Hypertherm HPR800XD Auto Gas Rev.2 - Manual (Page 234)

Maintenance
5-20 HPR800XD Auto Gas – 806500
Error code troubleshooting – error codes 102 to 111, 302 to 308
Error code
number
Name Description corrective action
102
Primary
302
Secondary
Chopper 1
current at
power-up
Chopper 1 current signal
is active at power-up.
See wiring diagrams in section 7
1. Verify that the voltage at CS1 is correct.
2. Verify that the wiring between CS1 and PCB3 is correct
and not damaged.
3. Swap CS1 with CS2. If the error code changes to 156,
replace the original CS1.
103
Primary
303
Secondary
High current
on CS1
A current greater
than 35 Amps has
been detected by
current sensor 1.
See the chopper test later in this section.
104
Primary
304
Secondary
High current
on CS2
HPR260XD
HPR400XD
only
A current greater
than 35 amps has
been detected by
current sensor 2.
See the chopper test later in this section.
105
Primary
305
Secondary
Low current
on CS1
A current less
than 10 amps has
been detected by
current sensor 1.
See the chopper test later in this section.
106
Primary
306
Secondary
Low current
on CS2
HPR260XD
HPR400XD
only
A current less than
10 amps has been
detected by
current sensor 2.
See the chopper test later in this section.
107
Primary
307
Secondary
High current
on CS3
HPR400XD
only
A current greater than
35 amps has been
detected by
current sensor 3.
See the chopper test later in this section.
108
Primary
308
Secondary
Transfer at
power-up
The system has detected
current on the work lead
during power-up.
1. Verify that the electrical connections to current sensors
CS1 and CS3 are correct and not damaged.
2. Replace PCB3 if connections are correct and not damaged.
3. Verify that the main contactor (CON1) is not welded closed,
or closing at power-up.
109
Coolant flow
at power-up
“Coolant flow OK” signal
is active during power-up
and before pump motor
is activated.
Either the coolant flow sensor was bypassed or it is faulty.
1. Verify that there is power at the sensor.
2. Verify that all the connectors have good connections.
111
Coolant
overtemp at
power-up
Coolant is indicating an
overtemp at power-up.
1. Verify that the coolant temperature sensor has not been
bypassed or the wires to the sensor are not shorted out in
the harness.
2. If not, the coolant temperature is over the set point and
needs time to cool to 70° C (158° F).