Hypertherm HPR800XD Auto Gas Rev.2 User Manual
Hpr800, Hyperformance, Plasma
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Table of contents
Document Outline
- Electromagnetic Compatibility (EMC)
- Warranty
- Section 1 - SAFETY
- Recognize safety information
- Follow safety instructions
- Inspect equipment before using
- Responsibility for safety
- A plasma arc can damage frozen pipes
- Static electricity can damage printed circuit boards
- Grounding safety
- Electrical hazards
- Electric shock can kill
- Cutting can cause fire or explosion
- Machine motion can cause injury
- Compressed gas equipment safety
- Gas cylinders can explode if damaged
- Toxic fumes can cause injury or death
- A plasma arc can cause injury and burns
- Arc rays can burn eyes and skin
- Pacemaker and hearing aid operation
- Noise can damage hearing
- Dry dust collection information
- Laser radiation
- Additional safety information
- Section 2 - Specifications
- Section 3 - Installation
- Upon receipt
- Claims
- Installation requirements
- Noise levels
- Placement of system components
- Installation requirements
- Recommended grounding and shielding practices
- Introduction
- Placement of the primary power supply
- Placement of the secondary power supply
- Install the ignition console
- Placement of the chiller
- Install the chiller interface console
- Install the metering console
- Placement of the selection console
- Primary power supply to secondary power supply cables
- Power supply to ignition console leads
- Primary power supply to chiller interface console
- Secondary power supply to chiller interface console
- Primary Power supply to selection console cables
- Selection console to metering console hose and lead assembly
- Power supply to CNC interface cable
- Remote ON/OFF switch (provided by customer)
- Torch lead assembly
- Torch lead junction box (Optional)
- Work lead
- Torch connections
- Torch mounting and alignment
- Torch lifter requirement
- HyperNet
- Power requirements (for each power supply)
- Main power cable (power supplies)
- Main power cable (chiller)
- Connect the power
- Torch coolant requirements
- Water purity requirements
- Fill the chiller with coolant
- Gas requirements
- Gas regulators
- Supply gas plumbing
- Supply gas hoses
- Section 4 - Operation
- Daily start-up
- Power indicators
- CNC controller requirements
- CNC screen examples
- Consumable selection
- Install and Inspect consumables
- Torch maintenance
- Torch connections
- Replace torch water tube
- Common cutting faults
- How to optimize cut quality
- Cut charts
- Thin stainless steel with HDi technology
- Thick stainless steel piercing technique
- Fine Feature cutting
- Bevel cutting
- Bevel cutting definitions
- Cutting thick material
- Underwater cut charts
- Estimated kerf-width compensation
- Section 5 - Maintenance
- Introduction
- Routine maintenance
- System description
- Sequence of operation
- Gas system purge cycle
- Gas system valve usage
- Power supply troubleshooting
- Error codes
- Error code troubleshooting – error codes 000 to 018
- Error code troubleshooting – error codes 020 to 028, 224 to 228
- Error code troubleshooting – error codes 030 to 042, 231 to 234
- Error code troubleshooting – error codes 044 to 046
- Error code troubleshooting – error codes 047 to 053, 248 to 250
- Error code troubleshooting – error codes 054 to 061
- Error code troubleshooting – error codes 062 to 067, 265 to 267
- Error code troubleshooting – error codes 071 to 075, 273 to 275
- Error code troubleshooting – error codes 076 to 101, 276 to 301
- Error code troubleshooting – error codes 102 to 111, 302 to 308
- Error code troubleshooting – error codes 116 to 133, 316
- Error code troubleshooting – error codes 134 to 140, 334 and 338
- Error code troubleshooting – error codes 141 to 152, 346 to 351
- Error code troubleshooting – error codes 153 to 156, 354 to 356
- Error code troubleshooting – error codes 157 to 159, 357 to 359
- Error code troubleshooting – error codes 160 to 180
- Error code troubleshooting – error code 181, 182, 298, and 383
- Power supply states
- Plasma system operation with pump time-out
- CNC operation with pump time-out
- Initial checks
- Power measurement
- Air filter element replacement
- Coolant system servicing
- Chiller interface coolant filter
- Gas leak tests
- Power supply control board PCB3
- Power supply power distribution board PCB2
- Start-circuit PCB1
- Pilot arc current levels
- Pump motor drive board PCB7
- Chiller interface power distribution board PCB1
- Coolant sensor board PCB2
- Selection console control board PCB2
- Selection console power distribution board PCB1
- Selection console, AC valve-driver board PCB3
- Metering console control board PCB2
- Metering console power distribution board PCB1
- Chopper tests
- Phase-loss detection test
- Torch lead test
- Preventive maintenance
- Section 6 - Parts List
- Section 7 - Wiring Diagrams
- Appendix A - Hypertherm Torch Coolant Safety Data
- 1 – Identification of the substance/mixture and of the company undertaking
- 2 – Hazards identification
- 3 – Composition/information on ingredients
- 4 – First aid measures
- 5 – Fire-fighting measures
- 6 – Accidental release measures
- 7 – Handling and storage
- 8 – Exposure controls/personal protection
- 9 – Physical and chemical properties
- 10 – Stability and reactivity
- 11 – Toxicological information
- 12 – Ecological information
- 13 – Disposal considerations
- 14 – Transport information
- 15 – Regulatory information
- 16 – Other information
- Freezing Point of Propylene Glycol Solution
- Appendix B - CNC Interface Protocol
- Appendix C - Robotic Applications