Hypertherm HPR800XD Auto Gas Rev.2 - Manual (Page 266)

Maintenance
5-52 HPR800XD Auto Gas – 806500
chopper tests
Automatic chopper tests during power-up
When the power is turned ON, the contactor will close and each chopper will automatically test in sequence (1, 3, 2,
and 4). If the status changes to 3, all choppers passed the test. After the tests are complete the unit will advance to the
purge cycle unless an error is detected on one of the choppers.
As each chopper is turned on, the current flows into the surge circuit and is measured for high and low limits. If the
chopper passes the test, the next chopper is tested.
If chopper 1 passes the test and one of the other choppers fails, you can assume that the main contactor, the input
power, and the surge circuit are OK.
Error codes:
Chopper 1 – low-current error code 105 Chopper 2 – low-current error code 106
Chopper 1 – high-current error code 103 Chopper 2 – high-current error code 104
Chopper 3 – low-current error code 075 Chopper 4 – low-current error code 076
Chopper 3 – high-current error code 107 Chopper 4 – high-current error code 095
chopper 1 failure
1. Turn OFF all power to the system.
2. Remove the cover over the main contactor (CON1) and inspect
the contacts for arcing or damage.
• If the contacts are damaged, replace the contactor.
• If the contacts are OK, replace the cover, turn ON the power,
and continue to step 3.
OK Excessive wear
CON1
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.