 1
4 027926 Filter assembly: 1/2” NPT low profile 1
5 229206 Flow switch assembly FLS 1
6 229066 Heat exchanger assembly 1
7 127039*** Fan (for pump motor): 230 cfm, 115 VAC, 50-60 Hz 1
8 129786 Control transformer: 200/208 volt, 50-60 HZ T2 1
229117 Control transformer: 220 volt, 50-60 HZ 1
129966 Control transformer: 240 volt, 60 HZ 1
229094 Control transformer: 380 volt, 50 HZ 1
129787 Control transformer: 400 volt, 50-60 HZ 1
229451 Control transformer: 415 volt, 50-60 HZ 1
229013 Control transformer: 440 volt, 50-60 HZ 1
129967 Control transformer: 480 volt, 50-60 HZ 1
129989 Control transformer: 600 volt, 50-60 HZ 1
*380, 400, 415, 440, 480, and 600 volt power supplies
**200/208 and 240 volt power supplies
***415 volt power supply only
Power supply
1 2
3
5
6
Part
Item Number Description Designator Qty.
1 109393 Temperature sensor T2 1
2 006132 Check valve (relief valve): 1/4” NPT, 200 psi 1
3 006075 Check valve: 1/4” FPT 1
4 229229 Solenoid valve assembly: 3/8”, 240 volt CLT SOL 1
5 228171 Kit: Pump with clamp 1
6 228230 Kit: Motor with clamp 1
Ignition console
Part
Item Number Description Designator Qty.
1 078172 Ignition Console
2 129831 Coil assembly T2 1
3 041817 HFHV Ignition PCB PCB IGN 1
4 129854 Transformer T1 1
Gas console
6
7
Part
Item Number Description Designator Qty.
1 078532 Gas Console
2 041805 Power distribution PCB PCB1 1
008756 Fuse: 5 amp, 250 volt 1
3 041822 Valve driver PCB PCB3 1
008756 Fuse: 5 amp, 250 volt 1
4 005263 Pressure sensor PT1-PT4 4
5 006109 Solenoid valve SV2, SV3, SV4, SV6, SV8-SV14 11
006112 Replacement solenoid coil
6 006136 Solenoid valve SV1, SV5, SV7 3
7 005262 Illuminated power switch SW1 1
Gas console
2
3
Part
Item Number Description Designator Qty.
1 041912 Control PCB PCB2 1
2 229128 Regulator assembly with elbow fitting PR1, PR3, PR4 3
3 229129 Regulator assembly with elbow and tee fitting PR2 1
228147 Kit: Regulator upgrade (replaces all 4 regulators)
4 011109 Filter assembly 1
011110 Filter element 1
Off-valve
Part
Item Number Description Designator Qty.
078534 Off valve assembly 1
1 006109 Solenoid valve V16-V20 5
006112 Replacement solenoid coil 5
2 123748 Off-valve cable 1
HyPerformance torch
Torch assembly
1
2 3 4 5
Part
Item Number Description
1 228521 HPR260 machine torch assembly
2 220706 Quick-disconnect torch
3 220571 Water tube
4 220705 Quick-disconnect receptacle
5 220789 Torch mounting sleeve assembly: Standard, 181 mm (7 in)
220788 Torch mounting sleeve assembly: Short, 114 mm (4.5 in)
220790 Torch mounting sleeve assembly: Long, 248 mm (9.75 in)
6 104269 2” spanner wrench
128879 Torch kit: o-rings, water tube and seal
128880 Quick disconnect kit: o-ring and connector
Torch leads
Ohmic contact wire (Not part of the HPR260XD system. Shown for reference only.)
30 A
50 A
220747 80 A
200 A
260 A
80 A
130 A
260 A
220571
220741 220794 220542 220442 220541
Part
Number Description Designator Qty.
129633 Green power lamp assembly 1
027634 Filter housing 1
027664 Filter element 1
129792 Chopper assembly CH1 1
127039 6” fan: 230 CFM, 115 VAC 50-60 HZ 1
027079 10” fan: 450-550 CFM, 120 VAC 50-60 HZ 1
003149 Relay: Pilot arc, 120 VAC CR1 1
041837 PCB: I/O 1
003217 Contactor (200 VAC-240 VAC) CON1 1
003233 Contactor (380 VAC-600 VAC) CON1 1
109004 Current sensor: Hall 100 amp, 4 volt 1
229238 Start circuit assembly PCB1 1
008551* Fuse: 7.5 amp, 600 volt F1, F2 2
228548 Control PCB PCB3 1
041802 Power distribution PCB PCB2 1
229206 Flow switch assembly FLS 1
006075 Check valve: 1/4” FPT 1
229229 Solenoid valve assembly CLT SOL 1
228171 Pump assembly with clamp: 80 gpm, 200 psi 1
228230 Motor with clamp: 1/3 HP, 240 volt, 50-60 HZ 1
Ignition console
Part
Number Description Designator Qty.
041817 HFHV Ignition PCB 1
129854 Transformer T1 1
Gas console
Part
Number Description Designator Qty.
041805 Power distribution PCB PCB1 1
041822 Valve driver PCB PCB3 1
005263 Pressure sensor PT1-PT3 1
006109 Solenoid valve SV1-SV14 2
005262 Illuminated power switch SW1 1
Off-valve
Part
Number Description Designator Qty.
006109 Solenoid valve V16-V19 1
Wiring Diagrams
Introduction
This section contains the wiring diagrams for the system. When tracing a signal path or referencing with the Parts List or
Troubleshooting sections, please be aware of the following format to assist you in understanding the wiring diagrams’
organization:
SHEET
C 4-D3
SHEET
4-D3 C
Destination and Source Coordinates refer to letters A-D on the Y-axis of each sheet and numbers 1-4 on the
X-axis of each sheet. Lining up the coordinates will bring you to the source or destination blocks (similar to a road map).
7-2
Normally Closed
Pin Resistor
Diode
Plug Shield
Fan
Switch, Pressure,
Normally Open Nozzle
Transformer, Air Core
Transformer Coil
Switch, 1 Pole, 2 Throw Shield
Switch, Temperature,
Normally Open Valve, Solenoid
Torch, HyDefinition™
Terminal Block
Voltage Source
7-3
Wiring Diagrams
Discrete output functionality
3 Phase
Power
w/ Ground
D D
A A
C SHEET
4-D4
D SHEET
4-C1
SHEET B E SHEET SHEET AA U SHEET AF SHEET
3-C1 3-A4 3-B4 8-A4
RED/BLK
3-D4
SHLD
RED
INPUT POWER
WHT
RED
BLU
BLK
D FROM FACILITY D
YEL/BLK
PE
RED/BLK
SHEET A J9.1 J9.6
L1 4-C1
1C
1B
1A
CHA CHA AJ SHEET
YEL
L2
RED
1
1
3
4
5
6
3
2
2
13-C2
L3 J1 J6
1A CHOPPER SA CHA CABLE: 123662
129792 J4.4
1B
1
3
2
T SHEET + 39 39
J4
3-B4 L1
RED
BLK
1C 38 J1
TB1 CS1
1 W – 38 (–)NEGATIVE
J11
2 V
RED/BLK
RED/BLK 20
19
1
2
3 U R9 R8 R1 C1
4 PE
2
4
3
1
350UF
RED
J12 10K10K10K
RED
T1 K1
BLK
WHT
GRN
RED
A4 1A
V W
A3 0
C A2 1B SHEET
I/O
R5 C3 C
SURGE INJECTION
L1 A4 A1 0 4-C1 G 041837 100K .22UF
L2 B4 B4 1C K1 A2
L3 C4 B3 0 A1 K2
B2 2A
CON1 B1 0
C4 2B R2 10 R3 100 R4 10
C30 J3
C2 2C (++)POSITIVE
C10 AK SHEET
BLK L2
BLK L3
4-C4
T1
SHOWN WIRED FOR 480V AL SHEET
SEE PAGES 6 AND 7 FOR 4-C1 .022UF C2 R7 10K
AM SHEET
OTHER CONFIGURATIONS 3-C1
RED/BLK
CS3 39 J2
+
RED
F1 F2 (+)POSITIVE
RED
RED
BLK
BLK
.22UF
J9.1 J9.6 C4 R6 10K
B B
3
4
2
H9
Shown for 480V CHB CHB J10
1
1
3
4
5
6
3
2
2
CR1
J1 J6
21 22
WHT
GRY
2A CHOPPER SA CHB
H9 40
WHT
GRN
129792
RED
BLK
2B
BLK
+ 39 39 39 H8
L2
BLK
2C CS2 SHEET
CONTROL – 38 J
TRANSFORMER 4-B1
T2 H9 H8
2
4
3
1
ORN 240VAC
J1.4 J4
RED 120VAC
J13 J1 J1.1
YEL 24VAC
1 1 RED
2 2
BLU
3 3 RED/BLK
BLK
WHT
GRN
RED
WHT PCB 1
4 PILOT ARC
F SHEET SHEET H CONTROLLER SHEET
3-D4 SHEET AN I
4-B1 4-C4 229238 3-C1
A A
AC1
AC2
WHT 14 2-A1
2 D1 CONTACTOR +
–
BLU 15
REMOTE ON/OFF
3 + PILOT ARC RELAY 16 RED START CIRCUIT
WHT
PUMP MOTOR
BLU
5 + HV XFMR 120VAC RTN 18
120VAC RTN
WHT
24VAC HOT
240VAC HOT
6 D5 HV XFMR
BLU
24VAC RTN
7 + SURGE SELECT
WHT 1 2
8 D7 SURGE SELECT J13
9
SS
CON
PAR
10 HF
11
240VAC
SIGNAL
12 AC PWR LT
24VAC
COM
COM
COM
B B
–
+
SHEET Y
7 RED/BLK
J3 J12 J13 J2 J7 J9 4-D1
1 2 3 4 5 6 7 8 9 10 1112 1 2 1 2 1 2 1 2 1 2 3 4 5 6
FLS POWER
6 RED
J2.3 J2.12 J2.13 J2.2 J2.7 WHT
MANUAL GAS
WHT
WHT
WHT
SHEET T
BLU
BLU
BLK
2-D4 CONSOLE POWER
RED/BLK RED
RED TB2 1 2 3 4 5 6 7
SHEET U 1 2 3 4 5 6 7
2-D1
J8 1 2 Q SHEET
RED/BLK 4-C1 B
RED RED
P SHEET
RED/BLK
1 2 HARNESS: 229329 WHT
RED/BLK 4-C4
WHT
FOR ARCGLIDE THC ONLY
RED
RED
RED B
SHEET BD
RED/BLK
1
7
6
4
3
5
2
CABLE: 123674
RED
RED/BLK
AH SHEET
10-A4
A HF A
1
4
3
2
1X3
ELEC SCH:HPR260XD PWR SPLY
GRN
WHT
BLK
CABLE: 123670
013377
AI SHEET
13-D3
SHEET 3 OF 19 B
4 3 2 1
7-9
4 3 2 1
J8.1
SHEET Y 3 2 1
3-B1 J1
RED
RED/BLK J3
120VAC RTN
120VAC HOT
B
B 1 RLY
B 2 GND
D J8.4 J4
B
FLS
D
B
PCB3 J201 J3.201 2 GND
POWER SUPPLY CONTROL
J3.301 J301 TP210 +24V 1
1 FLOW
041993
1 ARC BREAKOVER COM BLK
2
2 COM 2 RED
3 COOLANT FLOW SENSOR 3 SHIELD
RED 3 SHIELD J6
+5V 4
BLK A+3.3V RED
4 PWM DRV A 5 1 1
SHIELD BLK T2
SHEET C 5 TP206 COOLANT TEMP SENSOR 6 2 2
2-D3 RED BLU RED
6 7
BLK WHT BLK
7 PWM DRV B XFMR TEMP SENSOR 8
SHEET AK
SHIELD
8 9
BLU SHIELD A SHEET
WHT 2-D4
2-C3 9 CHOPPER TEMP SENSOR A 10 D SHEET
10 SS-C 11 2-D2
RED
11 SS-E CHOPPER TEMP SENSOR B 12 BLK
12 LINE VOLTAGE INPUT 13
BLU AL SHEET
BLU WHT SHIELD 2-B3
START CIRCUIT 13 PA-C 14
WHT
ENABLE 14 PA-E Q SHEET
C 3-B2 C
SHEET H
2-A2
J200 J3.200
J3.302 J302 TP200 RED SHIELD
+15V 1
BLU GRN
1 +24V –15V 2
WHT 1 WHT
2 HF CHOPPER SENSOR A 3
BLU
3
2
COM 4
BLK G SHEET
WHT 2-C2
4 PUMP 5
SHEET P BLU SHIELD
5 TP201 6
3-A2 WHT
6 CONTACTOR 7
BLU 1
7 CHOPPER SENSOR B 8
WHT
8 PILOT ARC RELAY
2
9 AN SHEET
2-A2
9 10
10 SPARE TP207 RED SHIELD
BLU 11
11 GRN
12
WHT 1 WHT
12 SURGE WORK LEAD SENSOR 13
2 BLK J SHEET
SHEET L 13 14 2-B1
BLU
CORNER CURRENT+
CORNER CURRENT–
3-C4 14 PHASE LOSS 15
B WHT
15 PWR GND 16
B
SHEET O 16 CNC
NOT READY-C
NOT READY-E
3-D1
MOTION2-C
MOTION3-C
MOTION4-C
MOTION2-E
MOTION3-E
MOTION4-E
MOTION-C
CNC +24V
PWR GND
MOTION-E
ERROR-C
RDERR-C
ERROR-E
RDERR-E
PIERCE+
422 GND
422 GND
PIERCE–
START+
HOLD+
START–
HOLD–
RX37+
TX37+
RX37–
TX37–
+24V
RX+
TX+
RX–
TX–
S101
121 0
t
121
A A
D D
PCB3
SHEET M
3-D4 POWER SUPPLY CONTROL
J3.105 J105
BLU +24V 041993
1
WHT PWR GND
2
3
BLU +5V
4
WHT GND
5
RED +15V
6
BLK COM
7
YEL –15V
8
C C
J110
TMS
1
TRST\
2
TDI
3
COM
4
+5V
5
6
TDO
7 JTAG
8
TCK
9
10
11
12
EMU0
13
EMU1 121 CANH +24V
14
B CANL B
CAN +24V
CAN GND
0
t
1
2
2
3
3
9
9
8
8
7
7
4
5
2
2
J3.101
CANA CANB
SHIELD
RED
RED
BLK
BLK
CABLE: 123691
SHEET AG
11-B4
A A
4 3 2 1
7-11
4 3 2 1
WHT
WHT
GRY
BLK
T2 T2
C C
INPUT POWER
INPUT POWER FROM FACILITY
FROM FACILITY PE
PE L1 WIRED FOR 200V 50-60HZ
L1 WIRED FOR 400V 50-60HZ L2
L2 L3
L3
TB1
TB1 1 W
1 W 2 V T1
2 V T1 3 U A4 1A
3 U A4 1A 4 PE V W A3 0
4 PE V W
B A30 A2 1B
B
A2 1B L1 A4 A1 0
L1 L1 A4 A10 L2 B4 B4 1C
EMI FILTER
L2 L2 B4 B4 1C L3 C4 B3 0
L3 L3 C4 B30 CON1 B2 2A
CON1 B2 2A B1 0
B10 C4 2B
C4 2B F1 F2 C30
F1 F2 C30 C2 2C
C2 2C C10
C10 T1
WHT
T1
BLK
WHT
BLU
T2
T2
A A
INPUT POWER
FROM FACILITY INPUT POWER
PE FROM FACILITY
D L1 WIRED FOR 440V 50-60HZ PE D
L2 L1 WIRED FOR 600V 60HZ
L3 L2
TB1 L3
1 W TB1
2 V T1 1 W T1
3 U A4 1A 2 V 1A
4 PE V W 3 U
A3 0 A1
A2 1B 4 PE V W 0 1B
L1 A4 A1 0
L2 B4 B4 1C L1 A4 1C
L3 C4 B3 0 L2 B4 B1
B2 2A L3 C4 0 2A
CON1
B1 0 CON1
C4 2B 2B
F1 F2 C30 C1
C2 2C 0 2C
C10 F1 F2
C T1 T1
C
WHT
BLK
WHT
GRY
T2
T2
WHT
BRN
BLK
T2 T2
A A
D CABLE: 123760 D
THC OPTION
COMMAND PLASMA INTERFACE PCB3
J300A
041842
J2B
J12.2B J3.300A POWER SUPPLY CONTROL
J2A
041993
1 RX– 1 1 RX37–
20 RX+ 20 20 RX37+
2 TX– 2 2 TX37–
21 TX+ 21 21 TX37+
3 3 3 422 GND
22 22 22
4 4 MOTION 1-E
4
23 23 MOTION 1-C
23
5 5 ERROR-E
5
24 24 ERROR-C
24
6 6 RDERR-E
6 RDERR-C
25 25 25
TO POWER SUPPLY 7 7 NOT READY-E
7
C 26 26 26 NOT READY-C C
8 8 MOTION 2-E
8 MOTION 2-C
27 27 27
9 9 9 MOTION 3-E
28 28 28 MOTION 3-C
10 TO COMMAND CONTROL MODULE 10 10 MOTION 4-E
29 29 29 MOTION 4-C
11 11 11
30 30 30
SPARE OUT 1– 12 12 CORNER–
12
SPARE OUT 1+ 31 31 CORNER+
31
PIERCE COMPLETE OUT– 13 13 PIERCE–
13
PIERCE COMPLETE OUT+ 32 32 PIERCE+
32
HOLE IGNITION OUT– 14 14 HOLD–
14 HOLD+
33 HOLD IGNITION OUT+ 33 33
PLASMA START OUT– 15 15 START–
15 START+
34 PLASMA START OUT+ 34 34
16 16 16
B 35 35 35 B
17 17 17
36 36 36
ELECTRODE
37
SHIELD
19
J304
1
2 0
+24V
J5 1 2 3 4 5 t
YEL/BLK 2
3
YEL
A SHEET AF A
2-D1
SHEET
3-D4 BC
D CABLE: 123760 D
THC OPTION PCB3
ARCGLIDE ETHERNET INTERFACE POWER SUPPLY CONTROL
J303B
141131 041993
J5
J13.5 J3.303B
RX– 1 1 RX37–
J7 RX+ 20 20 RX37+
J13.7 TX– 2 2 TX37–
RED/BLK 1 TX+ 21 21 TX37+
24VAC RTN
RED 2 3 3 422 GND
24VAC
22 22
MOTION IN 4 4 MOTION 1-E
+5V 23 23 MOTION 1-C
ERROR IN 5 5 ERROR-E
+5V
J1
24 24 ERROR-C
1 RAMPDOWN ERROR IN 6 6 RDERR-E
2 +5V 25 25 RDERR-C
NOT READY IN NOT READY-E
3 7 7
C 4 +5V 26 26 NOT READY-C C
5 TO ARCGLIDE MODULE(S) 8 8 MOTION 2-E
6 27 27 MOTION 2-C
7 9 9 MOTION 3-E
TO POWER SUPPLY
8 28 28 MOTION 3-C
10 10 MOTION 4-E
29 29 MOTION 4-C
11 11
30 30
CORNER OUT– 12 12 CORNER–
CORNER OUT+ 31 31 CORNER+
PIERCE COMPLETE OUT– 13 13 PIERCE–
PIERCE COMPLETE OUT+ 32 32 PIERCE+
HOLE IGNITION OUT– 14 14 HOLD–
HOLD IGNITION OUT+ HOLD+
J6
B J13.6 33 33
RED PLASMA START OUT– 15 15 START–
1 ON/OFF OUT+ PLASMA START OUT+ START+
WHT 34 34
2 ON/OFF OUT–
B 16 16
B 35 35 B
17 17
36 36
ELECTRODE
18 18 PWR GND
37 37
19 19 CNC +24V
WORK
SHEET BD
J301
3-A2
1
2 0
+24V
J4 2 1 t
YEL/BLK 2
1
YEL
A SHEET AF A
2-D1
D J1.2 J2 D
RED 120V RTN PCB1
1
RED/BLK 2 120V HOT GAS CONSOLE
3 F1 POWER DISTRIBUTION
SHEET AB 041805
10-B4
SHEET AB
10-D4
B B
RED/BLK
RED
SW1
1A 1
WHT
RED
2A 2
RED/BLK
WHT
RED
RED
REMOTE ON/OFF
GAS CLS PWR 3X1
1
7
6
4
3
5
2
SHIELD
A CABLE: 123674
A
WHT
RED
BLK
BLK
013377
SHEET 10 OF 19 B
4 3 2 1
7-16
4 3 2 1
J7
J2.4 J4 1
BLU +24V RXD 2
1 PCB2
WHT 2 +24V COM TXD 3
GAS CSL CONT
D 3 041912 4 D
BLU +5V RS-232 232 COM 5
4
WHT 5 +5V COM 6
6 7
SHEET AC
10-C4 7 8
8 9
J2.8 J8
1
2
3X2
CABLE: 123691 CABLE: 123692 J2.9 J9
1 1
BLK BLK
2 2 CANL
BLK 3 BLK 3 CAN GND
4 4
5 CAN A 5
6 6
RED RED
C 7 7 CANH C
8 8
RED RED CAN +24V J3
9 9
SHIELD TMS 1
TRST\ 2
SHIELD TDI 3
J10 +5V COM 4
1 +5V 5
2 CANL 6
3 CAN GND JTAG TDO 7
SHEET AG
5-A3 4 8
CAN B 5 TCK 9
6 10
7 CANH 11
8 12
9 CAN +24V EMU0 13
EMU1 14
J11 o
t
B 1 CAN PWR B
+24V
COM
2 CAN +24V
SIG
SIG
SIG
SIG
J2
11
12
13
14
15
16
10
1
2
3
4
5
6
7
8
9
J2.2
CABLE: 123703
A A
PT3-PP PT4-PC PT2-SP PT1-SC
ELEC SCH:HPR260XD PWR SPLY
013377
SHEET 11 OF 19 B
4 3 2 1
7-17
4 3 2 1
SHEET AE PCB3
10-C1 AC VALVE DRIVER
J3.1 J1 041822 J3 J3.3
RED/BLK RED/BLK RED/BLK
PCB2 1 120V HOT SV4 1
RED RED/BLK RED SV1
GAS CSL CONT 2 120V RTN SV3 2
041912 3 RED/BLK RED/BLK
SV2 3
RED/BLK RED SV2
SV1 4
SV5 RED/BLK
5
RED RED/BLK
J6 J2.6 J3.4 J4 120V RTN 6
D RED RED SV3 D
NOT USED 120V RTN 7
1 1 RED RED/BLK
120V RTN 8
NOT USED 3 3 RED/BLK RED SV4
SV6 9
NOT USED 5 5 RED
120V RTN 10
+5V 7 7 RED RED/BLK
120V RTN 11 SV5
+5V 9 9 RED RED
120V RTN 12
+5V 11 11 RED/BLK RED/BLK
SV7 13
SPARE 4 13 13 RED RED SV6
120V RTN 14
SPARE 3 15 15 RED
120V RTN 15 RED/BLK
SPARE 2 17 17 RED
120V RTN 16 RED SV7
SPARE 1 19 19 RED/BLK
SV8 17
SV20 21 21 D20 RED RED/BLK
120V RTN 18 SV8
SV19 23 23 D19 RED RED
120V RTN 19
SV18 25 25 D18 RED
120V RTN 20 RED/BLK
SV17 27 27 D17 RED/BLK
SV9 21 RED SV9
SV16 29 60 COND RIBBON 29 D16 RED
120V RTN 22 RED/BLK
SV15 31 31 D15 RED
120V RTN 23 RED SV10
SV14 33 33 D14
120V RTN 24
SV13 35 35 D13 RED/BLK
C 37 37 D12
SV10 25 RED/BLK C
SV12 26 SV11
120V RTN RED
SV11 39 39 D11
120V RTN 27 RED/BLK
SV10 41 41 D10
120V RTN 28 RED SV12
SV9 43 43 D9 RED/BLK
SV11 29
SV8 45 45 D8
120V HOT 30 RED/BLK
SV7 47 47 D7
120V HOT 31 RED SV13
SV6 49 49 D6
120V HOT 32 RED/BLK
SV5 51 51 D5 RED/BLK
SV12 33 RED SV14
SV4 53 53 D4 RED/BLK
SV13 34
SV3 55 55 D3 RED/BLK
SV14 35
SV2 57 57 D2
SPARE OUTPUT 36
SV1 59 59 D1
J2 J3.2
RED/BLK
SV16 1
CABLE: 123704 RED SV16
120V RTN 2
RED/BLK
SV17 3
B RED/BLK SV17 B
120V RTN 4
SV18 RED
5
RED SV18
120V RTN 6
RED/BLK
SV19 7
RED SV19
120V RTN 8
120V RTN
SV20
120V RTN
SV19
120V RTN
SV18
120V RTN
SV16
120V RTN
SV17
RED/BLK
SV20 9
RED SV20
120V RTN 10
3X3
RED/BLK
11
14
13
12
10
9
8
7
6
5
4
3
2
1
S
RED SV16
C
RED/BLK
S
RED SV17
P
A RED/BLK A
11
14
13
12
10
8
7
6
5
4
3
2
1
P
RED SV18
P RED/BLK
P
RED
RED/BLK
RED
RED/BLK
RED
RED/BLK
RED
RED/BLK
RED
RED/BLK
RED SV19
C ELEC SCH:HPR260XD PWR SPLY
129816
V
RED/BLK
RED SV20 OFF VALVE 013377
V MANIFOLD
SHEET 12 OF 19 B
V
V
C
P
P
P
C
S
P
S
4 3 2 1
7-18
4 3 2 1
D CABLE: 123670 D
SHEET AI
3-A4
WHT
GRN
BLK
1 2 3 4
2X1
CATHODE AJ SHEET
009045 FLTR 2-D1
BLOCK
CABLE: 123662
C C
TORCH C2
0.22uF 1kVDC PILOT ARC
T1 J4 009224
C1 J5
129854 0.22uF 1kVDC
009224 COIL SECONDARY IN
J6
J1 C3
SG1 1400pF 20kV COIL PRIMARY 2
109344 009975
5kV C4
1400pF 20kV
SG2 009975 T2
109344 C5 009793
5kV 1400pF 20kV
009975 COIL PRIMARY 1 NOZZLE
B COIL CONNECTION B
J2 J3 SECONDARY
OUT
A A
5 Micron Filter
V2 V1 V3
D D
V12
V4 V5 V6 V7 V8 V9 V10 V11
Gas Console
PR1 PR2 PR3 PR4
V14 V13
P1 P2 P3 P4
C C
Vent
B B
Shield Plasma
Vent
HPR260XD Manual
Torch
Gas Schematic
A A
D D
MANIFOLD
RELIEF VALVE
C C
THERMISTOR
PUMP
FILTER
SHUT OFF VALVE
B RHF B
TORCH
A A
D D
Unit 1 Unit 2 Unit 3 Unit 4
C C
041993 041993 041993 041993
CONTROL BOARD S101 CONTROL BOARD S101 CONTROL BOARD S101 CONTROL BOARD S101
ON J106 J107 ON J106 J107 ON J106 J107 ON J106 J107
1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
Serial ID Machine Motion Serial ID Machine Motion Serial ID Machine Motion Serial ID Machine Motion
Dipswitch Jumper Block Dipswitch Jumper Block Dipswitch Jumper Block Dipswitch Jumper Block
D D
Depress the Gas Console Power switch to the closed position (on position).
C C
TB2 2) For a multi-system installation set up as described above, set jumpers as shown on the
multi-system interface page
041993 CONTROL BOARD RED/BLK RED/BLK
J106 J107 3) The CNC will need a dedicated I/O for each system using the Remote On/Off feature
7
7
ON S101
1 2 1 2 RED RED (contact should be rated for min. 24Vac, 0.5 Amp)
21
6
6
5
5
S100 1 2 3 4 J303
4
ON 1 2 3 4 1 2 3 4 WHT 4
* If a Hypertherm Automation controller is being used, and there are intermittent communication
3
3
RED Gas Power Cable failures (PS Link Failure), try removing the jumnpers on J104 and J105 on the control board, and the
76
termination jumper (J6 or J8) on the serial isolation board in the controler. Only remove
2
2
1 2 3 4 5 6 7 8 WHT the termination jumper on the serial isolation board that is connected to the HPR
RED
Serial ID Machine Motion power supply. See figure below for details.
1
1
1X1
Dipswitch Jumper Block
J300A J300B J1
SV
RIBBON CABLE
B B
078170 BMD AMD
Gas Console
J2 J3
Remote On/Off
Customer Supplied BHST AHST
CNC Interface Cable J5 J6
4 3 2 1
7-23
4 3 2 1
Torch
J2A
Lifter I/O Interface Cable
1 2 3 4 5 6 7 8
Serial ID Machine Motion (Optional Unit)
Dipswitch Jumper Block Motor Drive Cable
J300B J300A J2B
B B
CNC Interface Cable
CNC
Interface Dipswitch setting example:
(Customer Supplied)
Notes: S100
ON 8
S100 ON 6
7
ON
1) For a single system installation set Serial ID (S100), Serial ID 4
5
3
Machine Motion (J303), J106 & J107 as shown above. Dipswitch 1 2 3 4 5 6 7 8 1
2
2) For a two system installation duplicate a second power supply and Command THC 1 2 3 4 5 6 7 8 for second system
as illustrated for a single system, set Serial ID as shown for the second system. Switch 1 is in the On position
3) For a three system installation set up as described above, set Serial ID as shown ON Switches 2-8 are in the Off position
S100
for the third system. Serial ID
4) For a four system installation set up as described above, set Serial ID as shown Dipswitch
for the fourth system. 1 2 3 4 5 6 7 8 for third system
A 5) All machine interface cables (Pwr. supply-CNC) used for serial communication between A
Pwr. supply-CNC will have a common connection node with the CNC. ON S100
6) The CNC will need a dedicated I/O port for each Command THC. Serial ID
7) If a Hypertherm Automation controller is being used, and there are intermittent communication
failures (PS Link Failure), try removing the jumpers on J106 and J107 on the control board, 1 2 3 4 5 6 7 8
Dipswitch
for fourth system ELEC SCH:HPR260XD PWR SPLY
and the termination jumper (J6 or J8) on the serial isolation board in the controler.
Only remove the termination jumper on the serial isolation board that is connected 013377
to the HPR power supply. See figure on Sheet 19 for details.
SHEET 18 OF 19 B
4 3 2 1
7-24
4 3 2 1
D D
Unit 1 Unit 2 Unit 3 Unit 4
5 67
5 67
5 67
1 23
1 23
1 23
1 23
SW1 SW1 SW1 SW1
4 4 4 4
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
Serial ID UNIT ADDRESS Serial ID UNIT ADDRESS Serial ID UNIT ADDRESS Serial ID UNIT ADDRESS
Dipswitch Dipswitch Dipswitch Dipswitch
B B
CNC Interface Cable CNC Interface Cable CNC Interface Cable CNC Interface Cable
1) For the 041993 control board, set Serial ID (S100), and Machine Motion (J303) as shown. S100
Jumpers J106 and J107 should be installed. ON 7 8
All 041993 DIPSWITCH and jumper settings are the same; serial IDs are determined
ON
4 5 6
3
by the 141131 board setting. 1 2 3 4 5 6 7 8 1 2
2) For a single system installation, set SW1 on the 141131 board as shown in Unit 1.
3) For a two system installation, set SW1 on the 141131 boards as shown in Units 1 through 2.
ArcGlide THC Switch 1 is in the On position
Switches 2-8 are in the Off position
4) For a three system installation, set SW1 on the 141131 boards as shown in Units 1 through 3. and/or EdgePro Module(s)
5) For a four system installation, set SW1 on the 141131 boards as shown in Units 1 through 4.
A A
In this section:
1 – Identification of the substance/mixture and of the company undertaking............................................................................a-2
2 – Hazards identification.......................................................................................................................................................................a-2
3 – Composition/information on ingredients......................................................................................................................................a-3
4 – First aid measures.............................................................................................................................................................................a-3
5 – Fire-fighting measures......................................................................................................................................................................a-3
6 – Accidental release measures..........................................................................................................................................................a-3
7 – Handling and storage.......................................................................................................................................................................a-4
8 – Exposure controls/personal protection........................................................................................................................................a-4
9 – Physical and chemical properties..................................................................................................................................................a-4
10 – Stability and reactivity....................................................................................................................................................................a-5
11 – Toxicological information...............................................................................................................................................................a-5
12 – Ecological information...................................................................................................................................................................a-5
13 – Disposal considerations................................................................................................................................................................a-6
14 – Transport information.....................................................................................................................................................................a-6
15 – Ecological information...................................................................................................................................................................a-6
16 – Other information............................................................................................................................................................................a-7
Freezing Point of Propylene Glycol Solution........................................................................................................................................a-8
2 – Hazards identification
3 – Composition/information on ingredients
For full text of R phrases see section 16. For full text of H/P phrases see section 16. Non-hazardous components are not listed.
5 – Fire-fighting measures
Handling Unlikely to cause harmful effects under normal conditions of handling and use
Storage Keep container tightly closed and dry. Keep away from heat. Keep out of the reach of
children. Keep away from oxidizing agents.
Storage Temperature: Ambient
Storage Life: Stable at ambient temperatures
Specific Use: Industrial use only
Respirators
Normally no personal respiratory protection is necessary. Wear suitable respiratory
protective equipment if exposure to levels above the occupational exposure limit is
likely. A suitable dust mask or dust respirator with filter type A/P may be appropriate.
Reactivity None
Chemical stability Stable under normal conditions
Possibility of hazardous reactions None
Conditions to avoid None anticipated
Incompatible materials Keep away from oxidizing agents
Hazardous Decomposition Product(s) Carbon monoxide, Carbon dioxide, Nitrogen oxides
11.1.1 – Substances
Acute toxicity
Ingestion Low oral toxicity, but ingestion may cause irritation of the
gastrointestinal tract
Inhalation Unlikely to be hazardous by inhalation
Skin Contact Mild irritant to rabbit skin
Eye Contact Mild irritant to the eye
Hazard label(s) None
Serious eye damage/irritation Mild irritant to the eye
Respiratory or skin sensitization Mild irritant to rabbit skin
Mutagenicity Not known
Carcinogenicity IARC, NTP, OSHA, ACGIH do not list this product or any
components thereof as known or suspected carcinogen
Reproductive toxicity Not known
STOT-single exposure Not known
STOT-repeated exposure Not known
Aspiration hazard Not known
Waste treatment methods - Disposal should be in accordance with local, state or national legislation. No special measures are
required. No specific waste water pretreatment required.
Additional Information – None
USA
TSCA (Toxic Substance Control Act) – Listed.
SARA 302 - Extremely Hazardous Substances – Not applicable.
SARA 313 - Toxic Chemicals – Not applicable.
SARA 311/312 - Hazard Categories – None.
CERCLA (Comprehensive Environmental Response Compensation and Liability Act) – Not applicable.
CWA (Clean Water Act) - CWA 307 - Priority Pollutants – None.
CAA (Clean Air Act 1990) CAA 112 - Hazardous Air Pollutants (HAP) – None.
Proposition 65 (California) – Not applicable.
State Right to Know Lists – CAS No. 95-14-7 Listed in MA, NJ, PA.
Canada
WHMIS Classification (Canada) – Not classified.
CANADA INGREDIENT DISCLOSURE LIST – Not applicable.
Canada (DSL/NDSL) – Listed.
EU
EINECS (Europe) – Listed.
Wassergefährdungsklasse (Germany) – None.
Legend
LTEL Long Term Exposure Limit
STEL Short Term Exposure Limit
STOT Specific Target Organ Toxicity
DNEL Derived No Effect Level
PNEL Predicted No Effect Concentration
References:
Risk Phrases and Safety Phrases
None. Preparation is not classified as hazardous in the sense of directive 1999/45/EC and 2006/121/EC.
Hazard statement(s) and Precautionary statement(s).
None. Preparation is not classified as hazardous in the sense of directive 1999/45/EC and 2006/121/EC.
°C °F
4 40
-1 30
-7 20
-12 10
-18 0
Temperature
-23 -10
-29 -20
-34 -30
-40 -40
-46 -50
-51 -60
-57 -70
0 10 20 30 40 50 60
% of Propylene Glycol
III. Power-up
a. Processor boots in microprocessor mode and begins to execute code in external flash memory.
b. Limited initialization of digital-signal processing (DSP) hardware.
c. Calculate checksum on external flash and on DSP internal flash.
– If checksums don’t match, copy code in external flash to internal flash.
d. Jump to internal flash and start execution.
III. Initialization
a. Full initialization of DSP hardware.
b. Read EEPROM for previous current setpoint.
1. Idle
2. Purge
• Turn on coolant pump or motor.
• Gas console runs preflow gases for 12 seconds.
• After preflow cycle is done, verify coolant flow.
• Gas console runs cutflow gases for 12 seconds.
• Verify that the Plasma Start signal is off before going to Idle2 state.
Error checking
• If coolant flow rate is less than 1.1 lpm (0.3 gpm) (093), shut down the system.
• If coolant flow rate is less than 2.2 lpm (0.6 gpm) (060), continue pumping coolant until flow is above 2.2
lpm (0.6 gpm), with no start allowed at this time.
3. Idle2
• If Start signal is active, the gas console goes into Preflow state, the contactor and the soft-start
controller turn on, and system goes into Preflow state.
• If the gas console or serial interface requests a state change, take action.
• After more than 10 seconds since the last Start signal, turn off the contactor and soft-start controller.
Error checking
• Check for coolant flow at power-up (093).
• Check for no chopper current (102).
• Verify that all temperatures are below the specified temperature limits.
4. Preflow_IHS
• Chopper setpoint = pilot arc current.
• Wait for preflow to finish (2 seconds if contactor timeout, otherwise 0.5 seconds) and for the Hold signal
to be removed.
Error checking
• Check for coolant flow at power-up (093).
• Check for over/under line voltage (047/046).
• Check for coolant over temperature (071).
• Check for chopper over temperature (065).
• Check for transformer over temperature (067).
6. Transfer
• If work lead current is > transfer reference current, go to Ramp-up state and turn off pilot arc controller
and pilot arc relay.
• If no transfer after 500 milliseconds, go to Auto Off state with error code (021), “No arc transfer.”
• If chopper current is < 1⁄2 of setpoint, turn on HF.
Error checking
• No error checking due to HF noise.
7. Ramp-up
• If Pierce-complete input is off, then switch to cutflow gases.
• Ramp-up current is based on tables.
• Once chopper current is = or > setpoint, go to Steady state.
Error checking
• Check for coolant flow at power-up (093).
• Check for over/under line voltage (047/046).
• Check for coolant over temperature (071).
• Check for chopper over temperature (065).
• Check for transformer over temperature (067).
9. Ramp-down
• Do current ramp-down according to tables.
• Put gas console into Idle state or Ramp-down state according to tables.
HPR260XD Manual Gas – 806340 Revision 2 b-3
Software functional description
11. Auto-off
• Turn off pilot arc relay, pilot arc controller, HF, and machine motion outputs.
• Preflow gases run for a 10-second postflow period.
• If error has occurred, turn on CNC error output.
• If Ramp-down error has occurred, turn on CNC Ramp-down error output.
• Postflow timer and contactor timer run for 10 seconds.
• If no Start signal, go to Idle2 state.
Error checking
• Check for coolant flow at power-up (093).
12. Shut-down
• Gas console goes to Shut-down state.
• All outputs off.
• CNC error output on.
• Chopper setpoints = 0.
• Wait for reset request.
13. Reset
• Reset CAN controller.
• Initialize timers.
• Go to Idle state.
robotic applications
In this section:
Components for robotic applications.....................................................................................................................................................c-2
Torch leads........................................................................................................................................................................................c-2
Ohmic contact extension................................................................................................................................................................c-2
Rotational mounting sleeve (optional) – 220864...................................................................................................................c-3
Leather overwrap – 024866........................................................................................................................................................c-3
Robotic teaching torch (laser pointer) – 228394..................................................................................................................c-3
Torch and rotational mounting sleeve dimensions...................................................................................................................c-3
Note: Consumable life will be reduced if the 2.5 m (8 ft) gas leads are used.
Overall length 1.8 M (6 feet) gas lead 2.4 M (8 feet) gas lead
2 m (6 ft) 228514 228516
2.5 m (8 ft) 228515 228517
3 m (10 ft) 228475 228482
3.5 m (12 ft) 228476 228483
4.5 m (15 ft) 228477 228484
6 m (20 ft) 228478 228485
7.5 m (25 ft) 228479 228486
10 m (35 ft) 228480 228487
15 m (50 ft) 228481 228488
50.80 mm
(2.00")
2X 56.01 mm 10.16 mm
(2.205") 50.67 mm (0.40")
(1.995") 56.64 mm
(2.23") 47°
3X 57.02 mm
(2.245")
2 X 12.95 mm
(0.51")
Added “See Supply gas hoses at the end of this section for recommendations” to the first paragraph.
Removed the note “Oxygen, nitrogen, and air are required for all systems. Nitrogen is used as a purge
3-45
gas.” from under the first paragraph. The statement was inaccurate. Changed regulator pressure from
8.3 bar (120 psi) to 8 bar (115 psi). Removed the reference to methane because it is not used.
Added reference to supply gas hoses that are listed at the end of the section. Removed the reference
3-47
to methane because it is not used.
Added “When using the argon marking processes, mark and cut individual parts. Marking the entire
4-6 nest prior to cutting may lead to reduced consumable life. For better results intersperse cuts and
marks.” under Marking..
4-9 Added graphics and part numbers for mild steel, thick percing, bevel consumables.
4-11 Expanded “Inspect consumables” from one page to 2. Increased size of graphics for clarity.
Added “(for example: 30 amp O2/O2 and 50 amp O2/O2 processes). The pierce complete signal
must be turned off for processes with shield gas preflow pressures that are lower than the cutflow
pressures (for example: 600 amp and 800 amp processes).” to the second paragraph. Added third
4-19
bullet point. Added “moving pierce”, (800 amp SST piercing can be extended to 100 mm (4 in), and
“an edge start is recommended unless the operator is experienced with this technique.” to the last
bullet point.
Updated kerf width compensation table data. Added mixed gas processes to the table. Added 5/16,
4-23
5/8, 1-1/4, and 1-1/2 in thicknesses. Populated empty boxes with N/A for not available.
Updated the Service Parts Replacement Schedule table. Corrected the part number for the annual
preventive maintenance kit (it was 228016 and was changed to 228606 and 228623). Corrected the
5-62 and 5-63
part number for the torch main body (it was 220162 and was changed to 220706). Corrected the
quantities for the 6 inch fan (127039 from 3 to 4) and the 10 inch fan (027079 from 1 to 3).
Added part numbers for power supplies with Hypernet and a note about Hypernet. Added the 415
6-2
volt power supply. Added Hypernet upgrade kit.
6-3 Added 415 V main transformer.
6-5 and 6-16 Added 415 V to the note.
6-13 Corrected the quantity for electrode part number 220307 from 6 to 4.
Added part numbers to Consumables for mirror image cutting for 80 amp, 130 amp and 260 amp
6-15
mild steel bevel cutting.
Appendix A Updated to the latest information and formatting for the Hypertherm torch coolant data (MSDS)
C-2 Added metric conversions for gas lead lengths. Added graphic of the ohmic contact extension.
Added graphics for the rotational mounting sleeve, the rotational mounting sleeve clamp, the leather
C-3 over wrap, and the robotic teaching torch. Also added a dimensional drawing for the torch and
rotational mounting sleeve.