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Instruction manual 806320 Revision 1
HPR130XD
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Copyright 2009 Hypertherm, Inc. All Rights Reserved Hypertherm, HyPerformance, HyDefinition, LongLife and Command THC are trademarks of Hypertherm, Inc. and may be registered in the United States and/or other countries
Hypertherm, Inc. Etna Road, P.O. Box 5010 Hanover, NH 03755 USA 603-643-3441 Tel (Main Office) 603-643-5352 Fax (All Departments) info@hypertherm.com (Main Office Email) 800-643-9878 Tel (Technical Service) technical.service@hypertherm.com (Technical Service Email) 800-737-2978 Tel (Customer Service) customer.service@hypertherm.com (Customer Service Email) Hypertherm Automation 5 Technology Drive, Suite 300 West Lebanon, NH 03784 USA 603-298-7970 Tel 603-298-7977 Fax Hypertherm Plasmatechnik GmbH Technologiepark Hanau Rodenbacher Chaussee 6 D-63457 Hanau-Wolfgang, Deutschland 49 6181 58 2100 Tel 49 6181 58 2134 Fax 49 6181 58 2123 (Technical Service) Hypertherm (S) Pte Ltd. 82 Genting Lane Media Centre Annexe Block #A01-01 Singapore 349567, Republic of Singapore 65 6841 2489 Tel 65 6841 2490 Fax 65 6841 2489 (Technical Service) Hypertherm (Shanghai) Trading Co., Ltd. Unit A, 5th Floor, Careri Building 432 West Huai Hai Road Shanghai, 200052 PR China 86-21 5258 3330/1 Tel 86-21 5258 3332 Fax
Hypertherm Europe B.V. Vaartveld 9 4704 SE Roosendaal, Nederland 31 165 596907 Tel 31 165 596901 Fax 31 165 596908 Tel (Marketing) 31 165 596900 Tel (Technical Service) 00 800 4973 7843 Tel (Technical Service) Hypertherm Japan Ltd. 801 Samty Will Building 2-40 Miyahara 1-Chome, Yodogawa-ku, Osaka 532-0003, Japan 81 6 6170 2020 Tel 81 6 6170 2015 Fax Hypertherm Brasil Ltda. Avenida Doutor Renato de Andrade Maia 350 Parque Renato Maia CEP 07114-000 Guarulhos, SP Brasil 55 11 2409 2636 Tel 55 11 2408 0462 Fax Hypertherm Mxico, S.A. de C.V. Avenida Toluca No. 444, Anexo 1, Colonia Olivar de los Padres Delegacin lvaro Obregn Mxico, D.F. C.P. 01780 52 55 5681 8109 Tel 52 55 5683 2127 Fax
7/1/09
EMC Introduction
Hypertherms CE-marked equipment is built in compliance with standard EN60974-10. The equipment should be installed and used in accordance with the information below to achieve electromagnetic compatibility. The limits required by EN60974-10 may not be adequate to completely eliminate interference when the affected equipment is in close proximity or has a high degree of sensitivity. In such cases it may be necessary to use other measures to further reduce interference. This cutting equipment is designed for use only in an industrial environment.
g. Immunity of other equipment in the environment. User shall ensure that other equipment being used in the environment is compatible. This may require additional protection measures. h. Time of day that cutting or other activities are to be carried out. The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.
Assessment of area
Before installing the equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area. The following shall be taken into account: a. Other supply cables, control cables, signalling and telephone cables; above, below and adjacent to the cutting equipment. b. Radio and television transmitters and receivers. c. Computer and other control equipment. d. Safety critical equipment, for example guarding of industrial equipment. e. Health of the people around, for example the use of pacemakers and hearing aids. f. Equipment used for calibration or measurement.
Cutting cables
The cutting cables should be kept as short as possible and should be positioned close together, running at or close to the floor level.
Equipotential bonding
Bonding of all metallic components in the cutting installation and adjacent to it should be considered. However, metallic components bonded to the workpiece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode (nozzle for laser heads) at the same time. The operator should be insulated from all such bonded metallic components.
Hypertherm
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Earthing of workpiece
Where the workpiece is not bonded to earth for electrical safety, nor connected to earth because of its size and position, for example, ships hull or building steelwork, a connection bonding the workpiece to earth may reduce emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connection of the workpiece to earth should be made by a direct connection to the workpiece, but in some countries where direct connection is not permitted, the bonding should be achieved by suitable capacitances selected according to national regulations. Note: the cutting circuit may or may not be earthed for safety reasons. Changing the earthing arrangements should only be authorized by a person who is competent to assess whether the changes will increase the risk of injury, for example, by allowing parallel cutting current return paths which may damage the earth circuits of other equipment. Further guidance is given in IEC/TS 62081 Arc Welding Equipment Installation and Use.
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Hypertherm
WARRANTY
Attention
Genuine Hypertherm parts are the factory-recommended replacement parts for your Hypertherm system. Any damage caused by the use of other than genuine Hypertherm parts may not be covered by the Hypertherm warranty. You are responsible for the safe use of the Product. Hypertherm does not and cannot make any guarantee or warranty regarding the safe use of the Product in your environment.
Distributors/OEMs may offer different or additional warranties, but Distributors/OEMs are not authorized to give any additional warranty protection to you or make any representation to you purporting to be binding upon Hypertherm.
General
Hypertherm, Inc. warrants that its Products shall be free from defects in materials and workmanship, if Hypertherm is notified of a defect (i) with respect to the power supply within a period of two (2) years from the date of its delivery to you, with the exception of Powermax brand power supplies, which shall be within a period of three (3) years from the date of delivery to you, and (ii) with respect to the torch and leads within a period of one (1) year from its date of delivery to you, and with respect to torch lifter assemblies within a period of one (1) year from its date of delivery to you, and with respect to laser heads within a period of one (1) year from its date of delivery to you. This warranty shall not apply to any Powermax brand power supplies that have been used with phase converters. In addition, Hypertherm does not warranty systems that have been damaged as a result of poor power quality, whether from phase converters or incoming line power. This warranty shall not apply to any Product which has been incorrectly installed, modified, or otherwise damaged. Hypertherm, at its sole option, shall repair, replace, or adjust, free of charge, any defective Products covered by this warranty which shall be returned with Hypertherms prior authorization (which shall not be unreasonably withheld), properly packed, to Hypertherms place of business in Hanover, New Hampshire, or to an authorized Hypertherm repair facility, all costs, insurance and freight prepaid. Hypertherm shall not be liable for any repairs, replacement, or adjustments of Products covered by this warranty, except those made pursuant to this paragraph or with Hypertherms prior written consent. The warranty above is exclusive and is in lieu of all other warranties, express, implied, statutory, or otherwise with respect to the Products or as to the results which may be obtained therefrom, and all implied warranties or conditions of quality or of merchantability or fitness for a particular purpose or against infringement. The foregoing shall constitute the sole and exclusive remedy for any breach by Hypertherm of its warranty.
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WARRANTY
These differences in national standards may make it impossible or impractical for all certification test marks to be placed on the same version of a product. For example, the CSA versions of Hypertherms products do not comply with European EMC requirements and they do not have a CE marking on the data plate. Countries that require CE marking or have compulsory EMC regulations must use CE versions of Hypertherm products with the CE marking on the data plate. These include: Australia New Zealand Countries in the European Union Russia It is important that the product and its certification test mark be suitable for the end-use installation site. When Hypertherm products are shipped to one country for export to another country, the product must be configured and certified properly for the end-use site.
When external interconnecting cables are subject to continuous movement, constant flexing ratings may be required. It is the responsibility of the end-use customer or the OEM to ensure the cables are suitable for the application. Since there are differences in the ratings and costs that can be required by local regulations for higherlevel systems, it is necessary to verify that any external interconnecting cables are suitable for the end-use installation site.
Patent indemnity
Except only in cases of products not manufactured by Hypertherm or manufactured by a person other than Hypertherm not in strict conformity with Hypertherms specifications and in cases of designs, processes, formulae, or combinations not developed or purported to be developed by Hypertherm, Hypertherm will defend or settle, at its own expense, any suit or proceeding brought against you alleging that the use of the Hypertherm product, alone and not in combination with any other product not supplied by Hypertherm, infringes any patent of any third party. You shall notify Hypertherm promptly upon learning of any action or threatened action in connection with any such alleged infringement, and Hypertherms obligation to indemnify shall be conditioned upon Hypertherms sole control of, and the indemnified partys cooperation and assistance in, the defense of the claim.
Higher-level systems
When a system integrator adds additional equipment; such as cutting tables, motor drives, motion controllers or robots; to a Hypertherm plasma cutting system, the combined system may be considered a higher-level system. A higher-level system with hazardous moving parts may constitute industrial machinery or robotic equipment, in which case the OEM or end-use customer may be subject to additional regulations and standards than those relevant to the plasma cutting system as manufactured by Hypertherm. It is the responsibility of the end-use customer and the OEM to perform a risk assessment for the higher-level system and to provide protection against hazardous moving parts. Unless the higher-level system is certified when the OEM incorporates Hypertherm products into it, the installation also may be subject to approval by local authorities. Seek advice from legal counsel and local regulatory experts if uncertain about compliance. External interconnecting cables between component parts of the higher level system must be suitable for contaminants and movement as required by the final end-use installation site. When the external interconnecting cables are subject to oil, dust, or water contaminants, hard usage ratings may be required.
Limitation of liability
In no event shall Hypertherm be liable to any person or entity for any incidental, consequential, indirect, or punitive damages (including but not limited to lost profits) regardless of whether such liability is based on breach of contract, tort, strict liability, breach of warranties, failure of essential purpose or otherwise and even if advised of the possibility of such damages.
Liability cap
In no event shall Hypertherms liability, 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 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.
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Hypertherm
WARRANTY
Insurance
At all times you will have and maintain insurance in such quantities and types, and with coverage sufficient and appropriate to defend and to hold Hypertherm harmless in the event of any cause of action arising from the use of the Products.
Transfer of rights
You may transfer any remaining rights you may have hereunder only in connection with the sale of all or substantially all of your assets or capital stock to a successor in interest who agrees to be bound by all of the terms and conditions of this Warranty.
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TABLE OF CONTENTS
Electromagnetic Compatibility (EMC)...................................................................................................................................i Warranty.......................................................................................................................................................................................iii Section 1 SAFETY ...............................................................................................................................................................1-1 Recognize safety information ..................................................................................................................................................................1-2 Follow safety instructions.........................................................................................................................................................................1-2 Cutting can cause fire or explosion .......................................................................................................................................................1-2 Electric shock can kill................................................................................................................................................................................1-3 Static electricity can damage circuit boards .......................................................................................................................................1-3 Toxic fumes can cause injury or death ..................................................................................................................................................1-4 A plasma arc can cause injury and burns.............................................................................................................................................1-5 Arc rays can burn eyes and skin.............................................................................................................................................................1-5 Grounding safety .......................................................................................................................................................................................1-6 Compressed gas equipment safety.......................................................................................................................................................1-6 Gas cylinders can explode if damaged.................................................................................................................................................1-6 Noise can damage hearing ......................................................................................................................................................................1-7 Pacemaker and hearing aid operation...................................................................................................................................................1-7 A plasma arc can damage frozen pipes................................................................................................................................................1-7 Additional safety information ...................................................................................................................................................................1-8 Symbols and markings..............................................................................................................................................................................1-8 Warning labels............................................................................................................................................................................................1-9 Dry dust collection information.............................................................................................................................................................1-11 Section 1a SCURIT .....................................................................................................................................................1a-1 Identifier les consignes de scurit.....................................................................................................................................................1a-2 Suivre les instructions de scurit.......................................................................................................................................................1a-2 Le coupage peut provoquer un incendie ou une explosion...........................................................................................................1a-2 Les chocs lectriques peuvent tre fatals .........................................................................................................................................1a-3 Llectricit statique peut endommager les cartes de circuits imprims ....................................................................................1a-3 Les vapeurs toxiques peuvent provoquer des blessures ou la mort............................................................................................1a-4 Larc plasma peut provoquer des blessures ou des brlures........................................................................................................1a-5 Les rayons de larc peuvent brler les yeux et la peau....................................................................................................................1a-5 Mise la masse et la terre..................................................................................................................................................................1a-6 Scurit des bouteilles de gaz comprim..........................................................................................................................................1a-6 Les bouteilles de gaz comprim peuvent exploser en cas de dommages .................................................................................1a-6 Le bruit peut provoquer des problmes auditifs...............................................................................................................................1a-7 Pacemakers et prothses auditives .....................................................................................................................................................1a-7 Un arc plasma peut endommager les tuyaux gels .........................................................................................................................1a-7 Symboles et marquage...........................................................................................................................................................................1a-8 tiquettes de scurit.............................................................................................................................................................................1a-9 Information sur le dpoussirage ......................................................................................................................................................1a-11 Section 1b SEGURIDAD.................................................................................................................................................1b-1 Reconocimiento de informacin de seguridad.................................................................................................................................1b-2 Siga las instrucciones de seguridad...................................................................................................................................................1b-2 Los cortes pueden provocar incendios o explosiones ...................................................................................................................1b-2 El choque elctrico puede provocar la muerte.................................................................................................................................1b-3 Electricidad esttica puede daar tablillas de circuito ...................................................................................................................1b-3
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TABLE OF CONTENTS
Humos txicos pueden causar lesiones o muerte...........................................................................................................................1b-4 El arco de plasma puede causar lesiones y quemaduras..............................................................................................................1b-5 Los rayos del arco pueden producir quemaduras en los ojos y en la piel .................................................................................1b-5 Seguridad de toma a tierra....................................................................................................................................................................1b-6 Seguridad de los equipos de gas comprimido ................................................................................................................................1b-6 Los cilindros de gas pueden explotar si estn daados ................................................................................................................1b-6 El ruido puede deteriorar la audicin ..................................................................................................................................................1b-7 Operacin de marcapasos y de audfonos........................................................................................................................................1b-7 Un arco plasma puede daar tubos congelados .............................................................................................................................1b-7 Smbolos y marcas..................................................................................................................................................................................1b-8 Etiquetas de advertencia .......................................................................................................................................................................1b-9 Informacin sobre la coleccin de polvo seco...............................................................................................................................1b-11 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 228354 ............................................................................................................................................................................2-10 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
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TABLE OF CONTENTS
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 Gas console to off-valve cable ..................................................................................................................................................3-22 Off-valve cable ..............................................................................................................................................................................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 .............................................................................................................................................................................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 Mounting the torch .......................................................................................................................................................................3-36 Torch alignment .............................................................................................................................................................................3-36 Torch lifter requirement ..........................................................................................................................................................................3-36 Power requirements................................................................................................................................................................................3-37 General............................................................................................................................................................................................3-37 Line disconnect switch................................................................................................................................................................3-38 Power cable ...................................................................................................................................................................................3-38 Connect the power .................................................................................................................................................................................3-39 Torch coolant requirements...................................................................................................................................................................3-40 Premixed coolant for standard operating temperatures ......................................................................................................3-40 Custom Coolant mix for cold operating temperatures .........................................................................................................3-41 Custom Coolant mix for hot operating temperatures ...........................................................................................................3-42 Water purity requirements.....................................................................................................................................................................3-42 Fill the power supply with coolant .......................................................................................................................................................3-43 Gas requirements....................................................................................................................................................................................3-44 Setting the supply regulators .....................................................................................................................................................3-44 Gas regulators .........................................................................................................................................................................................3-45 Supply gas plumbing..............................................................................................................................................................................3-46 Connect the supply gases ..........................................................................................................................................................3-47 Supply gas hoses....................................................................................................................................................................................3-48
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TABLE OF CONTENTS
Section 4 OPERATION .......................................................................................................................................................4-1 Daily start-up...............................................................................................................................................................................................4-2 Check torch ......................................................................................................................................................................................4-2 Controls and indicators ............................................................................................................................................................................4-3 General ..............................................................................................................................................................................................4-3 Main power switch ..........................................................................................................................................................................4-3 Power indicators..............................................................................................................................................................................4-3 Manual gas console operation................................................................................................................................................................4-4 Consumable selection ..............................................................................................................................................................................4-5 Standard cutting..............................................................................................................................................................................4-5 Bevel cutting.....................................................................................................................................................................................4-5 Marking ..............................................................................................................................................................................................4-5 Consumables for mirror-image cutting.......................................................................................................................................4-5 SilverPlus electrodes ......................................................................................................................................................................4-5 Mild steel ...........................................................................................................................................................................................4-6 Stainless steel ..................................................................................................................................................................................4-6 Aluminum ...........................................................................................................................................................................................4-7 Mild steel bevel cutting ..................................................................................................................................................................4-8 Stainless steel bevel cutting .........................................................................................................................................................4-8 Install and inspect consumables ............................................................................................................................................................4-9 Torch maintenance ..................................................................................................................................................................................4-11 Torch connections ...................................................................................................................................................................................4-12 Replace torch water tube ......................................................................................................................................................................4-12 Common cutting faults...........................................................................................................................................................................4-13 How to optimize cut quality...................................................................................................................................................................4-14 Tips for table and torch................................................................................................................................................................4-14 Plasma set-up tips........................................................................................................................................................................4-14 Maximize the life of consumable parts .....................................................................................................................................4-14 Additional factors of cut quality .................................................................................................................................................4-15 Additional improvements.............................................................................................................................................................4-16 Cut charts..................................................................................................................................................................................................4-17 Bevel cut charts.............................................................................................................................................................................4-17 Bevel cutting definitions.........................................................................................................................................................................4-18 Estimated kerf width compensation....................................................................................................................................................4-19 Section 5 MAINTENANCE.................................................................................................................................................5-1 Introduction .................................................................................................................................................................................................5-3 Routine maintenance ................................................................................................................................................................................5-3 System description....................................................................................................................................................................................5-4 Control 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 Error code troubleshooting Error codes 000 to 020.....................................................................................................5-11
TABLE OF CONTENTS
Error code troubleshooting Error codes 021 to 028.....................................................................................................5-12 Error code troubleshooting Error codes 030 to 042.....................................................................................................5-13 Error code troubleshooting Error codes 044 to 046 ....................................................................................................5-14 Error code troubleshooting Error codes 047 to 053.....................................................................................................5-15 Error code troubleshooting Error codes 054 to 061.....................................................................................................5-16 Error code troubleshooting Error codes 062 to 067 .....................................................................................................5-17 Error code troubleshooting Error codes 071 to 076 .....................................................................................................5-18 Error code troubleshooting Error codes 093 to 105 .....................................................................................................5-19 Error code troubleshooting Error codes 106 to 123 .....................................................................................................5-20 Error code troubleshooting Error codes 124 to 134.....................................................................................................5-21 Error code troubleshooting Error codes 138 to 143.....................................................................................................5-22 Error code troubleshooting Error codes 144 to 154.....................................................................................................5-23 Error code troubleshooting Error codes 155 to 158.....................................................................................................5-24 Error code troubleshooting Error codes 159 to 160.....................................................................................................5-25 Error code troubleshooting Error codes 180 to 181.....................................................................................................5-26 Power supply states ...............................................................................................................................................................................5-27 Plasma system operation with pump timeout ...................................................................................................................................5-28 CNC operation with pump timeout.....................................................................................................................................................5-29 Initial checks .............................................................................................................................................................................................5-30 Power measurement...............................................................................................................................................................................5-31 Air filter element replacement...............................................................................................................................................................5-32 Power supply coolant system servicing .............................................................................................................................................5-33 Draining the coolant system. ......................................................................................................................................................5-33 Coolant system filter and strainer........................................................................................................................................................5-34 Filter replacement .........................................................................................................................................................................5-34 Pump strainer cleaning................................................................................................................................................................5-34 Coolant flow troubleshooting chart.....................................................................................................................................................5-35 Coolant flow tests ...................................................................................................................................................................................5-36 Before testing ................................................................................................................................................................................5-36 Using the Hypertherm flow meter (128933)..........................................................................................................................5-36 Manual pump operation...............................................................................................................................................................5-37 Test 1 return line .....................................................................................................................................................................5-38 Test 2 supply line at ignition console.................................................................................................................................5-38 Test 3 change the torch ........................................................................................................................................................5-39 Test 4 supply line to the torch receptacle ........................................................................................................................5-39 Test 5 return line from the torch receptacle .....................................................................................................................5-39 Test 6 bucket test at the pump ...........................................................................................................................................5-40 Test 7 bypass the check valve.............................................................................................................................................5-40 Pump and motor troubleshooting..............................................................................................................................................5-41 Testing the flow sensor................................................................................................................................................................5-42 Gas leak tests ..........................................................................................................................................................................................5-43 Power supply control board PCB3.....................................................................................................................................................5-44 Power supply power distribution board PCB2 ................................................................................................................................5-45 Start circuit PCB1 ..................................................................................................................................................................................5-46 Operation........................................................................................................................................................................................5-46 Start circuit functional schematic..............................................................................................................................................5-46
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TABLE OF CONTENTS
Start circuit troubleshooting.......................................................................................................................................................5-46 Pilot arc current levels .................................................................................................................................................................5-48 Gas console control board PCB2 ......................................................................................................................................................5-49 Gas console power distribution board PCB1..................................................................................................................................5-50 Gas console, AC valve-driver board PCB3......................................................................................................................................5-51 Chopper tests ..........................................................................................................................................................................................5-52 Phase-loss detection test......................................................................................................................................................................5-54 Torch lead test..........................................................................................................................................................................................5-55 Preventive maintenance.........................................................................................................................................................................5-56 Section 6 PARTS LIST ........................................................................................................................................................6-1 Power supply ..............................................................................................................................................................................................6-2 Ignition console...........................................................................................................................................................................................6-7 Gas console 1 of 2 ................................................................................................................................................................................6-8 Gas console 2 of 2 ................................................................................................................................................................................6-9 Off-valve.......................................................................................................................................................................................................6-9 HyPerformance torch ..............................................................................................................................................................................6-10 Torch assembly ..............................................................................................................................................................................6-10 Torch leads .....................................................................................................................................................................................6-11 Ohmic contact wire ......................................................................................................................................................................6-11 Consumable parts kit 128878..........................................................................................................................................................6-12 Consumables for mirror-image cutting...............................................................................................................................................6-13 Recommended spare parts...................................................................................................................................................................6-14 Section 7 WIRING DIAGRAMS .......................................................................................................................................7-1 Introduction..................................................................................................................................................................................................7-1 Wiring diagrams .........................................................................................................................................................................................7-5 Appendix A PROPYLENE GLYCOL SAFETY DATA / BENZOTRIAZOLE SAFETY DATA ..................................a-1 Section 1 Chemical Product and Company Identification.........................................................................................................a-2 Section 2 Information on Ingredients ..............................................................................................................................................a-2 Section 3 Hazards Identification ......................................................................................................................................................a-2 Section 4 First Aid Measures............................................................................................................................................................a-3 Section 5 Fire Fighting Measures....................................................................................................................................................a-3 Section 6 Accidental Release Measures .......................................................................................................................................a-3 Section 7 Handling and Storage .....................................................................................................................................................a-3 Section 8 Exposure Controls / Personal Protection....................................................................................................................a-4 Section 9 Physical and Chemical Properties................................................................................................................................a-4 Section 10 Stability and Reactivity.....................................................................................................................................................a-4 Section 11 Toxicological Information .................................................................................................................................................a-4 Section 12 Ecological Information .....................................................................................................................................................a-5 Section 13 Disposal Considerations.................................................................................................................................................a-5 Section 14 Transport Information .......................................................................................................................................................a-5 Section 15 Regulatory Information.....................................................................................................................................................a-5 Section 16 Other Information..............................................................................................................................................................a-5 Freezing Point of Propylene Glycol Solution .......................................................................................................................................a-6
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TABLE OF CONTENTS
Appendix B
Appendix C ROBOTIC APPLICATIONS ..........................................................................................................................c-1 Components for robotic applications....................................................................................................................................................c-2 Torch leads ........................................................................................................................................................................................c-2 Ohmic contact wire.........................................................................................................................................................................c-2 Rotational mounting sleeve (optional).........................................................................................................................................c-3 Leather overwrap .............................................................................................................................................................................c-3 Robotic teaching torch (laser pointer) ........................................................................................................................................c-3
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Section 1 SAFETY
In this section:
Recognize safety information...................................................................................................................................................................1-2 Follow safety instructions .........................................................................................................................................................................1-2 Cutting can cause fire or explosion........................................................................................................................................................1-2 Electric shock can kill ................................................................................................................................................................................1-3 Static electricity can damage circuit boards........................................................................................................................................1-3 Toxic fumes can cause injury or death...................................................................................................................................................1-4 A plasma arc can cause injury and burns .............................................................................................................................................1-5 Arc rays can burn eyes and skin .............................................................................................................................................................1-5 Grounding safety........................................................................................................................................................................................1-6 Compressed gas equipment safety .......................................................................................................................................................1-6 Gas cylinders can explode if damaged .................................................................................................................................................1-6 Noise can damage hearing.......................................................................................................................................................................1-7 Pacemaker and hearing aid operation ...................................................................................................................................................1-7 A plasma arc can damage frozen pipes ................................................................................................................................................1-7 Additional safety information....................................................................................................................................................................1-8 Symbols and markings ..............................................................................................................................................................................1-8 Warning labels ............................................................................................................................................................................................1-9 Dry dust collection information .............................................................................................................................................................1-11
Hypertherm
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SAFETY
DANGER
WARNING
CAUTION
Hypertherm uses American National Standards Institute guidelines for safety signal words and symbols. A signal word DANGER or WARNING is used with a safety symbol. DANGER identifies the most serious hazards. DANGER and WARNING safety labels are located on your machine near specific hazards.
Fire prevention Be sure the area is safe before doing any cutting. Keep a fire extinguisher nearby. Remove all flammables within 35 feet (10 m) of the cutting area. Quench hot metal or allow it to cool before handling or before letting it touch combustible materials. Never cut containers with potentially flammable materials inside they must be emptied and properly cleaned first. Ventilate potentially flammable atmospheres before cutting. When cutting with oxygen as the plasma gas, an exhaust ventilation system is required. Explosion prevention Do not use the plasma system if explosive dust or vapors may be present. Do not cut pressurized cylinders, pipes, or any closed container. Do not cut containers that have held combustible materials.
WARNING Explosion Hazard Argon-Hydrogen and Methane Hydrogen and methane are flammable gases that present an explosion hazard. Keep flames away from cylinders and hoses that contain methane or hydrogen mixtures. Keep flames and sparks away from the torch when using methane or argon-hydrogen plasma.
WARNING Hydrogen Detonation with Aluminum Cutting When cutting aluminum underwater, or with the water touching the underside of the aluminum, free hydrogen gas may collect under the workpiece and detonate during plasma cutting operations. Install an aeration manifold on the floor of the water table to eliminate the possibility of hydrogen detonation. Refer to the Appendix section of this manual for aeration manifold details.
1-2
11/08
Hypertherm
SAFETY
Touching live electrical parts can cause a fatal shock or severe burn. Operating the plasma system completes an electrical circuit between the torch and the workpiece. The workpiece and anything touching the workpiece are part of the electrical circuit. Never touch the torch body, workpiece or the water in a water table when the plasma system is operating. Electric shock prevention All Hypertherm plasma systems use high voltage in the cutting process (200 to 400 VDC are common). Take the following precautions when operating this system: Wear insulated gloves and boots, and keep your body and clothing dry. Do not stand, sit or lie on or touch any wet surface when using the plasma system. Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground. If you must work in or near a damp area, use extreme caution. Provide a disconnect switch close to the power supply with properly sized fuses. This switch allows the operator to turn off the power supply quickly in an emergency situation. When using a water table, be sure that it is correctly connected to earth ground.
Install and ground this equipment according to the instruction manual and in accordance with national and local codes. Inspect the input power cord frequently for damage or cracking of the cover. Replace a damaged power cord immediately. Bare wiring can kill. Inspect and replace any worn or damaged torch leads. Do not pick up the workpiece, including the waste cutoff, while you cut. Leave the workpiece in place or on the workbench with the work cable attached during the cutting process. Before checking, cleaning or changing torch parts, disconnect the main power or unplug the power supply. Never bypass or shortcut the safety interlocks. Before removing any power supply or system enclosure cover, disconnect electrical input power. Wait 5 minutes after disconnecting the main power to allow capacitors to discharge. Never operate the plasma system unless the power supply covers are in place. Exposed power supply connections present a severe electrical hazard. When making input connections, attach proper grounding conductor first. Each Hypertherm plasma system is designed to be used only with specific Hypertherm torches. Do not substitute other torches which could overheat and present a safety hazard.
Store PC boards in anti-static containers. Wear a grounded wrist strap when handling PC boards.
Hypertherm
1-3
11/08
SAFETY
The plasma arc by itself is the heat source used for cutting. Accordingly, although the plasma arc has not been identified as a source of toxic fumes, the material being cut can be a source of toxic fumes or gases that deplete oxygen. Fumes produced vary depending on the metal that is cut. Metals that may release toxic fumes include, but are not limited to, stainless steel, carbon steel, zinc (galvanized), and copper. In some cases, the metal may be coated with a substance that could release toxic fumes. Toxic coatings include, but are not limited to, lead (in some paints), cadmium (in some paints and fillers), and beryllium. Gases produced by plasma cutting vary based on the material to be cut and the method of cutting, but may include ozone, oxides of nitrogen, hexavalent chromium, hydrogen, and other substances if such are contained in or released by the material being cut. Caution should be taken to minimize exposure to fumes produced by any industrial process. Depending upon the chemical composition and concentration of the fumes (as well as other factors, such as ventilation), there may be a risk of physical illness, such as birth defects or cancer. It is the responsibility of the equipment and site owner to test the air quality in the area where the equipment is used and to ensure that the air quality in the workplace meets all local and national standards and regulations. The air quality level in any relevant workplace depends on site-specific variables such as: Table design (wet, dry, underwater). Material composition, surface finish, and composition of coatings.
Volume of material removed. Duration of cutting or gouging. Size, air volume, ventilation and filtration of the work area. Personal protective equipment. Number of welding and cutting systems in operation. Other site processes that may produce fumes. If the workplace must conform to national or local regulations, only monitoring or testing done at the site can determine whether the site is above or below allowable levels. To reduce the risk of exposure to fumes: Remove all coatings and solvents from the metal before cutting. Use local exhaust ventilation to remove fumes from the air. Do not inhale fumes. Wear an air-supplied respirator when cutting any metal coated with, containing, or suspected to contain toxic elements. Assure that those using welding or cutting equipment, as well as air-supplied respiration devices, are qualified and trained in the proper use of such equipment. Never cut containers with potentially toxic materials inside. Empty and properly clean the container first. Monitor or test the air quality at the site as needed. Consult with a local expert to implement a site plan to ensure safe air quality.
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11/08
Hypertherm
SAFETY
Instant-on torches Plasma arc comes on immediately when the torch switch is activated.
The plasma arc will cut quickly through gloves and skin. Keep away from the torch tip. Do not hold metal near the cutting path. Never point the torch toward yourself or others.
Eye protection Plasma arc rays produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Use eye protection in accordance with applicable national or local codes. Wear eye protection (safety glasses or goggles with side shields, and a welding helmet) with appropriate lens shading to protect your eyes from the arcs ultraviolet and infrared rays. Skin protection Wear protective clothing to protect against burns caused by ultraviolet light, sparks, and hot metal. Gauntlet gloves, safety shoes and hat. Flame-retardant clothing to cover all exposed areas. Cuffless trousers to prevent entry of sparks and slag. Remove any combustibles, such as a butane lighter or matches, from your pockets before cutting. Cutting area Prepare the cutting area to reduce reflection and transmission of ultraviolet light: Paint walls and other surfaces with dark colors to reduce reflection. Use protective screens or barriers to protect others from flash and glare. Warn others not to watch the arc. Use placards or signs. Arc current (amps) Less than 40 A 41 to 60 A 61 to 80 A 81 to 125 A 126 to 150 A 151 to 175 A 176 to 250 A 251 to 300 A 301 to 400 A 401 to 800 A Minimum protective Suggested shade shade number number for comfort (ANSI Z49.1:2005) (ANSI Z49.1:2005) 5 6 8 8 8 8 8 8 9 10 5 6 8 9 9 9 9 9 12 14 OSHA 29CFR 1910.133(a)(5) 8 8 8 8 8
8
Europe EN168:2002 9 9 9
9
10 11 12 13 13
8 8 9 10
Hypertherm
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11/08
SAFETY
GROUNDING SAFETY
Work cable Attach the work cable securely to the workpiece or the work table with good metal-to-metal contact. Do not connect it to the piece that will fall away when the cut is complete. Work table Connect the work table to an earth ground, in accordance with appropriate national or local electrical codes.
Input power Be sure to connect the power cord ground wire to the ground in the disconnect box. If installation of the plasma system involves connecting the power cord to the power supply, be sure to connect the power cord ground wire properly. 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.
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11/08
Hypertherm
SAFETY
Prolonged exposure to noise from cutting or gouging can damage hearing. Use approved ear protection when using plasma system. Warn others nearby about the noise hazard.
Keep both the work cable and the torch lead to one side, away from your body. Route the torch leads as close as possible to the 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.
Frozen pipes may be damaged or can burst if you attempt to thaw them with a plasma torch.
Hypertherm
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11/08
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 TV.
CE marking
The CE marking signifies the manufacturers declaration of conformity to applicable European directives 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
CE versions of Hypertherm products with a c-Tick mark comply with the EMC regulations required for sale 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.
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Hypertherm
Read and follow these instructions, employer safety practices, and material safety data sheets. Refer to ANS Z49.1, Safety in Welding, Cutting and Allied Processes from American Welding Society (http://www.aws.org) and OSHA Safety and Health Standards, 29 CFR 1910 (http://www.osha.gov).
WARNING
Plasma cutting can be injurious to operator and persons in the work area. Consult manual before operating. Failure to follow all these safety instructions can result in death. 1. Cutting sparks can cause explosion or fire.
1.1 Do not cut near flammables. 1.2 Have a fire extinguisher nearby and ready to use. 1.3 Do not use a drum or other closed container as a cutting table.
AVERTISSEMENT
Le coupage plasma peut tre prjudiciable pour loprateur et les personnes qui se trouvent sur les lieux de travail. Consulter le manuel avant de faire fonctionner. Le non respect des ces instructions de scurit peut entraner la mort.
2. Plasma arc can injure and burn; point the nozzle away from yourself. Arc starts instantly when triggered.
2.1 Turn off power before disassembling torch. 2.2 Do not grip the workpiece near the cutting path. 2.3 Wear complete body protection.
2. Larc plasma peut blesser et brler; loigner la buse de soi. Il sallume instantanment quand on lamorce;
2.1 Couper lalimentation avant de dmonter la torche. 2.2 Ne pas saisir la pice couper de la trajectoire de coupage. 2.3 Se protger entirement le corps.
Hypertherm
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Hypertherm
SAFETY
Hypertherm
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11/08
Section 1a SCURIT
Hypertherm
1a-1
11/08
SCURIT
DANGER
AVERTISSEMENT
ATTENTION
Hypertherm adopte les lignes directrices de lAmerican National Standards Institute relativement aux termes, aux symboles et la signalisation de scurit. Les signaux DANGER ou AVERTISSEMENT sont utiliss avec un symbole de scurit, DANGER correspondant aux risques les plus srieux. Les tiquettes de scurit DANGER et AVERTISSE MENT sont situes sur la machine pour signaler certains dangers spcifiques. Les messages de scurit DANGER prcdent les directives associes dans le manuel qui, si elles ne sont pas suivies scrupuleusement, entranent des blessures graves voire mortelles. Les messages dAVERTISSEMENT prcdent les instructions dutilisation expliques dans ce manuel et signalent les risques de blessures ou de mort au cas o ces instructions ne seraient pas suivies correctement. Les messages de scurit ATTENTION prcdent les directives associes dans le manuel qui, si elles ne sont pas suivies scrupuleusement, peuvent entraner des blessures secondaires ou endommager lquipement.
AVERTISSEMENT
Risque dexplosion argon-hydrogne et mthane Lhydrogne et le mthane sont des gaz inflammables et potentiellement explosifs. Conserver lcart de toute flamme les bouteilles et tuyaux contenant des mlanges base dhydrogne ou de mthane. Maintenir toute flamme et tincelle lcart de la torche lors de lutilisation dun plasma dargon-hydrogne ou de mthane.
AVERTISSEMENT
Dtonation de lhydrogne lors du coupage de laluminium Lors du coupage de laluminium sous leau, ou si leau touche la partie infrieure de la pice daluminium, de lhydrogne libre peut saccumuler sous la pice couper et dtonner lors du coupage plasma. Installer un collecteur daration au fond de la table eau afin dliminer les risques de dtonation de lhydrogne. Se rfrer lannexe du manuel pour plus de renseignements sur les collecteurs daration.
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Hypertherm
SCURIT
Toucher une pice lectrique sous tension peut provoquer un choc lectrique fatal ou des brlures graves. La mise en fonctionnement du systme plasma ferme un circuit lectrique entre la torche et la pice couper. La pice couper et tout autre lment en contact avec cette pice font partie du circuit lectrique. Ne jamais toucher le corps de la torche, la pice couper ou leau de la table eau pendant le fonctionnement du systme plasma. Prvention des chocs lectriques Tous les systmes plasma Hypertherm utilisent des hautes tensions pour le coupage (souvent de 200 400 V). On doit prendre les prcautions suivantes quand on utilise le systme plasma : Porter des bottes et des gants isolants et garder le corps et les vtements au sec. Ne pas se tenir, sasseoir ou se coucher sur une surface mouille, ni la toucher quand on utilise le systme plasma. Sisoler de la surface de travail et du sol en utilisant des tapis isolants secs ou des couvertures assez grandes pour viter tout contact physique avec le travail ou le sol. Sil savre ncessaire de travailler dans ou prs dun endroit humide, procder avec une extrme prudence. Installer un sectionneur avec fusibles appropris, proximit de la source de courant. Ce dispositif permet loprateur darrter rapidement la source de courant en cas durgence. En cas dutilisation dune table eau, sassurer que cette dernire est correctement mise la terre. Installer et mettre la terre lquipement selon les instructions du prsent manuel et conformment aux codes lectriques locaux et nationaux.
Inspecter frquemment le cordon dalimentation primaire pour sassurer quil nest ni endommag, ni fendu. Remplacer immdiatement un cordon endommag. Un cble dnud peut tuer. Inspecter et remplacer les cbles de la torche qui sont uss ou endommags. Ne pas saisir la pice couper ni les chutes lors du coupage. Laisser la pice couper en place ou sur la table de travail, le cble de retour connect lors du coupage. Avant de vrifier, de nettoyer ou de remplacer les pices de la torche, couper lalimentation ou dbrancher la prise de courant. Ne jamais contourner ou court-circuiter les verrouillages de scurit. Avant denlever le capot du systme ou de la source de courant, couper lalimentation lectrique. Attendre ensuite 5 minutes pour que les condensateurs se dchargent. Ne jamais faire fonctionner le systme plasma sans que les capots de la source de courant ne soient en place. Les raccords exposs de la source de courant sont extrmement dangereux. Lors de linstallation des connexions, attacher tout dabord la prise de terre approprie. Chaque systme plasma Hypertherm est conu pour tre utilis uniquement avec des torches Hypertherm spcifiques. Ne pas utiliser des torches inappropries qui pourraient surchauffer et prsenter des risques pour la scurit.
Hypertherm
1a-3
11/08
SCURIT
1a-4
11/08
Hypertherm
SCURIT
Torches allumage instantan Larc plasma sallume immdiatement aprs que la torche soit mise en marche.
Larc plasma coupe facilement les gants et la peau. Rester loign de lextrmit de la torche. Ne pas tenir de mtal prs de la trajectoire de coupe. Ne jamais pointer la torche vers soi ou dautres personnes.
Protection des yeux Les rayons de larc plasma produisent de puissants rayons visibles ou invisibles (ultraviolets et infrarouges) qui peuvent brler les yeux et la peau. Utiliser des lunettes de scurit conformment aux codes locaux ou nationaux en vigueur. Porter des lunettes de protection (lunettes ou masque muni dcrans latraux et encore masque de soudure) avec des verres teints appropris pour protger les yeux des rayons ultraviolets et infrarouges de larc. Protection de la peau Porter des vtements de scurit pour se protger contre les brlures que peuvent causer les rayons ultraviolets, les tincelles et le mtal brlant : Gants crispin, chaussures et casque de scurit. Vtements ignifuges couvrant toutes les parties exposes du corps. Pantalon sans revers pour viter que des tincelles ou des scories puissent sy loger. Avant le coupage, retirer de ses poches tout objet combustible comme les briquets au butane ou les allumettes. Zone de coupage Prparer la zone de coupage afin de rduire la rverbration et la transmission de la lumire ultraviolette : Peindre les murs et autres surfaces de couleur sombre pour rduire la rflexion de la lumire. Utiliser des crans et autres dispositifs de protection afin de protger les autres personnes de la lumire et de la rverbration. Prvenir les autres personnes de ne pas regarder larc. Utiliser des affiches ou des panneaux. Indice de protection minimum (ANSI Z49.1:2005) 5 6 8 8 8 8 8 8 9 10 Indice de protection suggr pour assurer le confort (ANSI Z49.1:2005) 5 6 8 9 9 9 9 9 12 14
Courant de larc (A) Moins de 40 A 41 60 A 61 80 A 81 125 A 126 150 A 151 175 A 176 250 A 251 300 A 301 400 A 401 800 A
Europe EN168:2002 9 9 9
9
10 11 12 13 13
8 8 9 10
Hypertherm
1a-5
11/08
SCURIT
Cble de retour Bien fixer le cble de retour (ou de masse) la pice couper ou la table de travail de faon assurer un bon contact mtal-mtal. Ne pas fixer le cble de retour la partie de la pice qui doit se dtacher. Table de travail Raccorder la table de travail la terre, conformment aux codes de scurit locaux ou nationaux appropris.
Alimentation Sassurer que le fil de terre du cordon dalimentation est connect la terre dans le coffret du sectionneur. Sil est ncessaire de brancher le cordon dalimentation la source de courant lors de linstallation du systme, sassurer que le fil de terre est correctement branch. Placer tout dabord le fil de terre du cordon dalimentation sur le plot de mise la terre puis placer les autres fils de terre par-dessus. Bien serrer lcrou de retenue. Sassurer que toutes les connexions sont bien serres pour viter la surchauffe.
1a-6
11/08
Hypertherm
SCURIT
Les champs magntiques produits par les courants haute tension peuvent affecter le fonctionnement des prothses auditives et des pacemakers. Les personnes portant ce type dappareil doivent consulter un mdecin avant de sapprocher dun lieu o seffectue le coupage ou le gougeage plasma. Pour rduire les risques associs aux champs magntiques :
Garder loin de soi et du mme ct du corps le cble de retour et le faisceau de la torche. Faire passer le faisceau de la torche le plus prs possible du cble de retour. Ne pas senrouler le faisceau de la torche ou le cble de retour autour du corps. Se tenir le plus loin possible de la source de courant.
Hypertherm
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Symbole marque S
Le symbole de marque S indique que la source de courant et la torche conviennent pour les travaux effectus dans les milieux risque accru de choc lectrique selon lIEC 60974-1.
Marque CSA
Les produits Hypertherm comportant la marque CSA rpondent aux rglements des tats-Unis et du Canada relatifs la scurit du produit. Les produits sont valus, mis lessai et certifis par la CSA-International. En outre, le produit peut porter une marque dun des laboratoires dessai reconnus sur le plan national (NRTL) accrdit aux tats-Unis et au Canada comme les Underwriters Laboratories, Incorporated (UL) ou TV.
Marque CE
La marque CE signifie la dclaration de conformit du fabricant aux directives et normes europennes applicables. Seules les versions des produits Hypertherm portant la marque CE place sur la plaque signaltique ou proximit ont t mises lessai de conformit la directive europenne sur la basse tension et la compatibilit lectromagntique europenne (CEM). Les filtres CEM qui doivent se conformer la directive CEM europenne sont intgrs aux versions du produit portant la marque CE.
Marque GOST-R
Les versions CE des produits Hypertherm qui portent la marque de conformit GOST-R rpondent aux exigences de scurit du produit et de CEM en vue de lexportation la Fdration russe.
Marque c-Tick
Les versions CE des produits Hypertherm portant la marque c-Tick sont conformes aux rglements CEM prescrits pour la vente en Australie et en Nouvelle-Zlande.
Marque CCC
La marque de certification obligatoire en Chine (CCC) indique que le produit a t mis lessai et dclar conforme aux rglements de scurit du produit prescrits pour la vente en Chine.
1a-8
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Hypertherm
Read and follow these instructions, employer safety practices, and material safety data sheets. Refer to ANS Z49.1, Safety in Welding, Cutting and Allied Processes from American Welding Society (http://www.aws.org) and OSHA Safety and Health Standards, 29 CFR 1910 (http://www.osha.gov).
WARNING
Plasma cutting can be injurious to operator and persons in the work area. Consult manual before operating. Failure to follow all these safety instructions can result in death. 1. Cutting sparks can cause explosion or fire.
1.1 Do not cut near flammables. 1.2 Have a fire extinguisher nearby and ready to use. 1.3 Do not use a drum or other closed container as a cutting table.
AVERTISSEMENT
Le coupage plasma peut tre prjudiciable pour loprateur et les personnes qui se trouvent sur les lieux de travail. Consulter le manuel avant de faire fonctionner. Le non respect des ces instructions de scurit peut entraner la mort.
2. Plasma arc can injure and burn; point the nozzle away from yourself. Arc starts instantly when triggered.
2.1 Turn off power before disassembling torch. 2.2 Do not grip the workpiece near the cutting path. 2.3 Wear complete body protection.
2. Larc plasma peut blesser et brler; loigner la buse de soi. Il sallume instantanment quand on lamorce;
2.1 Couper lalimentation avant de dmonter la torche. 2.2 Ne pas saisir la pice couper de la trajectoire de coupage. 2.3 Se protger entirement le corps.
Hypertherm
1a-9
11/08
1.1 Ne pas couper prs des matires inflammables. 1.2 Un extincteur doit tre proximit et prt tre utilis. 1.3 Ne pas utiliser un ft ou un autre contenant ferm comme table de coupage. 2. Larc plasma peut blesser et brler; loigner la buse de soi. Il sallume instantanment quand on lamorce;
2.1 Couper lalimentation avant de dmonter la torche. 2.2 Ne pas saisir la pice couper de la trajectoire de coupage. 2.3 Se protger entirement le corps. 3. Tension dangereuse. Risque de choc lectrique ou de brlure.
3.1 Porter des gants isolants. Remplacer les gants quand ils sont humides ou endommags. 3.2 Se protger contre les chocs en sisolant de la pice et de la terre. 3.3 Couper lalimentation avant lentretien. Ne pas toucher les pices sous tension 4. Les fumes plasma peuvent tre dangereuses.
4.1 Ne pas inhaler les fumes. 4.2 Utiliser une ventilation force ou un extracteur local pour dissiper les fumes. 4.3 Ne pas couper dans des espaces clos. Chasser les fumes par ventilation. 5. Les rayons darc peuvent brler les yeux et blesser la peau.
5.1 Porter un bon quipement de protection pour se protger la tte, les yeux, les oreilles, les mains et le corps. Boutonner le col de la chemise. Protger les oreilles contre le bruit. Utiliser un masque de soudeur avec un filtre de nuance approprie. 6. Suivre une formation. Seul le personnel qualifi a le droit de faire fonctionner cet quipement. Utiliser exclusivement les torches indiques dans le manual. Le personnel non qualifi et les enfants doivent se tenir lcart. Ne pas enlever, dtruire ni couvrir cette tiquette. La remplacer si elle est absente, endommage ou use (PN 110584 Rev C).
7.
1a-10
11/08
Hypertherm
SCURIT
Hypertherm
1a-11
11/08
Seccon 1b SEGURIDAD
En esta seccin:
Reconocimiento de informacin de seguridad .................................................................................................................................1b-2 Siga las instrucciones de seguridad ...................................................................................................................................................1b-2 Los cortes pueden provocar incendios o explosiones....................................................................................................................1b-2 El choque elctrico puede provocar la muerte .................................................................................................................................1b-3 Electricidad esttica puede daar tablillas de circuito....................................................................................................................1b-3 Humos txicos pueden causar lesiones o muerte ...........................................................................................................................1b-4 El arco de plasma puede causar lesiones y quemaduras ..............................................................................................................1b-5 Los rayos del arco pueden producir quemaduras en los ojos y en la piel .................................................................................1b-5 Seguridad de toma a tierra ....................................................................................................................................................................1b-6 Seguridad de los equipos de gas comprimido .................................................................................................................................1b-6 Los cilindros de gas pueden explotar si estn daados.................................................................................................................1b-6 El ruido puede deteriorar la audicin...................................................................................................................................................1b-7 Operacin de marcapasos y de audfonos ........................................................................................................................................1b-7 Un arco plasma puede daar tubos congelados..............................................................................................................................1b-7 Smbolos y marcas ..................................................................................................................................................................................1b-8 Etiquetas de advertencia........................................................................................................................................................................1b-9 Informacin sobre la coleccin de polvo seco ...............................................................................................................................1b-11
Hypertherm
1b-1
11/08
SEGURIDAD
PELIGRO
ADVERTENCIA
PRECAUCIN
Hypertherm usa las directivas del Instituto Americano de Normas Nacionales (American National Standards Institute) para las palabras y smbolos que sealan seguridad. Las palabras PELIGRO y ADVERTENCIA se utilizan conjuntamente con un smbolo de seguridad. La palabra PELIGRO se utiliza para identificar los mayores peligros. Encontrar etiquetas de seguridad con las inscripciones PELIGRO y ADVERTENCIA en su mquina, junto a peligros especficos. Los mensajes de seguridad de PELIGRO preceden instrucciones relacionadas en el manual que resultarn en lesin grave o muerte si no se las sigue correctamente. En este manual, la palabra ADVERTENCIA va seguida de instrucciones que, si no se siguen correctamente, pueden provocar lesiones e inclusive la muerte. Los mensajes de seguridad de CUIDADO o PRECAUCIN preceden mensajes relacionados con instrucciones en el manual que puede resultar en lesiones menores, o dao a equipo, si no se siguen correctamente.
Prevencin ante el fuego Asegrese de que el rea sea segura antes de proceder a cortar. Tenga a mano un extinguidor de incendios. Retire todos los materiales inflamables, colocndolos a por lo menos 10 metros del rea de corte. Remoje los metales calientes o permita que se enfren antes de que entren en contacto con materiales combustibles. Nunca corte depsitos que contengan materiales inflamables primero es necesario vaciarlos y limpiarlos debidamente. Antes de realizar cortes en atmsferas potencialmente inflamables, asegrese de ventilar bien. Al realizar cortes utilizando oxgeno como gas plasma, se requiere tener un sistema de ventilacin de escape. Prevencin ante explosiones No corte en atmsferas que contengan polvo o vapores explosivos. No corte depsitos o tubos a presin ni cualquier depsito cerrado. No corte depsitos que hayan contenido materiales combustibles.
ADVERTENCIA
Peligro de explosin Argn-Hidrgeno y metano El hidrgeno y el metano son gases inflamables que suponen un peligro de explosin. Mantenga el fuego lejos de los cilindros y las mangueras que contengan mezclas de hidrgeno o metano. Mantenga la llama y las chispas lejos de la antorcha al utilizar metano o argn-hidrgeno como plasma.
ADVERTENCIA
Detonacin de hidrgeno con el corte de aluminio Al cortar aluminio bajo agua o con agua en contacto con el lado inferior del aluminio, puede acumularse gas hidrgeno bajo la pieza a cortar y detonar durante la operacin de corte por plasma. Instale un mltiple de aireacin en el fondo de la mesa de agua para eliminar la posibilidad de la detonacin del hidrgeno. Consulte la seccin del apndice de este manual para conocer detalles acerca del mltiple de aireacin.
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SEGURIDAD
El contacto directo con piezas elctricas conectadas puede provocar un electrochoque fatal o quemaduras graves. Al hacer funcionar el sistema de plasma, se completa un circuito elctrico entre la antorcha y la pieza a cortar. La pieza a cortar es una parte del circuito elctrico, como tambin cualquier cosa que se encuentre en contacto con ella. Nunca toque el cuerpo de la antorcha, la pieza a cortar o el agua en una mesa de agua cuando el sistema de plasma se encuentre en funcionamiento. Prevencin ante el electrochoque Todos los sistemas por plasma de Hypertherm usan alto voltaje en el proceso de corte (son comunes los voltajes CD de 200 a 400). Tome las siguientes precauciones cuando se utiliza el equipo de plasma: Use guantes y botas aislantes y mantenga el cuerpo y la ropa secos. No se siente, se pare o se ponga sobre cualquier superficie hmeda cuando est trabajando con el equipo. Aslese elctricamente de la pieza a cortar y de la tierra utilizando alfombrillas o cubiertas de aislamiento secas lo suficientemente grandes como para impedir todo contacto fsico con la pieza a cortar o con la tierra. Si su nica opcin es trabajar en una rea hmeda o cerca de ella, sea muy cauteloso. Instale un interruptor de corriente adecuado en cuanto a fusibles, en una pared cercana a la fuente de energa. Este interruptor permitir al operador desconectar rpidamente la fuente de energa en caso de emergencia. Al utilizar una mesa de agua, asegrese de que sta se encuentre correctamente conectada a la toma a tierra.
Instale este equipo y conctelo a tierra segn el manual de instrucciones y de conformidad con los cdigos locales y nacionales. Inspeccione el cordn de alimentacin primaria con frecuencia para asegurarse de que no est daado ni agrietado. Si el cordn de alimentacin primaria est daado, reemplcelo inmediatamente. Un cable pelado puede provocar la muerte. Inspeccione las mangueras de la antorcha y reemplcelas cuando se encuentren daadas. No toque la pieza ni los recortes cuando se est cortando. Deje la pieza en su lugar o sobre la mesa de trabajo con el cable de trabajo conectado en todo momento. Antes de inspeccionar, limpiar o cambiar las piezas de la antorcha, desconecte la potencia primaria o desenchufe la fuente de energa. Nunca evite o descuide los bloqueos de seguridad. Antes de retirar la cubierta de una fuente de energa o del gabinete de un sistema, desconecte la potencia primaria de entrada. Espere 5 minutos despus de desconectar la potencia primaria para permitir la descarga de los condensadores. Nunca opere el sistema de plasma sin que las tapas de la fuente de energa estn en su lugar. Las conexiones expuestas de la fuente de energa presentan un serio riesgo elctrico. Al hacer conexiones de entrada, conecte el conductor de conexin a tierra en primer lugar. Cada sistema de plasma Hypertherm est diseado para ser utilizado slo con antorchas Hypertherm especficas. No utilice antorchas diferentes, que podran recalentarse y ser peligrosas.
Almacene las tablillas PC en recipientes antiestticos. Use la defensa de mueca conectada a tierra cuando maneje tablillas PC.
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SEGURIDAD
El arco plasma es por si solo la fuente de calor que se usa para cortar. Segn esto, aunque el arco de plasma no ha sido identificado como la fuente de humo txico, el material que se corta puede ser la fuente de humo o gases txicos que vacan el oxgeno. El humo producido vara segn el metal que est cortndose. Metales que pueden liberar humo txico incluyen, pero no estn limitados a, acero inoxidable, acero al carbn, cinc (galvanizado), y cobre. En algunos casos, el metal puede estar recubierto con una sustancia que podra liberar humos txicos. Los recubrimientos txicos incluyen, pero no estn limitados a, plomo (en algunas pinturas), cadmio (en algunas pinturas y rellenos), y berilio. Los gases producidos por el corte por plasma varan basndose en el material a cortarse y el mtodo de cortar, pero pueden incluir ozono, xidos de nitrgeno, cromo hexavalente, hidrgeno, y otras substancias, si estn contenidas dentro o liberadas por el material que se corta. Se debe tener cuidado de minimizar la exposicin del humo producido por cualquier proceso industrial. Segn la composicin qumica y la concentracin del humo (al igual que otros factores, tales como ventilacin), puede haber el riesgo de enfermedad fsica, tal como defectos de natividad o cncer. Es la responsabilidad del dueo del equipo y instalacin el comprobar la calidad de aire en el lugar donde se est usando el equipo para garantizar que la calidad del aire en el lugar de trabajo cumpla con todas las normas y reglamentos locales y nacionales. El nivel de la calidad del aire en cualquier lugar de trabajo relevante depende en variables especficas al sitio tales como: Diseo de mesa (mojada, seca, bajo agua). La composicin del material, el acabado de la superficie, y la composicin de los recubrimientos. Volumen que se quita del material.
La duracin del corte o ranura. Tamao, volumen del aire, ventilacin y filtracin del lugar de trabajo. Equipo de proteccin personal. Nmero de sistemas de soldar y cortar en la operacin. Otros procesos del lugar que pueden producir humo. Si el lugar de trabajo debe cumplir reglamentos nacionales o locales, solamente el monitoreo o las pruebas que se hacen en el lugar pueden determinar si el sitio est encima o debajo de los niveles permitidos. Para reducir el riesgo de exposicin a humo: Quite todos los recubrimientos y solventes del metal antes de cortar. Use ventilacin extractora local para quitar humo del aire. No inhale el humo. Use un respirador con fuente propia de aire cuando corte cualquier metal recubierto con, o sospechado de contener, elementos txicos. Garantice que aqullos usando equipo de soldar o cortar, al igual que aparatos de respiracin con aire propio de aire, estn capacitados y entrenados en el uso apropiado de tal equipo. Nunca corte recipientes con materiales potencialmente txicos adentro. Primero, vace y limpie el recipiente adecuadamente. Monitoree o compruebe la calidad del aire en el sitio como fuera necesario. Consulte con un experto local para realizar un plan al sitio para garantizar la calidad de aire seguro.
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SEGURIDAD
Antorchas de encendido instantneo El arco de plasma se enciende inmediatamente despus de activarse el interruptor de la antorcha.
El arco de plasma puede cortar a travs de guantes y de la piel con rapidez. Mantngase alejado de la punta de la antorcha. No sostenga el metal junto al trayecto de corte. Nunca apunte la antorcha hacia Ud. mismo o hacia otras personas.
LOS RAYOS DEL ARCO PUEDEN PRODUCIR QUEMADURAS EN LOS OJOS Y EN LA PIEL
Proteccin para los ojos Los rayos del arco de plasma producen rayos intensos visibles e invisibles (ultravioleta e infrarrojo) que pueden quemar los ojos y la piel. Utilice proteccin para los ojos de conformidad con los cdigos locales o nacionales aplicables. Colquese protectores para los ojos (gafas o anteojos protectores con protectores laterales, y bien un casco de soldar) con lentes con sombreado adecuado para proteger sus ojos de los rayos ultravioleta e infrarrojos del arco. Proteccin para la piel Vista ropa de proteccin para proteger la piel contra quemaduras causadas por la radiacin ultravioleta de alta intensidad, por las chispas y por el metal caliente: Guantes largos, zapatos de seguridad y gorro. Roipa de combustin retardada y que cubra todas las partes expuestas. Pantalones sin dobladillos para impedir que recojan chispas y escorias. Retire todo material combustible de los bolsillos, como encendedores a butano e inclusive cerillas, antes de comenzar a cortar. rea de corte Prepare el rea de corte para reducir la reflexin y la transmisin de la luz ultravioleta: Pinte las paredes y dems superficies con colores oscuros para reducir la reflexin. Utilice pantallas o barreras protectoras para proteger a los dems de los destellos. Advierta a los dems que no debe mirarse el arco. Utilice carteles o letreros. El nmero de matiz protector mnimo (ANSI Z49.1:2005) 5 6 8 8 8 8 8 8 9 10 El nmero de matiz sugerido para comodidad (ANSI Z49.1:2005) 5 6 8 9 9 9 9 9 12 14
Corriente de arco (amps.) Menos de 40 A 41 a 60 A 61 a 80 A 81 a 125 A 126 a 150 A 151 a 175 A 176 a 250 A 251 a 300 A 301 a 400 A 401 a 800 A
Europa EN168:2002 9 9 9
9
10 11 12 13 13
8 8 9 10
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SEGURIDAD
Cable de trabajo La pinza del cable de trabajo debe estar bien sujetada a la pieza y hacer un buen contacto de metal a metal con ella o bien con la mesa de trabajo. No conecte el cable con la parte que va a quedar separada por el corte. Mesa de trabajo Conecte la mesa de trabajo a una buena toma de tierra, de conformidad con los cdigos elctricos nacionales o locales apropiados.
Potencia primaria de entrada Asegrese de que el alambre de toma a tierra del cordn de alimentacin est conectado al terminal de tierra en la caja del interruptor de corriente. Si la instalacin del sistema de plasma supone la conexin del cordn de alimentacin primaria a la fuente de energa, asegrese de conectar correctamente el alambre de toma a tierra del cordn de alimentacin primaria. Coloque en primer lugar el alambre de toma a tierra del cordn de alimentacin primaria en el esprrago luego coloque cualquier otro alambre de tierra sobre el conductor de tierra del cable. Ajuste firmemente la tuerca de retencin. Asegrese de que todas las conexiones elctricas estn firmemente realizadas para evitar sobrecalentamientos.
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SEGURIDAD
Los campos magnticos producidos por las elevadas corrientes pueden afectar la operacin de marcapasos y de audfonos. Las personas que lleven marcapasos y audfonos debern consultar a un mdico antes de acercarse a sitios donde se realizan operaciones de corte y ranurado por plasma. Para reducir los peligros de los campos magnticos:
Mantenga el cable de trabajo y la manguera de la antorcha a un lado, lejos del cuerpo. Dirija la manguera antorcha lo ms cerca posible del cable de trabajo. No envuelva el cable de trabajo ni la manguera de la antorcha en su cuerpo. Mantngase tan lejos de la fuente de energa como sea posible.
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Smbolo de marca S
El smbolo de marca S indica que la fuente de energa y antorcha son aptas para operaciones que se llevan a cabo en entornos con peligro aumentado de choque o descarga elctrica segn IEC 60974-1.
Marca CSA
Los productos de Hypertherm con la marca CSA cumplen con los reglamentos de Estados Unidos y Canad para la seguridad del producto. Estos productos fueron evaluados, comprobados, y certificados por CSA-Internacional. Alternativamente, el producto puede tener la marca segn uno de los otros Laboratorios de Prueba Reconocidos nacionalmente (NRTL siglas en ingls) acreditados en ambos Estados Unidos y Canad, tales como Underwriters Laboratories, Incorporated (UL) TV.
Marcas CE
Las marcas CE significan una declaracin del fabricante de conformidad a las directivas y estndares aplicables Europeos. Slo aquellas versiones del producto Hypertherm con la marca CE ubicada en o cerca de la placa de datos han sido comprobadas para cumplir con la Directiva Europea de Voltaje Bajo, la Compatibilidad Electromagntico Europea (EMC). Los filtros EMC que necesitan cumplir con la Directiva Europea EMC estn incorporados dentro de las versiones del producto con la marca CE.
Marca GOST-R
Las versiones de los productos Hypertherm CE que incluye la marca de conformidad GOST-R cumplen con la seguridad del productos y los requisitos EMC para exportarse a la Federacin Rusa.
Marca c-Tick
Las versiones CE de los productos Hypertherm con la marca c-Tick cumple con los reglamentos EMC requeridos para venta en Australia y Nueva Zelandia.
Marca CCC
La marca de Certificacin Obligatoria China (CCC en ingls) indica que el producto ha sido comprobado y se lo ha encontrado que cumple con los reglamentos de seguridad del producto requeridos para venta en China.
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Read and follow these instructions, employer safety practices, and material safety data sheets. Refer to ANS Z49.1, Safety in Welding, Cutting and Allied Processes from American Welding Society (http://www.aws.org) and OSHA Safety and Health Standards, 29 CFR 1910 (http://www.osha.gov).
WARNING
Plasma cutting can be injurious to operator and persons in the work area. Consult manual before operating. Failure to follow all these safety instructions can result in death. 1. Cutting sparks can cause explosion or fire.
1.1 Do not cut near flammables. 1.2 Have a fire extinguisher nearby and ready to use. 1.3 Do not use a drum or other closed container as a cutting table.
AVERTISSEMENT
Le coupage plasma peut tre prjudiciable pour loprateur et les personnes qui se trouvent sur les lieux de travail. Consulter le manuel avant de faire fonctionner. Le non respect des ces instructions de scurit peut entraner la mort.
2. Plasma arc can injure and burn; point the nozzle away from yourself. Arc starts instantly when triggered.
2.1 Turn off power before disassembling torch. 2.2 Do not grip the workpiece near the cutting path. 2.3 Wear complete body protection.
2. Larc plasma peut blesser et brler; loigner la buse de soi. Il sallume instantanment quand on lamorce;
2.1 Couper lalimentation avant de dmonter la torche. 2.2 Ne pas saisir la pice couper de la trajectoire de coupage. 2.3 Se protger entirement le corps.
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1.1 Mantenga los materiales inflamables lejos del lugar de corte. 1.2 Tenga a mano un extinguidor de incendios y asegrese de que alguien est preparado para utilizarlo. 1.3 No corte depsitos cerrados. 2. El arco de plasma puede causar quemaduras y lesiones.
2.1 Apague la fuente de energa antes de desarmar la antorcha. 2.2 No sostenga el material junto al trayecto de corte. 2.3 Proteja su cuerpo completamente. 3. Los electrochoques provocados por la antorcha o el cableado pueden ser fatales. Protjase del electrochoque.
3.1 Colquese guantes aislantes. No utilice guantes daados o mojados. 3.2 Aslese de la pieza de trabajo y de la tierra. 3.3 Antes de trabajar en una mquina, desconecte el enchufe de entrada o la potencia primaria. 4. La inhalacin de los humos provenientes del rea de corte puede ser nociva para la salud.
4.1 Mantenga la cabeza fuera de los gases txicos. 4.2 Utilice ventilacin forzada o un sistema local de escape para eliminar los humos. 4.3 Utilice un ventilador para eliminar los humos. 5. Los rayos del arco pueden producir quemaduras en los ojos y en la piel.
5.1 Utilice un sombrero y gafas de seguridad. Utilice proteccin para los odos y abrchese el botn del cuello de la camisa. Utilice un casco de soldar con el filtro de sombreado adecuado. Proteja su cuerpo completamente. 6. Antes de trabajar en la mquina o de proceder a cortar, capactese y lea las instrucciones completamente. No retire las etiquetas de advertencia ni las cubra con pintura.
7.
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SEGURIDAD
Hypertherm
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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 228520.............................................................................................................................................................................2-10
2-1
SPECIFICATIONS
2-2
SPECIFICATIONS
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 130-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 highvoltage, 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 torch can cut 12 mm mild steel at up to 2032 mm/min (1/2 in at up to 80 ipm). The maximum production cutting capability of the torch is 16 mm (5/8 in) for HyDefinition and conventional cutting. Maximum pierce capability is 32 mm (1.25 in) for mild steel and 19 mm (3/4 in) for stainless steel and aluminum. The maximum severance capability is 38 mm (1.5 in) for mild steel and 25 mm (1 in) for stainless steel and aluminum.
2-3
SPECIFICATIONS
Specifications
System gas requirements
Gas quality and pressure requirements Gas type O2 oxygen* N2 nitrogen* Air* H35 argon-hydrogen F5 nitrogen-hydrogen Ar argon Quality 99.5% pure Clean, dry, oil-free 99.99% pure Clean, dry, oil-free ** Clean, dry, oil-free per ISO 8573-1 Class 1.4.2 99.995% pure (H35 = 65% Argon, 35% Hydrogen) 99.98% pure (F5 = 95% Nitrogen, 5% Hydrogen) 99.99% pure Clean, dry, oil-free Pressure +/- 10% 793 kPa / 8 bar 115 psi 793 kPa / 8 bar 115 psi 793 kPa / 8 bar 115 psi 793 kPa / 8 bar 115 psi 793 kPa / 8 bar 115 psi 793 kPa / 8 bar 115 psi Flow rate 4250 l/h 150 scfh 7080 l/h 250 scfh 7080 l/h 250 scfh 4250 l/h 150 scfh 4250 l/h 150 scfh
* Oxygen, nitrogen, and air are required for all systems. Nitrogen is used as a purge gas. ** ISO standard 8573-1 Class 1.4.2 requirements are: Particulates no more than 100 particles per cubic meter of air at a Size of 0.1 to 0.5 microns in the largest dimension and 1 particle per cubic meter of air at a Size of 0.5 to 5.0 microns in the largest dimension. Water the pressure dewpoint of the humidity must be less than or equal to 3 C (37.4 F). Oil the concentration of oil can be no more than 0.1 mg per cubic meter of air.
Mild steel
Stainless steel
Aluminum
Plasma O2 O2 O2
Shield N2 N2 N2
2-4
1079.5 mm 42.5"
154.9 mm 6.1"
566.4 mm 22.3"
2-5
219 mm 8.625"
283 mm 11.125"
194 mm 7.625"
9.1 kg 20 lb
216 mm 8.5"
152 mm 6"
2-6
SPECIFICATIONS
LHF mounting (local)
Horizontal mounting
Vertical mounting
2-7
292 mm 11.5"
359 mm 14.125"
317 mm 12.5"
14 kg 31 lb
276 mm 10.88"
178 mm 7"
2-8
A
70 mm 2.75"
19 mm 0.75"
157 mm 6.18"
1.1 kg 2.5 lb
165 mm 6.5"
A-A
2-9
1.8 m 6'
193 mm 7.59"
51 mm 2.00" 95 mm 3.74"
51 mm 57 mm 2.25" 2"
43 345 mm 13.60"
1.9 kg 4.2 lb
2-10
Section 3 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 Gas console to off-valve cable ..................................................................................................................................................3-22 Off-valve cable ..............................................................................................................................................................................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
3-1
INSTALLATION
Examples of output circuits ........................................................................................................................................................3-26 Examples of input circuits ...........................................................................................................................................................3-27 Remote on/off switch .............................................................................................................................................................................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 Mounting the torch .......................................................................................................................................................................3-36 Torch alignment .............................................................................................................................................................................3-36 Torch lifter requirement ..........................................................................................................................................................................3-36 Power requirements................................................................................................................................................................................3-37 General............................................................................................................................................................................................3-37 Line disconnect switch................................................................................................................................................................3-38 Power cable ...................................................................................................................................................................................3-38 Connect the power .................................................................................................................................................................................3-39 Torch coolant requirements...................................................................................................................................................................3-40 Premixed coolant for standard operating temperatures ......................................................................................................3-40 Custom Coolant mix for cold operating temperatures .........................................................................................................3-41 Custom Coolant mix for hot operating temperatures ...........................................................................................................3-42 Water purity requirements.....................................................................................................................................................................3-42 Fill the power supply with coolant .......................................................................................................................................................3-43 Gas requirements....................................................................................................................................................................................3-44 Setting the supply regulators .....................................................................................................................................................3-44 Gas regulators .........................................................................................................................................................................................3-45 Supply gas plumbing..............................................................................................................................................................................3-46 Connect the supply gases ..........................................................................................................................................................3-47 Supply gas hoses....................................................................................................................................................................................3-48
3-2
INSTALLATION
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 back 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. See also Noise can damage hearing in the Safety section of this manual. Data was taken while cutting at 130 A using an O2/Air process on a dry cutting table. The decibel readings at 12 m (39.4 ft) from the front of torch, 1.4 m (4.6 ft) from the floor and 0.34 m (1.12 ft) above the arc are: 119.2 Max Level, dBC (MaxP) and 99.6 Lav5, dBA.
Torque specifications
Gas or water hose size Up to 10 mm (3/8") 12 mm (1/2")
2WRENCHES
3-3
INSTALLATION
Installation requirements
16
2 4 1 3
11
D
15 14
10
5 6
13 12
3-4
B C D E
3-5
INSTALLATION
Disconnect electrical power before performing any maintenance. All work requiring the removal of the power supply cover must be performed by a qualified technician. See Section 1 of the plasma system instruction manual for more safety precautions.
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 3-5 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
3-6
11-08
3-7
INSTALLATION
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.
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.
3-8
INSTALLATION
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.
3-9
**
RHF console Metering console Gas/Selection console CNC console
3-10
Bus bar
INSTALLATION
Command THC
**
Bus bar
Cooler
Grounding diagram (some systems will not include all the components shown) Chassis and RFI ground
AC earth/service ground
INSTALLATION
DANGER
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. 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.
3-11
INSTALLATION
32 mm 1.25"
32 mm 1.25"
7 mm .028" (4 places)
3-12
INSTALLATION
LHF mounting
3-13
INSTALLATION
Off-valve grounding
A A-A
70 mm 2.75"
A
92 mm 3.62"
157 mm 6.18"
165 mm 6.5"
3-14
INSTALLATION
50.8 mm 2.0"
228.6 mm 9.0"
314.5 mm 12.38"
38.1 mm 1.5"
3-15
INSTALLATION
Ignition console Part no. 123683* 123820 123821 123666 123822 123667 Length 1.5 m (5 ft) 3 m (10 ft) 4.5 m (15 ft) 7.5 m (25 ft) 10 m (35 ft) 15 m (50 ft) Part no. 123823 123735 123668 123669 123824 123825 Length 20 m (65 ft) 25 m (82 ft) 35 m (115 ft) 45 m (150 ft) 60 m (200 ft) 75 m (250 ft)
I/O board
2 Negative lead
Ignition console Part no. 123702* 123661 123813 123662 123814 123663 Length 1.5 m (5 ft) 3 m (10 ft) 4.5 m (15 ft) 7.5 m (25 ft) 10 m (35 ft) 15 m (50 ft) Part no. 123815 123734 123664 123665 123778 123779 Power supply Length 20 m (65 ft) 25 m (82 ft) 35 m (115 ft) 45 m (150 ft) 60 m (200 ft) 75 m (250 ft)
* Cable numbers 123683 and 123702 are for use with systems that have the ignition console mounted on the power supply
Negative lead
3-16
INSTALLATION
Work lead
2
Negative lead
1
Pilot arc lead
1
Pilot arc lead
2
Negative lead
3-17
INSTALLATION
* Cable number 123865 is for use with systems that have the ignition console mounted on the power supply
3-18
INSTALLATION
Red
Green
Length 0.7 m (2.5 ft) 3 m (10 ft) 4.5 m (15 ft) 7.5 m (25 ft) 10 m (35 ft) 15 m (50 ft)
Length 20 m (65 ft) 25 m (82 ft) 35 m (115 ft) 45 m (150 ft) 60 m (200 ft) 75 m (250 ft)
Green Red
* Hose set number 228030 is for use with systems that have the ignition console mounted on the power supply
3-19
INSTALLATION
Control cable
Length 3 m (10 ft) 4.5 m (15 ft) 6 m (20 ft) 7.5 m (25 ft) 10 m (35 ft) 15 m (50 ft)
Length 20 m (65 ft) 25 m (82 ft) 35 m (115 ft) 45 m (150 ft) 60 m (200 ft) 75 m (250 ft)
Power cable
Cable signal list power supply to gas console
Power supply end Pin No. Part no. 123785* 123846 123964 123674 123847 123675 Length 3 m (10 ft) 4.5 m (15 ft) 6 m (20 ft) 7.5 m (25 ft) 10 m (35 ft) 15 m (50 ft) Part no. 123848 123740 123676 123677 123849 123850 Length 20 m (65 ft) 25 m (82 ft) 35 m (115 ft) 45 m (150 ft) 60 m (200 ft) 75 m (250 ft) 1 2 3 4 5 6 7 Description 120 Vac-hot 120 Vac-return Ground Not used Not used 24 Vac-hot 24 Vac-return Gas console end Pin No. 1 2 3 4 5 6 7
* Cable numbers 123784 and 123785 are for use with systems that have the gas console mounted on the power supply
3-20
INSTALLATION
1X5
J300
J103
Female
Male
5 6
3X3
3X1
3X2
3-21
INSTALLATION
Length 3 m (10 ft) 4.5 m (15 ft) 7.5 m (25 ft) 10 m (35 ft) 15 m (50 ft) 20 m (65 ft)
Off-valve cable
Shield Preflow Shield Cutflow
1 2 3 4 5 6 7 8 9 10 11 12 13 14
End B
3-22
INSTALLATION
Green
Blue
Black
Red
Green
Black
Blue
Red
3-23
INSTALLATION
8
To J 300
Optional multi-system CNC interface cable (see schematics for installation information)
Power supply end CNC end Function RS-422 serial receiver RS-422 serial receiver RS-422 serial transmitter RS-422 serial transmitter RS-422 serial ground Not used Notifies the CNC that an arc transfer has occurred and to begin machine motion once the CNCs pierce delay has timed out. Notifies the CNC that an error has occurred Notifies the CNC that a rampdown error has occurred Notifies the CNC that the plasma system is not ready to fire an arc Notifies the CNC that an arc transfer has occurred and to begin machine motion once the CNCs pierce delay has timed out Notifies the CNC that an arc transfer has occurred and to begin machine motion once the CNCs pierce delay has timed out Notifies the CNC that an arc transfer has occurred and to begin machine motion once the CNCs pierce delay has timed out Not used Not used The CNC Notifies the plasma system that a corner is approaching and to reduce cut current (Cut current is CNC selectable or defaults to 50% of cut current) The CNC Notifies the plasma system to maintain the shield preflow until the CNC releases the signal Not required without CommandTHC. CommandTHC requires signal to preflow gases during IHS The CNC initiates the plasma arc Not used Not used Not used Ground Ground Available 24 VDC (200 milliamps maximum) see notes Not connected 4 Output Output Output Output Output Output 1 Input Input Input Input Input Input Input Input Input Input Input Input 2&3 2 2 2 2&3 2&3 2&3 Input/ Output Output Output Input Input Notes
Wire color Black Red Black Green Black Blue Black Yellow Black Brown Black Orange Red White Red Green Red Blue Red Yellow Red Brown Red Orange Green White Green Blue Green Yellow Green Brown Green Orange White Black
Pin # 1 20 2 21 3 22 4 23 5 24 6 25 7 26 8 27 9 28 10 29 11 30 12 31 13 32 14 33 15 34 16 35 17 36 18 37 19
Output Output Output Output Output Output Output Output Output Output Output Output Output Output
Motion 1 E () Motion 1 C (+) Error E () Error C (+) Rampdown error E () Rampdown error C (+) Not ready E () Not ready C (+) Motion 2 E () Motion 2 C (+) Motion 3 E () Motion 3 C (+) Motion 4 E () Motion 4 C (+) None None
Corner () Corner (+) Pierce () Pierce (+) Hold () Hold (+) Start () Start (+) None None None Power ground Power ground CNC +24 VDC CNC +24 VDC
1 1 1
3-24
INSTALLATION
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.
3-25
5 VDC-24 VDC
CNC/PLC
HPR C + E
CNC/PLC
CNC +24 V
Power ground
External relay 24 VDC low-power coil 10 mA or 2400 ohms All relay coils require a freewheeling diode across the relay coil
V WA OI D RR S AN TY
3-26
Note:
The external relay's life may be improved by adding a metallized-polyester capacitor (0.022F 100 V or higher) in parallel with the relay contacts.
1. Relay interface
+24 VDC Output from CNC/PLC External relay (AC or DC) Power ground HPR
CNC/PLC
12 V-24 VDC
Active-high drive
Power ground
Power ground
3-27
INSTALLATION
Disconnect electrical power before performing any maintenance. See the Safety section in this manual for more safety precautions.
1. Locate terminal block 2 (TB2) in the power supply.
TB2
1
1
3
3
TB2
2
1
Note:
The main power switch on the gas console must be in the ON position for the remote switch to function.
3-28
3 3
1 1
Note:
Use a switch, relay or solid-state relay that is compatible with 24 VAC @ 100 mA. It must be a maintained-contact switch, not a momentary-contact switch.
INSTALLATION
10
Part no. 228291 228292 228293 228294 228295 228296 228297 228547
Length 2 m (6 ft) 3 m (10 ft) 4.5 m (15 ft) 6 m (20 ft) 7.5 m (25 ft) 10 m (35 ft) 15 m (50 ft) 20 m (65 ft)
Blue
Black
Caution:
The length of the hoses from the torch to the off-valve are critical to cut quality and consumable life.
Caution:
10
Locate the exposed end of the plasma-gas vent hose away from sparks caused by piercing to avoid ignition and possible damage to the torch leads.
3-29
11
Work lead
Work lead
3-30
INSTALLATION
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
3-31
INSTALLATION
5. Connect the pilot arc lead (yellow). Insert the connector into the torch receptacle and turn it by hand until it is tight.
6. Connect the optional ohmic contact wire. 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 HPR130XD system. Shown for reference only)
Part no. 123983 123984 123985 123986 123987 123988 123989 123990 123991 Length 3 m (10 ft) 6 m (20 ft) 7.5 m (25 ft) 9 m (30 ft) 12 m (40 ft) 15 m (50 ft) 23 m (75 ft) 30 m (100 ft) 45 m (150 ft)
3-32
INSTALLATION
7. Connect the plasma-gas vent hose (white). Note: The connectors in steps 710 are push-to-connect fittings. To make a connection, push the hose fitting into the appropriate connector until it stops, 13 mm (0.5 in.).
connector-collar
8. Connect the coolant supply hose (green). To disconnect a fitting, push the connector-collar toward the torch, and pull the hose away from the torch.
3-33
INSTALLATION
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.
3-34
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.
3-35
INSTALLATION
2. Position the torch below the mounting bracket, so that the bracket is around the lower portion of the torch sleeve but not touching the torch quick-disconnect. 3. Tighten the securing screws. Note: The bracket should be as low on the torch sleeve as possible to minimize vibration at the tip of the torch.
Quick-disconnect receptacle
Torch alignment
To align the torch at right angles to the workpiece, use a square. See figure above.
3-36
INSTALLATION
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.
Input voltage 200/208 VAC 220 VAC 240 VAC 380 VAC 400 VAC 440 VAC 480 VAC 600 VAC Note:
Phase 3 3 3 3 3 3 3 3
Rated input current (FLA) @ 19.5 kW output 62/60 amps 57 amps 52 amps 33 amps 32 amps 28 amps 26 amps 21 amps
Recommended time delay, high inrush fuse size 85 amps 85 amps 65 amps 40 amps 40 amps 35 amps 35 amps 30 amps
Recommended Cable size for 15 m (50 feet) maximum length Rated for 60 C 26.7 mm2 (3 AWG) 26.7 mm2 (3 AWG) 21.2 mm2 (4 AWG) 8.3 mm2 (8 AWG) 8.3 mm2 (8 AWG) 8.3 mm2 (8 AWG) 8.3 mm2 (8 AWG) 5.3 mm2 (10 AWG)
Cable AWG recommendations taken from table 310-16 of the National Electric Code handbook (USA).
3-37
16
Wire sizes vary based on the distance of the receptacle from the main box. The wire sizes listed in the table above were taken from the National Electric Code 1990 handbook, table 310.16 (USA). Use a 4-conductor Type SO input power cable with a conductor temperature rating of 60 C (140 F). Installation must be performed by a licensed electrician.
3-38
INSTALLATION
DANGER
(PE) W V U
Power cable
TB1
3-39
INSTALLATION
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.
Caution:
Never use automotive anti-freeze in place of propylene glycol. Antifreeze contains corrosion inhibitors that will damage the torch coolant system. Always use purified water in the coolant mixture in order to prevent damage to the pump and corrosion in the torch coolant system.
10/16/08
3-40
INSTALLATION
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. Note: Maximum percentage of glycol should never exceed 50%.
C
4 -1 -7 -12
F
40 30 20 10 0 -10 -20 -30 -40 -50 -60 -70 0 10 20 30 40 50 60
Maximum glycol percentage Hypertherm pre-mix (028872)
Temperature
% of Propylene Glycol
10/16/08
3-41
INSTALLATION
Water purity measurement method Conductivity S/cm at 25 C 0.055 0.5 18 1000 Resistivity m-cm at 25 C 18.3 2 0.054 0.001 Dissolved solids (ppm of NaCl) 0 0.206 8.5 495 Grains per gallon (gpg of CaCO2) 0 0.010 0.43 25
Water purity Pure water (for reference only) Maximum purity Minimum purity Maximum potable water (for reference only)
10/16/08
3-42
INSTALLATION
Press and hold the current selection knob (8) and press power switch on the gas console. The pump will run continuously while (8) is pressed.
The current display shows the flow rate. When the flow rate is constant and greater than 22.7 lpm (0.6 gpm), release the knob. The display will show the current again. The pump will continue to run.
Add coolant to the power supply until the tank is full and replace the filler cap.
3-43
INSTALLATION
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 Section 2 for gas and flow specifications. Note: Oxygen, air and nitrogen are required for all systems. Nitrogen is used as a purge gas. 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 too high in the case of methane) or if there are leaks in the supply hoses or connections, Cut speeds can decrease Cut quality can deteriorate Cutting thickness capability can decrease Parts life can shorten
Caution:
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 8.3 bar (120 psi).
7. While gas is flowing adjust the supply regulator for the plasma gas to 8.3 bar (120 psi).
3-44
INSTALLATION
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 and local codes.
2-stage regulator
Part Number 128544 128545 128546 128547 128548 022037 022038 022039 022040 022041
Description Kit: Oxygen, 2-stage* Kit: Inert Gas, 2-stage Kit: Hydrogen (H5, H35 and methane) 2-stage Kit: Air, 2-stage Kit: 1-stage (for use with cryogenic liquid nitrogen or oxygen) Oxygen, 2-stage Inert gas, 2-stage Hydrogen/methane, 2-stage Air, 2-stage Line regulator, 1-stage
Qty. 1 1 1 1 1 1 1 3 1 1
3-45
INSTALLATION
Caution:
When configuring the gas console to the supply gases, make sure that all hoses, hose connections and fittings are acceptable for use with oxygen, argon-hydrogen and methane. 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 gas console to achieve the proper mixtures in the preflow and cutflow conditions.
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 to supply gas.
WARNING
3-46
Caution:
Replacing the fittings on the gas console may cause the internal valves to malfunction, because particulates can migrate into the valves.
3-47
INSTALLATION
Oxygen hose
Length 3 m (10 ft) 4.5 m (15 ft) 7.5 m (25 ft) 10 m (35 ft) 15 m (50 ft) 20 m (65 ft)
Length 25 m (82 ft) 35 m (115 ft) 45 m (150 ft) 60 m (200 ft) 75 m (250 ft)
13
Length 3 m (10 ft) 4.5 m (15 ft) 7.5 m (25 ft) 10 m (35 ft) 15 m (50 ft) 20 m (65 ft)
Length 25 m (82 ft) 35 m (115 ft) 45 m (150 ft) 60 m (200 ft) 75 m (250 ft)
14
Air hose
Length 3 m (10 ft) 4.5 m (15 ft) 7.5 m (25 ft) 10 m (35 ft) 15 m (50 ft) 20 m (65 ft)
Length 25 m (82 ft) 35 m (115 ft) 45 m (150 ft) 60 m (200 ft) 75 m (250 ft)
15
Length 3 m (10 ft) 4.5 m (15 ft) 7.5 m (25 ft) 10 m (35 ft) 15 m (50 ft) 20 m (65 ft)
Length 25 m (82 ft) 35 m (115 ft) 45 m (150 ft) 60 m (200 ft) 75 m (250 ft)
3-48
Section 4 OPERATION
In this section:
Daily start-up...............................................................................................................................................................................................4-2 Check torch ......................................................................................................................................................................................4-2 Controls and indicators ............................................................................................................................................................................4-3 General ..............................................................................................................................................................................................4-3 Main power switch ..........................................................................................................................................................................4-3 Power indicators..............................................................................................................................................................................4-3 Manual gas console operation................................................................................................................................................................4-4 Consumable selection ..............................................................................................................................................................................4-5 Standard cutting..............................................................................................................................................................................4-5 Bevel cutting.....................................................................................................................................................................................4-5 Marking ..............................................................................................................................................................................................4-5 Consumables for mirror-image cutting.......................................................................................................................................4-5 SilverPlus electrodes ......................................................................................................................................................................4-5 Mild steel ...........................................................................................................................................................................................4-6 Stainless steel ..................................................................................................................................................................................4-6 Aluminum ...........................................................................................................................................................................................4-7 Mild steel bevel cutting ..................................................................................................................................................................4-8 Stainless steel bevel cutting .........................................................................................................................................................4-8 Install and inspect consumables ............................................................................................................................................................4-9 Torch maintenance ..................................................................................................................................................................................4-11 Torch connections ...................................................................................................................................................................................4-12 Replace torch water tube ......................................................................................................................................................................4-12 Common cutting faults...........................................................................................................................................................................4-13 How to optimize cut quality...................................................................................................................................................................4-14 Tips for table and torch................................................................................................................................................................4-14 Plasma set-up tips........................................................................................................................................................................4-14 Maximize the life of consumable parts .....................................................................................................................................4-14 Additional factors of cut quality .................................................................................................................................................4-15 Additional improvements.............................................................................................................................................................4-16 Cut charts..................................................................................................................................................................................................4-17 Bevel cut charts.............................................................................................................................................................................4-17 Bevel cutting definitions.........................................................................................................................................................................4-18 Estimated kerf width compensation....................................................................................................................................................4-19
4-1
OPERATION
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.
1. Turn main disconnect switch to the power supply OFF. 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 later in this section for details. 4. Ensure that the torch is perpendicular to the workpiece.
Shield cap
Shield
Nozzle
Swirl ring
Electrode
Current ring
Torch
4-2
OPERATION
Off Position (O) AC power is cut off to the control transformer, to turn off the power supply.
Power indicators
4-3
OPERATION
3-digit display*
Position number
1. Turn ON the power. 2. Follow instructions below using the settings provided in the Cut charts. Position # 1 2 3, 4 & 7 5, 6 & 7 7 8 Instruction Select PLASMA GAS. Select SHIELD GAS. Position switch (7) to SET PREFLOW (3-4). Set plasma preflow (3). Set shield preflow (4). Position switch (7) to SET CUTFLOW (5-6). Set plasma cutflow (5). Set shield cutflow (6). Position switch (7) to RUN. 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.
4-4
OPERATION
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. Poor quality marking or burn-through may occur with material less than 1.5 mm (.060 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.
4-5
30A
220194 220754 220193 220180 220192
50A
220555 220754 220554 220553 220552 220340 220747
80A
220189 220756 220188 220179 220187
130A
220183 220756 220182 220179 220181*
* SilverPlus electrodes are available for the following process. Mild steel, 130 amp, O2 / Air 220665
Stainless steel
Shield cap 45A
220202 220755 220201 220180 220308
Shield
Nozzle
Swirl ring
Electrode
Water tube
80A
220340 220747 220338 220755 220337 220179 220339
130A
220198 220755 (H35) 220756 (N2) 220197 220179 220307
4-6
OPERATION Aluminum
Shield cap 45A
220202 220756 220201 220180 220308 220340 220747
Shield
Nozzle
Swirl ring
Electrode
Water tube
130A
220198 220755 (H35) 220756 (Air) 220197 220179 220307 (H35) 220181 (Air)
4-7
Shield
Nozzle
Electrode
Water tube
220637
220742
220845
220806
220179
220802
220700
130 A
220637
220742
220740
220646
220179
220649
220700
130 A
220637
220738
220739
220656
220179
220606
220571
4-8
OPERATION
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. The o-ring should look shiny, but there should not be any excess or built-up grease.
Wipe the internal and external surfaces of the torch with a clean cloth or paper towel.
Tool: 104119
4-9
Poor cut quality after Replace nozzle retaining cap replacing other consumables General: Erosion or missing material Blocked gas holes Replace nozzle Replace nozzle Replace the nozzle when the hole is no longer round Replace nozzle Replace nozzle Apply a thin film of silicone lubricant if the o-rings are dry Replace swirl ring Replace swirl ring Clean and check for damage; replace when damaged Replace swirl ring Apply a thin film of silicone lubricant if the o-rings are dry In general, replace the electrode when the pit depth is 0.04 inches or greater. For the 400 amp mild steel electrode and all SilverPlus electrodes, replace the electrode when the pit depth is 0.06 inches or greater. Replace electrode Apply a thin film of silicone lubricant if the o-rings are dry
Center hole: Must be round Signs of arcing O-rings: Damage Lubricant General: Chips or cracks Blocked gas holes
Swirl ring
Emitter
Center surface: Emitter wear - a pit forms as the emitter wears. O-rings: Damage Lubricant
4-10
OPERATION
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: 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 compressed air to blow them off before they are installed again. This is especially critical for the nozzle retaining cap. Front view of the torch
External o-rings (2)
Quick-disconnect maintenance
The following steps should be completed every 5-10 times consumables are changed: 1. Remove the torch from the quick-disconnect assembly. 2. Use compressed air to blow off all internal surfaces and the external threads. 3. Use compressed air to blow off all internal surfaces at the rear of the torch. 4. Inspect each of the 5 o-rings at the rear of the torch for nicks or cuts. Replace any damaged o-rings. If they are not damaged, apply a thin film of silicone lubricant on each o-ring. The o-rings should look shiny, but there should not be any excess or built-up grease.
O-rings (5)
External threads
Maintenance kit
Even with proper care, the o-rings at the rear of the torch will need to be replaced periodically. Hypertherm provides a kit (128879) of replacement parts. Kits should be kept in stock and be used as part of your routine maintenance schedule.
4-11
OPERATION
Torch connections
Plasma vent Shield gas Ohmic contact pin Plasma gas Coolant in Torch
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.
Note:
The water tube may seem loose when correctly inserted, but any side-to-side looseness will disappear after the electrode is installed.
1. Turn OFF all power to the system. 2. Remove consumables from torch. See Install and inspect consumables in this section. 3. Remove the old water tube. 4. Apply a thin film of silicone lubricant on the o-ring, and install a new water tube. The o-ring should look shiny, but there should not be any excess or built-up grease. 5. Replace consumables. See Install and inspect consumables in this section.
4-12
OPERATION
4-13
OPERATION
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.
Note:
4-14
OPERATION
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.
Problem
Cause
Solution
Dross Low-speed dross forms when the torchs 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: Decrease the cutting speed. Decrease arc voltage, to decrease the torch-to-work distance. Increase O2 in the shield gas to increase the range of dross-free cutting speeds. (Only HyDefinition and HT4400 systems can accommodate mixed-gas shield gases.) Notes: Dross is more likely to form on warm or hot metal than on cool metal. For example, the first cut in a series of cuts will likely produce the least dross. As the workpiece heats up, more dross may form on subsequent cuts. Dross is more likely to form on mild steel than on stainless steel or aluminum. Worn or damaged consumables may produce intermittent dross.
4-15
OPERATION
Straightness of the cut surface A typical plasma cut surface is slightly concave. The cut surface may become more concave, or convex. Correct torch height is required to keep the 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. 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 flying pierce (i.e. 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 or other components, a stationary or edge start is recommended. How to increase cutting speed Decrease the torch-to-work distance. Trade-off: This will increase the negative cut angle. Note: The torch must not touch the workpiece while piercing or cutting.
4-16
OPERATION
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.
4-17
OPERATION
Arc voltage
Torch center-line
0 Bevel angle
Torch-to-work distance
Equivalent thickness
4-18
OPERATION
Metric
Thickness (mm)
Process Mild steel 130A O2 / Air 80A O2 / Air 50A O2 / O2 30A O2 / O2 Stainless steel 130A H35 / N2 130A N2 / N2 80A F5 / N2 45A F5 / N2 45A N2 / N2 Aluminum 130A H35 / N2 130A Air / Air 45A Air / Air 1.067 1.092 2.083 1.245 2.718 2.083 2.769 2.184 2.896 0.584 0.483 0.381 0.229 1.829 1.194 0.533 0.152 2.718 1.879 2.769 2.413 2.896 1.516 1.346 1.372 1.740 1.448 1.803 1.727 1.854 2.032 1.905 2.108 2.642 3.429 1.5 3 6 10 12 20 25
English
Thickness (in)
Process Mild steel 130A O2 / Air 80A O2 / Air 50A O2 / O2 30A O2 / O2 Stainless steel 130A H35 / N2 130A N2 / N2 80A F5 / N2 45A F5 / N2 45A N2 / N2 Aluminum 130A H35 / N2 130A Air / Air 45A Air / Air 0.042 0.043 0.082 0.049 0.107 0.082 0.109 0.086 0.114 0.023 0.019 0.015 0.009 0.072 0.047 0.021 0.006 0.107 0.074 0.109 0.095 0.114 0.060 0.053 0.054 0.073 0.057 0.071 0.068 0.073 0.080 0.075 0.083 0.104 0.135 0.060" 0.135" 1/4" 3/8" 1/2" 3/4" 1"
4-19
OPERATION
Mild steel
O2 Plasma / O2 Shield 30 A Cutting
Note: Air must be connected to use this process. It is used as the preflow gas
220747
220194
220754
220193
220180
220192
220340
Metric
Select Gases Set Preflow Set Cutflow Material Thickness mm 0.5 0.8 1 1.2 1.5 2 2.5 3* 4* 6* Arc Torch-to-Work Cutting Voltage Distance Speed Volts 114 115 116 117 119 120 122 123 125 128 mm mm/m 5355 4225 3615 2865 2210 1490 1325 1160 905 665 Initial Pierce Height mm factor % Pierce Delay Time seconds 0.1 0.2 2.3 0.3 180 0.4 2.7 0.5 0.7 1.0 Plasma Shield Plasma Shield Plasma Shield
15
15
1.3
O2
O2
80 35
92
5 75
1.5
English
Select Gases Set Preflow Set Cutflow Material Thickness in 0.018 0.024 0.030 0.036 0.048 0.060 0.075 0.105 0.135* 3/16* 1/4* Arc Torch-to-Work Cutting Voltage Distance Speed Volts 114 115 116 117 119 120 122 123 128 0.050 in ipm 215 200 170 155 110 85 60 50 40 30 25 Initial Pierce Height in factor % Pierce Delay Time seconds 0.1 0.090 0.2 0.3 180 0.4 0.110 0.5 0.7 1.0 Plasma Shield Plasma Shield Plasma Shield
15
15
O2
O2
80 35
92
5 75
0.060
Marking
Select Gases N2 Ar N2 Air Set Preflow 10 90 10 10 Set Cutflow 10 90 10 10 Amperage Amps 15 9 Torch-to-Work Distance mm 2.5 2.5 in 0.10 0.10 Marking Speed mm/min 6350 2540 ipm 250 100 Arc Voltage Volts 105 80
4-20
OPERATION
Mild steel
O2 Plasma / O2 Shield 50 A Cutting
Note: Air must be connected to use this process. It is used as the preflow gas
220747
220555
220754
220554
220553
220552
220340
Metric
Select Gases Set Preflow Set Cutflow Material Thickness mm 0.8 1 1.2 1.5 2 O2 O2 70 30 75 15 2.5 3 4 5 6 7 8 Arc Torch-to-Work Cutting Voltage Distance Speed Volts 110 111 112 114 115 117 119 121 122 126 128 130 2.0 1.5 1.3 mm 1.0 mm/m 6500 5000 4150 3200 2700 2200 1800 1400 1200 950 780 630 4.0 0.5 3.0 2.6 200 0.1 0.2 0.3 0.4 Initial Pierce Height mm 2.0 0.0 factor % Pierce Delay Time seconds
English
Select Gases Set Preflow Set Cutflow Material Thickness in 0.030 0.036 0.048 0.060 0.075 0.105 0.135 3/16 1/4 5/16 Arc Torch-to-Work Cutting Voltage Distance Speed Volts 110 112 114 115 118 120 121 125 130 in 0.04 ipm 270 210 160 125 110 80 60 50 35 25 Initial Pierce Height in 0.08 0.0 0.10 factor % Pierce Delay Time seconds
O2
O2
70
30
75
15
0.05
200
0.06 0.08
0.12 0.16
Marking
Select Gases N2 Ar N2 Air Set Preflow 10 90 10 10 Set Cutflow 10 90 10 10 Amperage Amps 15 9 Torch-to-Work Distance mm 2.5 2.5 in 0.10 0.10 Marking Speed mm/min 6350 2540 ipm 250 100 Arc Voltage Volts 118 77
4-21
OPERATION
Mild steel
O2 Plasma / Air Shield 80 A Cutting
220747
220189
220756
220188
220179
220187
220340
Metric
Select Gases Set Preflow Set Cutflow Material Thickness mm 2 2.5 3 4 6 10 12 15 20 Arc Torch-to-Work Cutting Voltage Distance Speed Volts 112 115 117 120 123 127 130 133 135 mm 2.5 mm/m 9810 7980 6145 4300 3045 1810 1410 1030 545 Initial Pierce Height mm 3.8 factor % 150 Pierce Delay Time seconds 0.1 0.2 4.0 200 0.3 0.5 0.7 0.8 0.9
30 O2 Air 50 30 72
2.0
15
5.0 6.3
250
2.5
English
Select Gases Set Preflow Set Cutflow Material Thickness in 0.075 0.105 0.135 3/16 1/4 3/8 1/2 5/8 3/4 Arc Torch-to-Work Cutting Voltage Distance Speed Volts 112 115 117 120 123 127 130 133 135 in 0.100 ipm 400 290 180 155 110 75 50 37 25 Initial Pierce Height in 0.150 factor % 150 Pierce Delay Time seconds 0.1 0.2 0.160 200 0.3 0.5 0.7 0.8 0.9
30 O2 Air 50 30 72
0.080
15
0.200 0.250
250
0.100
Marking
Select Gases N2 Ar N2 Air Set Preflow 10 50 10 10 Set Cutflow 10 50 10 10 Amperage Amps 15 15 Torch-to-Work Distance mm 2.5 3.0 in 0.10 0.12 Marking Speed mm/min 6350 2540 ipm 250 100 Arc Voltage Volts 130 78
4-22
OPERATION
220637
220742
220845
220806
220179
220802
220700
Metric
Select Gases Set Preflow Set Cutflow Equivalent Minimum Torch-to-Work Cutting Material Clearance Distance Speed Thickness mm mm 2 2.5 3 4 6 10 12 15 20 mm 2.5 8.6 mm/m 9810 7980 6145 4300 3045 1810 1410 1030 545 Initial Pierce Height mm 3.8 factor % 150 Pierce Delay Time seconds 0.1 0.2 4.0 200 0.3 0.5 0.7 0.8 0.9
48 O2 Air 50 48 72 2.0
2.0 8.6
24
5.0 6.3
250
2.5 8.6
English
Select Gases Set Preflow Set Cutflow Equivalent Minimum Torch-to-Work Cutting Material Clearance Distance Speed Thickness in in 0.75 0.105 0.135 3/16 1/4 3/8 1/2 5/8 3/4 in 0.1 0.34 ipm 400 290 180 155 110 75 50 37 25 Initial Pierce Height in 0.150 factor % 150 Pierce Delay Time seconds 0.1 0.2 0.160 200 0.3 0.5 0.7 0.8 0.9
48 O2 Air 50 48 72 0.08
0.08 0.34
24
0.200 0.250
250
0.1 0.34
Marking
Select Gases N2 Ar N2 Air Set Preflow 10 50 10 10 Set Cutflow 10 50 10 10 Amperage Amps 15 15 Torch-to-Work Distance mm 2.5 3.0 in 0.10 0.12 Marking Speed mm/min 6350 2540 ipm 250 100 Arc Voltage Volts 130 78
4-23
OPERATION
Mild steel
O2 Plasma / Air Shield 130 A Cutting
220747
220183
220756
220182
220179
220181
220340
Metric
Select Gases Set Preflow Set Cutflow Material Thickness mm 3 35 40 O2 Air 35 80 28 65 4 6 10 12 15 20 25 32 38 Arc Torch-to-Work Cutting Voltage Distance Speed Volts 124 126 127 130 132 135 138 141 160 167 mm 2.5 2.8 3.0 3.3 3.8 4.0 4.5 mm/m 6505 5550 4035 2680 2200 1665 1050 550 375 255 7.6 190 Edge start Initial Pierce Height mm 5.0 5.6 6.0 6.6 200 factor % Pierce Delay Time seconds 0.1 0.2 0.3 0.5 0.7 1.0 1.8 Plasma Shield Plasma Shield Plasma Shield
English
Select Gases Set Preflow Set Cutflow Material Thickness in 0.135 3/16 1/4 3/8 1/2 5/8 3/4 1 1-1/4 1-1/2 Arc Torch-to-Work Cutting Voltage Distance Speed Volts 124 126 127 130 132 135 138 141 160 167 in 0.100 0.110 0.120 0.130 0.150 0.160 0.180 ipm 240 190 150 110 80 60 45 20 15 10 Initial Pierce Height in 0.200 0.220 0.240 0.260 0.300 190 Edge start 200 factor % Pierce Delay Time seconds 0.1 0.2 0.3 0.5 0.7 1.0 1.8 Plasma Shield Plasma Shield Plasma Shield 35 40 O2 Air 35 80 28 65
Marking
Select Gases N2 Ar N2 Air Set Preflow 10 50 10 10 Set Cutflow 10 50 10 10 Amperage Amps 15 15 Torch-to-Work Distance mm 2.5 3.0 in 0.10 0.12 Marking Speed mm/min 6350 2540 ipm 250 100 Arc Voltage Volts 130 75
4-24
OPERATION
220637 Note:
220742
220740
220646
220179
220649
220700
Metric
Select Gases Set Preflow Set Cutflow Minimum Clearance mm Initial Pierce Height mm 5.0 5.6 6.0 6.6 200 factor % Pierce Delay Time seconds 0.1 0.2 0.3 0.5 0.7 1.0 1.8 4.0
O2
Air
15
English
Select Gases Set Preflow Set Cutflow Minimum Clearance in Equivalent Torch-to-Work Cutting Material Distance Speed Thickness in 0.135 3/16 1/4 3/8 1/2 5/8 3/4 1 1-1/4* 1-1/2 in 0.100 0.340 0.110 0.340 0.120 0.340 0.130 0.340 0.150 0.340 0.160 0.340 0.180 0.340 ipm 240 190 150 110 80 60 45 20 15 10 Initial Pierce Height in 0.200 0.220 0.240 0.260 0.300 0.4 190 220 Edge start 200 factor % Pierce Delay Time seconds 0.1 0.2 0.3 0.5 0.7 1.0 1.8 4.0
33 O2 Air 15 80 23 0.080
49
Marking
Select Gases N2 Ar N2 Air Set Preflow 10 50 10 10 Set Cutflow 10 50 10 10 Amperage Amps 15 15 Torch-to-Work Distance mm 2.5 3.0 in 0.10 0.12 Marking Speed mm/min 6350 2540 ipm 250 100 Arc Voltage Volts 130 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
4-25
OPERATION
Stainless steel
N2 Plasma / N2 Shield 45 A Cutting
220747
220202
220755
220201
220180
220308
220340
Metric
Select Gases Set Preflow Set Cutflow Material Thickness mm 0.8 1 1.2 1.5 2 2.5 3 4 Arc Torch-to-Work Cutting Voltage Distance Speed Volts 94 95 97 101 103 mm mm/m 6380 5880 5380 4630 3935 3270 2550 1580 Initial Pierce Height mm factor % Pierce Delay Time seconds 0.0 0.1
N2
N2
35
55
60
2.5
3.8
150
0.2
0.3
English
Select Gases Set Preflow Set Cutflow Material Thickness in 0.036 0.048 0.060 0.075 0.105 0.135 Arc Torch-to-Work Cutting Voltage Distance Speed Volts 94 95 97 101 103 0.100 in ipm 240 210 180 160 120 75 Initial Pierce Height in factor % Pierce Delay Time seconds 0.0 0.1 0.150 150 0.2 0.3
N2
N2
35
55
60
Marking
Select Gases N2 Ar N2 Air Set Preflow 10 90 10 10 Set Cutflow 10 90 10 10 Amperage Amps 15 12 Torch-to-Work Distance mm 2.5 2.5 in 0.10 0.10 Marking Speed mm/min 6350 2540 ipm 250 100 Arc Voltage Volts 85 65
Note:
This process produces a darker cut edge than the 45 A, F5/N2 stainless steel process.
4-26
OPERATION
Stainless steel
F5 Plasma / N2 Shield 45 A Cutting
220747
220202
220755
220201
220180
220308
220340
Metric
Select Gases Set Preflow Set Cutflow Material Thickness mm 0.8 1 1.2 1.5 2 2.5 3 4 6 Arc Torch-to-Work Cutting Voltage Distance Speed Volts mm mm/m 6570 5740 4905 3890 3175 2510 2010 1435 845 Initial Pierce Height mm factor % Pierce Delay Time seconds
99 2.5
F5
N2
35
25
55
60
15
2.0
English
Select Gases Set Preflow Set Cutflow Material Thickness in 0.036 0.048 0.060 0.075 0.105 0.135 3/16 1/4 99 100 102 104 108 110 0.100 Arc Torch-to-Work Cutting Voltage Distance Speed Volts in ipm 240 190 150 130 90 65 45 30 0.2 Initial Pierce Height in factor % Pierce Delay Time seconds
60 F5 N2 35 25 55
150 0.150
15
0.080
190
Marking
Select Gases N2 Ar N2 Air Set Preflow 10 90 10 10 Set Cutflow 10 90 10 10 Amperage Amps 15 12 Torch-to-Work Distance mm 2.5 2.5 in 0.10 0.10 Marking Speed mm/min 6350 2540 ipm 250 100 Arc Voltage Volts 85 65
Note:
This process produces a shinier cut edge than the 45 A, N2/N2 stainless steel process.
4-27
OPERATION
Stainless steel
F5 Plasma / N2 Shield 80 A Cutting
220747
220338
220755
220337
220179
220339
220340
Metric
Select Gases Set Preflow Set Cutflow Material Thickness mm 4 6 10 Arc Torch-to-Work Cutting Voltage Distance Speed Volts 108 112 120 mm 3.0 2.5 3.0 mm/m 2180 1225 560 Initial Pierce Height mm 4.5 3.8 4.5 factor % 150 Pierce Delay Time seconds 0.2 0.3 0.5
English
Select Gases Set Preflow Set Cutflow Material Thickness in 0.135 3/16 1/4 3/8 Arc Torch-to-Work Cutting Voltage Distance Speed Volts 108 110 112 120 in 0.120 0.110 0.100 0.120 ipm 105 60 45 25 Initial Pierce Height in 0.180 0.170 0.150 0.180 factor % Pierce Delay Time seconds 0.2 150 0.3 0.5 Plasma Shield Plasma Shield Plasma Shield
F5
N2
35
30
60
75
Marking
Select Gases N2 Ar N2 Air Set Preflow 10 50 10 10 Set Cutflow 10 50 10 10 Amperage Amps 15 12 Torch-to-Work Distance mm 2.5 3.0 in 0.10 0.12 Marking Speed mm/min 6350 2540 ipm 250 100 Arc Voltage Volts 95 60
4-28
OPERATION
Stainless steel
N2 Plasma / N2 Shield 130 A Cutting
220747
220198
220756
220197
220179
220307
220340
Metric
Select Gases Set Preflow Set Cutflow Material Thickness mm 6 10 12 15 20 Arc Torch-to-Work Cutting Voltage Distance Speed Volts 153 156 162 167 176 mm 3.0 3.5 3.8 4.3 mm/m 1960 1300 900 670 305 Initial Pierce Height mm 6.0 7.0 Edge start factor % 200 Pierce Delay Time seconds 0.3 0.5 0.8
N2
N2
20
65
70
30
English
Select Gases Set Preflow Set Cutflow Material Thickness in 1/4 3/8 1/2 5/8 3/4 Arc Torch-to-Work Cutting Voltage Distance Speed Volts 153 156 162 167 176 in 0.120 0.140 0.150 0.170 ipm 75 55 30 25 15 Initial Pierce Height in 0.240 0.280 Edge start factor % 200 Pierce Delay Time seconds 0.3 0.5 0.8
N2
N2
20
65
70
30
Marking
Select Gases N2 Ar N2 Air Set Preflow 10 50 10 10 Set Cutflow 10 50 10 10 Amperage Amps 18 15 Torch-to-Work Distance mm 2.5 3.0 in 0.10 0.12 Marking Speed mm/min 6350 2540 ipm 250 100 Arc Voltage Volts 140 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.
4-29
OPERATION
Stainless steel
H35 Plasma / N2 Shield 130 A Cutting
220747
220198
220755
220197
220179
220307
220340
Metric
Select Gases Set Preflow Set Cutflow 60 45 H35 N2 20 40 70 30 20 Material Thickness mm 10 12 15 20 25 Arc Torch-to-Work Cutting Voltage Distance Speed Volts 154 158 162 165 172 mm mm/m 980 820 580 360 260 Initial Pierce Height mm factor % Pierce Delay Time seconds 0.3 0.5 0.8 1.3
4.5
7.7
170
Edge start
English
Select Gases Set Preflow Set Cutflow 60 45 H35 N2 20 40 70 30 20 Material Thickness in 3/8 1/2 5/8 3/4 1 Arc Torch-to-Work Cutting Voltage Distance Speed Volts 154 158 162 165 172 in ipm 40 30 20 15 10 Initial Pierce Height in factor % Pierce Delay Time seconds 0.3 0.5 0.8 1.3
0.180
0.310
170
Edge start
Marking
Select Gases N2 Ar N2 Air Set Preflow 10 50 10 10 Set Cutflow 10 50 10 10 Amperage Amps 18 15 Torch-to-Work Distance mm 2.5 3.0 in 0.10 0.12 Marking Speed mm/min 6350 2540 ipm 250 100 Arc Voltage Volts 130 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.
4-30
220637 Note:
220738
220739
220656
220179
220606
220571
Metric
Select Gases Set Preflow Set Cutflow Minimum Clearance mm Equivalent Torch-to-Work Cutting Material Distance Speed Thickness mm 6 10 12 15 20 mm 3.0 10.0 3.5 10.0 3.8 10.0 4.3 10.0 mm/m 1960 1300 900 670 305 Initial Pierce Height mm 6.0 7.0 Edge start factor % 200 Pierce Delay Time seconds 0.3 0.5 0.8
N2
N2
20
65
70
80
2.0
English
Select Gases Set Preflow Set Cutflow Minimum Clearance in Equivalent Torch-to-Work Cutting Material Distance Speed Thickness in 1/4 3/8 1/2 5/8 3/4 in 0.120 0.400 0.140 0.400 0.150 0.400 0.170 0.400 ipm 75 55 30 25 15 Initial Pierce Height in 0.240 0.280 Edge start factor % 200 Pierce Delay Time seconds 0.3 0.5 0.8
N2
N2
20
65
70
80
0.080
Marking
Select Gases N2 Ar N2 Air Set Preflow 10 50 10 10 Set Cutflow 10 50 10 10 Amperage Amps 18 15 Torch-to-Work Distance mm 2.5 3.0 in 0.10 0.12 Marking Speed mm/min 6350 2540 ipm 250 100 Arc Voltage Volts 140 75
4-31
Flow rates lpm/scfh Preflow Cutflow H35 0/0 26 / 54 N2 90 / 190 114 / 240
220637 Note:
220738
220739
220656
220179
220606
220571
Metric
Select Gases Set Preflow Set Cutflow Minimum Clearance mm Initial Pierce Height mm factor % Pierce Delay Time seconds 0.3 0.5 0.8 1.3
H35
N2
20
40
70
80
2.0
4.5 10.0
7.7
170
Edge start
English
Select Gases Set Preflow Set Cutflow Minimum Clearance in Equivalent Torch-to-Work Cutting Material Distance Speed Thickness in 3/8 1/2 5/8 3/4 1 in ipm 40 30 20 15 10 Initial Pierce Height in factor % Pierce Delay Time seconds 0.3 0.5 0.8 1.3
H35
N2
20
40
70
80
0.080
0.180 0.400
0.310
170
Edge start
Marking
Select Gases N2 Ar N2 Air Set Preflow 10 50 10 10 Set Cutflow 10 50 10 10 Amperage Amps 18 15 Torch-to-Work Distance mm 2.5 3.0 in 0.10 0.12 Marking Speed mm/min 6350 2540 ipm 250 100 Arc Voltage Volts 130 75
4-32
OPERATION
Aluminum
Air Plasma / Air Shield 45 A Cutting
220747
220202
220756
220201
220180
220308
220340
Metric
Select Gases Set Preflow Set Cutflow Material Thickness mm 1.2 1.5 2 2.5 3 4 6 Arc Torch-to-Work Cutting Voltage Distance Speed Volts 130 115 113 110 107 102 117 mm mm/m 4750 4160 3865 3675 2850 2660 1695 Initial Pierce Height mm factor % Pierce Delay Time seconds
60 Air Air 35 25 55
2.5
0.2
40
1.8 3.0
0.3 0.6
English
Select Gases Set Preflow Set Cutflow Material Thickness in 0.040 0.051 0.064 0.102 0.125 3/16 1/4 Arc Torch-to-Work Cutting Voltage Distance Speed Volts 130 115 113 110 102 114 117 in ipm 220 170 160 140 110 90 60 Initial Pierce Height in factor % Pierce Delay Time seconds
60 Air Air 35 25 55 40
0.100
0.2
0.070 0.120
Marking
Select Gases N2 Ar N2 Air Set Preflow 10 90 10 10 Set Cutflow 10 90 10 10 Amperage Amps 15 12 Torch-to-Work Distance mm 2.5 2.5 in 0.10 0.10 Marking Speed mm/min 6350 2540 ipm 250 100 Arc Voltage Volts 85 75
4-33
OPERATION
Aluminum
Air Plasma / Air Shield 130 A Cutting
220747
220198
220756
220197
220179
220181
220340
Metric
Select Gases Set Preflow Set Cutflow Material Thickness mm 6 10 12 15 20 25 Arc Torch-to-Work Cutting Voltage Distance Speed Volts 153 154 156 158 162 172 mm 2.8 3.0 3.3 3.5 4.0 mm/m 2370 1465 1225 1050 725 525 Initial Pierce Height mm 5.6 6.0 6.6 7.0 N/A 200 factor % Pierce Delay Time seconds 0.2 0.3 0.5 0.8 1.3
Air
Air
20
40
70
30
English
Select Gases Set Preflow Set Cutflow Material Thickness in 1/4 3/8 1/2 5/8 3/4 1 Arc Torch-to-Work Cutting Voltage Distance Speed Volts 153 154 156 158 162 172 in 0.110 0.120 0.130 0.140 0.160 ipm 90 60 45 40 30 20 Initial Pierce Height in 0.220 0.240 0.260 0.280 N/A 200 factor % Pierce Delay Time seconds 0.2 0.3 0.5 0.8 1.3 Plasma Shield Plasma Shield Plasma Shield
Air
Air
20
40
70
30
Marking
Select Gases N2 Ar N2 Air Set Preflow 10 50 10 10 Set Cutflow 10 50 10 10 Amperage Amps 18 15 Torch-to-Work Distance mm 2.5 3.0 in 0.10 0.12 Marking Speed mm/min 6350 2540 ipm 250 100 Arc Voltage Volts 120 82
Note:
This process produces a rougher cut edge that is less perpendicular than the 130 A, H35/N2 process.
4-34
OPERATION
Aluminum
H35 Plasma / N2 Shield 130 A Cutting
220747
220198
220755
220197
220179
220307
220340
Metric
Select Gases Set Preflow Set Cutflow 60 45 H35 N2 20 40 70 30 20 Material Thickness mm 10 12 15 20 25 Arc Torch-to-Work Cutting Voltage Distance Speed Volts 158 156 157 176 4.5 mm 5.0 mm/m 1615 1455 1305 940 540 Initial Pierce Height mm 6.5 7.7 factor % 130 170 Edge start Pierce Delay Time seconds 0.3 0.5 0.8 1.3
English
Select Gases Set Preflow Set Cutflow 60 45 H35 N2 20 40 70 30 20 Material Thickness in 3/8 1/2 5/8 3/4 1 Arc Torch-to-Work Cutting Voltage Distance Speed Volts 158 156 157 176 0.180 in 0.200 ipm 65 55 50 40 20 Initial Pierce Height in 0.260 0.310 factor % 130 170 Edge start Pierce Delay Time seconds 0.3 0.5 0.8 1.3
Marking
Select Gases N2 Ar N2 Air Set Preflow 10 50 10 10 Set Cutflow 10 50 10 10 Amperage Amps 18 15 Torch-to-Work Distance mm 2.5 3.0 in 0.10 0.12 Marking Speed mm/min 6350 2540 ipm 250 100 Arc Voltage Volts 130 75
Note:
This process produces a smoother cut edge that is more perpendicular than the 130 A, Air/Air process.
4-35
Section 5 MAINTENANCE
In this section:
Introduction .................................................................................................................................................................................................5-3 Routine maintenance ................................................................................................................................................................................5-3 System description....................................................................................................................................................................................5-4 Control 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 Error code troubleshooting Error codes 000 to 020.....................................................................................................5-11 Error code troubleshooting Error codes 021 to 028.....................................................................................................5-12 Error code troubleshooting Error codes 030 to 042.....................................................................................................5-13 Error code troubleshooting Error codes 044 to 046 ....................................................................................................5-14 Error code troubleshooting Error codes 047 to 053.....................................................................................................5-15 Error code troubleshooting Error codes 054 to 061.....................................................................................................5-16 Error code troubleshooting Error codes 062 to 067 .....................................................................................................5-17 Error code troubleshooting Error codes 071 to 076 .....................................................................................................5-18 Error code troubleshooting Error codes 093 to 105 .....................................................................................................5-19 Error code troubleshooting Error codes 106 to 123 .....................................................................................................5-20 Error code troubleshooting Error codes 124 to 134.....................................................................................................5-21 Error code troubleshooting Error codes 138 to 143.....................................................................................................5-22 Error code troubleshooting Error codes 144 to 154.....................................................................................................5-23 Error code troubleshooting Error codes 155 to 158.....................................................................................................5-24 Error code troubleshooting Error codes 159 to 160.....................................................................................................5-25 Error code troubleshooting Error codes 180 to 181.....................................................................................................5-26 Power supply states ...............................................................................................................................................................................5-27 Plasma system operation with pump timeout ...................................................................................................................................5-28 CNC operation with pump timeout.....................................................................................................................................................5-29 Initial checks .............................................................................................................................................................................................5-30 Power measurement...............................................................................................................................................................................5-31 Air filter element replacement...............................................................................................................................................................5-32 Power supply coolant system servicing .............................................................................................................................................5-33 Draining the coolant system. ......................................................................................................................................................5-33 Coolant system filter and strainer........................................................................................................................................................5-34 Filter replacement .........................................................................................................................................................................5-34 Pump strainer cleaning................................................................................................................................................................5-34 Coolant flow troubleshooting chart.....................................................................................................................................................5-35
5-1
MAINTENANCE
Coolant flow tests ...................................................................................................................................................................................5-36 Before testing ................................................................................................................................................................................5-36 Using the Hypertherm flow meter (128933)..........................................................................................................................5-36 Manual pump operation...............................................................................................................................................................5-37 Test 1 return line .....................................................................................................................................................................5-38 Test 2 supply line at ignition console.................................................................................................................................5-38 Test 3 change the torch ........................................................................................................................................................5-39 Test 4 supply line to the torch receptacle ........................................................................................................................5-39 Test 5 return line from the torch receptacle .....................................................................................................................5-39 Test 6 bucket test at the pump ...........................................................................................................................................5-40 Test 7 bypass the check valve.............................................................................................................................................5-40 Pump and motor troubleshooting..............................................................................................................................................5-41 Testing the flow sensor................................................................................................................................................................5-42 Gas leak tests ..........................................................................................................................................................................................5-43 Power supply control board PCB3.....................................................................................................................................................5-44 Power supply power distribution board PCB2 ................................................................................................................................5-45 Start circuit PCB1 ..................................................................................................................................................................................5-46 Operation........................................................................................................................................................................................5-46 Start circuit functional schematic..............................................................................................................................................5-46 Start circuit troubleshooting.......................................................................................................................................................5-46 Pilot arc current levels .................................................................................................................................................................5-48 Gas console control board PCB2 ......................................................................................................................................................5-49 Gas console power distribution board PCB1..................................................................................................................................5-50 Gas console, AC valve-driver board PCB3......................................................................................................................................5-51 Chopper tests ..........................................................................................................................................................................................5-52 Phase-loss detection test......................................................................................................................................................................5-54 Torch lead test..........................................................................................................................................................................................5-55 Preventive maintenance.........................................................................................................................................................................5-56
5-2
MAINTENANCE
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.
SHOCK HAZARD Use extreme care when working near the chopper modules. The large blue capacitors store high voltage. Even if the power is off, dangerous voltages exist at the capacitor terminals, on the chopper and the heatsinks. Discharging any capacitor with a screwdriver or other implement may result in an explosion, property damage or personal injury. Wait at least 5 minutes after turning the power supply off before touching the chopper or the capacitors.
WARNING
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.
5-3
MAINTENANCE
System description
Control and signal cables
Signal cable: Provides process and status signals between the power supply and the gas console.
Power cable: Provides 120 VAC to the ignition console and control power to the off-valve assembly.
Control cable: Provides 120 VAC control power to the solenoid valves.
5-4
MAINTENANCE
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 2. Purge Air or N2 gas flows through torch for 20 seconds Coolant flow on Contactor closes and the chopper performs a chopper test and a current sensor test Plasma start off Contactor opens when the purge cycle ends 3. Idle Gas pressure ok Coolant flow on Chopper current off Line voltage ok 4. Preflow 2 second flow of gas 5. Pilot Arc Current flow between electrode and nozzle Chopper, main contactor and pilot arc relay are on High frequency present Chopper current sensor = pilot arc current 6. Transfer Pilot arc current sensed on the worklead 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 8. Steady State normal operating parameters Coolant flow on Gas pressure ok Phase loss on Chopper 1 over-temp off Magnetics over-temp off Coolant over-temp off 9. Ramp-down Current and gas flow decreases after plasma start has been removed Cutflow gas off 10. Auto Off 10 second postflow Main contactors off Choppers off
5-5
MAINTENANCE
Exception 2 no purge process will occur if the operator changes from any process to a nitrogen marking process.
Off-valve 10
SV10 SV10 SV14 SV16
7
SV7 SV7
11
12
13
14
15
16
17
18
19
20
Off-valve 10
SV10 SV10 SV14 SV16
7
SV7 SV7
11
12
13
14
15
16
17
18
19
20
5-6
MAINTENANCE
Off-valve 10 11
SV11 SV11 SV14 SV16
8
SV8 SV8
12
13
14
15
16
17
18
19
20
Off-valve 10 11 12
SV12 SV12 SV14 SV16
6
SV6 SV6
8
SV8 SV8
13
14
15
16
17
18
19
20
Off-valve 10 11 12
SV12 SV12 SV14 SV16
6
SV6 SV6
8
SV8 SV8
13
14
15
16
17
18
19
20
Off-valve 10 11
SV11 SV11 SV14 SV16
5
SV5 SV5
8
SV8 SV8
12
13
14
15
16
17
18
19
20
Off-valve 10 11 12 13 14 15 16 17 18 19 20
5
SV5 SV5
7
SV7 SV7
9
SV9 SV9
5-7
Off-valve 10 11
SV11 SV11 SV14 SV16
8
SV8 SV8
12
13
14
15
16
17
18
19
20
Valves active when changing from a process that does use a fuel gas N2/N2 process Valve location LED number Preflow Cutflow Ar/Ar process Valve location LED number Preflow Cutflow Ar/Air 25 to 35 amps LED number Preflow Cutflow Ar/Air < 25 or > 35 amps LED number Preflow Cutflow 1
SV1 SV1
Off-valve 10 11
SV11 SV11 SV14 SV16
8
SV8 SV8
12
13
14
15
16
17
18
19
20
Off-valve 10 11
SV11 SV11 SV14 SV16
8
SV8 SV8
12
13
14
15
16
17
18
19
20
Off-valve 10 11
SV11 SV11 SV14 SV16
5
SV5 SV5
7
SV7 SV7
12
13
14
15
16
17
18
19
20
Off-valve 10 11
SV11 SV11 SV14 SV16
8
SV8 SV8
12
13
14
15
16
17
18
19
20
5-8
Power supply
Start circuit PA enable AC power Control signals to outputs Power distribution board
Gas console
DC power in
MAINTENANCE
5-9
MAINTENANCE
Error codes
HyPerformance plasma system error codes
Error codes are displayed in the 3-digit LED display on the gas console.
5-10
009
The flow switch is tested when the pump restarts after a pump timeout Flow switch (30 minutes without a start Wait 10 seconds for the flow rate to stabilize. test signal). The test ensures that the coolant flow is correct before firing the torch. Test in progress One of the gas test modes Wait for the test to finish. is running.
012
013
No action required.
014
Cut gas channel 1 fail Cut gas channel 2 fail Plasma rampdown fail Shield rampdown fail Pump over pressure HPR260 only
The gas pressure in channel 1 is decreasing, which indicates a leak. The gas pressure in channel 2 is decreasing, which indicates a leak. Plasma pressure did not decrease in the time allowed. Shield pressure did not decrease in the time allowed. Pump output has exceeded 15.5 bar (225 psi).
Look for leaks and loose connections between the selection console and the metering console.
015
Look for leaks and loose connections between the selection console and the metering console.
016
017
Inspect the holes in the shield for obstructions. Replace the shield if the holes are blocked.
018
1. Verify that coolant filters are in good condition. 2. Verify that there are no restrictions in the coolant system.
020
No current detected from No pilot arc chopper at ignition and before 1-second timeout.
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). 4. Verify spark across spark gap. 5. Inspect CON1 and pilot arc relay for excessive wear. 6. Perform gas flow test (see Maintenance section). 7. Perform torch lead test (see Maintenance section). 8. Perform start circuit test (see Maintenance section). 9. Perform chopper test (see Maintenance section).
5-11
021
No arc transfer
No current detected on 1. Verify proper pierce height. work lead 500 milli-seconds 2. Verify proper preflow and cut-flow settings. after pilot arc current was 3. Inspect work lead for damage or loose connections. established.
024
1. Verify that the consumable parts are in good condition. 2. Verify proper cut-flow gas settings. Lost current Lost the current signal from 3. Verify pierce delay time. Chopper 1 Chopper 1 after transfer. 4. Verify arc did not lose contact with plate while cutting (hole cutting, scrap cutting, etc). 5. Perform chopper test (see Maintenance section). 1. Verify that the consumable parts are in good condition. Lost current 2. Verify proper cut-flow gas settings. Chopper 2 Lost the current signal from 3. Verify pierce delay time. HPR260 Chopper 2 after transfer. 4. Verify arc did not lose contact with plate while cutting (hole HPR400 cutting, scrap cutting, etc). Only 5. Perform chopper test (see Maintenance section). 1. Verify that the consumable parts are in good condition. 2. Verify proper cut-flow gas settings. 3. Verify pierce delay time. Lost the transfer signal after 4. Verify arc did not loose contact with plate while cutting Lost transfer transfer completed. (hole cutting, scrap cutting, etc). 5. Inspect work lead for damage or loose connections. 6. Try connecting work lead directly to the plate. 7. Perform chopper test (see Maintenance section).
025
026
027
Phase imbalance to Lost phase chopper after contactor engaged or while cutting.
1. Verify phase-to-phase voltage to power supply. 2. Disconnect power to power supply, remove cover on contactor and inspect contacts for excessive wear. 3. Inspect power cord, contactor, and input to chopper for loose connections. 4. Inspect phase loss fuses on Power Distribution board. Replace board if fuses are blown. 5. Perform phase loss test (see Maintenance section).
028
1. Verify that the consumable parts are in good condition. Lost current 2. Verify proper cut-flow gas settings. Chopper 3 Lost the current signal from 3. Verify pierce delay time. HPR400 Chopper 3 after transfer. 4. Verify arc did not lose contact with plate while cutting (hole Only cutting, scrap cutting, etc). 5. Perform chopper test (see Maintenance section).
5-12
030
Gas system error A failure has occurred in Auto Gas the gas system. Only
031
Start lost
1. If a mechanical relay is being used to provide the HPR with a start signal, this relay is either bouncing when activated or the contacts are faulty. Replace the relay. Start signal was received 2. Inspect interface cable for damage; faulty crimps, or poor and then lost before an arc electrical connections. was established. 3. If interface cable is good and a relay is not driving the start input, the CNC is dropping the start signal before a steady state arc has been established. 1. Check the interface cable for damage. The hold wires may be short-circuiting inside. 2. The CNC is maintaining this input, it could be waiting for an IHS complete input from another torch. 3. If CNC interface cable is good and it is a 1-torch system, change PCB3.
032
Hold timeout
033
Selection console was not This is a warning for a possible gas restriction in the leads. able to charge the lines to Verify that there are no restrictions in the plasma and shield the correct value. hoses, or low inlet-gas pressure. 1. Verify that the consumable parts are in good condition. 2. Verify proper cut-flow gas settings. 3. Verify pierce delay time. 4. Verify arc did not lose contact with plate while cutting (hole cutting, scrap cutting, etc). 5. Perform chopper test (see Maintenance section).
034
Lost current Lost the current signal Chopper 4 from Chopper 4 after HPR400 transfer. Only
042
Nitrogen gas pressure under lower limit of 2.07 bar (30 psi) cutting 1.Verify that the nitrogen supply is turned on and inspect gas Low nitrogen supply pressure and volume of gas remaining in supply tanks. 0.34 bar (5 psi) marking (N2) gas During N2 purge, when 2. Verify that the gas regulator is set to 8.27 bar (120 psi). See pressure changing between a fuel Setting the supply regulators (Installation section). gas process and an oxidizer process.
5-13
044
Plasma gas pressure under lower limit of 0.34 bar (5 psi) preflow Low plasma 3.45 bar (50 psi) cutflow gas pressure (cutting) 0.34 bar (5 psi) cutflow (marking)
1. Inspect gas supply pressure and volume of gas remaining in supply tanks. 2. Verify the gas regulator settings on gas console with the parameters in the cut charts. 3. See Setting the supply regulators (Installation section). 4. Perform gas leak tests (Maintenance section).
045
1. Verify gas supply pressure settings. 2. Verify gas regulator settings on gas console with cut chart. Plasma gas pressure over 3. See Setting the supply regulators (Installation section). High plasma upper limit of: 4. Solenoid at off-valve is not opening. Verify power to valves, gas pressure 7.58 bar (110 psi) manual disconnect plasma and shield hoses exiting off-valve. 9.65 bar (140 psi) auto If pressures decrease a valve is not functioning or no power to the valve.
046
1. Verify input-line voltage at PCB2 in the power supply and PCB1 in the cooler. 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 with a DC volt meter. It should be about 0.415 VDC between TP23 and Line voltage is close to or TP2 on PCB1. less than the lower limit of 5. If AC voltage on PCB2, J2.4, pins 3 and 4, is greater than 102 VAC (120 VAC -15%). 108 VAC and DC voltage between TP23 and TP2 on The normal lower limit for PCB1 is less than 0.38 VDC, verify minimum 108 VAC operation is voltage on plug J4, pins 1 and 2 on PCB1. Verify the wiring 108 VAC (120 VAC -10%). between PCB2 in the power supply and J4 on PCB1. If the voltage on plug J4 is greater than 108 VAC, but the DC voltage on TP23 and TP2 is less than 0.38, replace PCB1. 6. If the AC voltage on PCB2 in the power supply at J2.4, pins 3 and 4, is greater than 108 VAC and the DC voltage between TP23 and TP2 on PCB1 in the cooler is also greater than 0.38 VDC, verify the CAN link between PCB3 in the power supply and PCB1 in the cooler.
5-14
047
1. Verify input-line voltage at PCB2 in the power supply and PCB1 in the cooler. 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 with a DC volt Line voltage is close to or meter. It Should be about 0.415 VDC between TP23 and greater than the upper limit TP2 on PCB1. of 138 VAC 5. If AC voltage on PCB2, J2.4, pins 3 and 4, is less than (120 VAC +15%). 132 VAC and DC voltage between TP23 and TP2 on PCB1 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 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 power cable) is not damaged and is properly connected An error occurred with the inside the power supply and to the rear of the gas console. CAN communications 3. Verify that D1 (+5 VDC) and D2 (+3.3 VDC) are illuminated between the power supply on PCB2 inside the gas console. These LEDs indicate 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.
048
CAN error
050
1. Stop or clear the cutting program. The plasma start signal to the plasma was not dropped after the last cut. 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 is on at active during power-up of open circuit between pins 15 and 34. power-up power supply. 4. If the circuit is closed either the CNC is issuing a plasma 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. Shield pressure is below Low shield lower limit of 0.14 bar gas pressure (2 psi). 1. Verify gas supply pressure and that a sufficient volume of gas remains in your supply. 2. Verify gas regulator settings on gas console with cut chart. 3. See Setting the supply regulators (Installation section). 4. Perform gas leak tests (Maintenance section).
053
5-15
054
1. Verify gas supply regulator settings. See Setting the supply regulators (Installation section). Shield gas pressure is over High shield 2. Verify pressure settings on gas console with cut chart. upper limit of: gas 3. Solenoid at off-valve is not opening. Verify power to valves, 7.58 bar (110 psi) manual pressure disconnect plasma and shield hoses exiting off-valve. If 9.65 bar (140 psi) auto pressures decrease, a valve is not functioning or no power to the valve. MV1 inlet pressure Auto Gas Only MV2 inlet pressure Auto Gas Only Motor valve 1 inlet pressure 1. Verify that gas pressure transducer P1 is between 3.45 bar is less than 3.45 bar (50 psi) and 9.65 bar (140 psi). Increase or decrease the (50 psi) or greater than inlet gas pressure to correct the problem. 9.65 bar (140 psi). Motor valve 2 inlet pressure 1. Verify that gas pressure transducer P2 is between 3.45 bar is less than 3.45 bar (50 psi) and 9.65 bar (140 psi). Increase or decrease the (50 psi) or greater than inlet gas pressure to correct the problem. 9.65 bar (140 psi).
055
056
057
Cut gas 1 outlet pressure is Cut gas 1 less than 3.45 bar 1. Verify that gas pressure transducer P3 is between 3.45 bar pressure (50 psi) or greater than (50 psi) and 9.65 bar (140 psi). Increase or decrease the Auto Gas 9.65 bar (140 psi) in the inlet gas pressure to correct the problem. Only selection console. Cut gas 2 outlet pressure is less than 3.45 bar Cut gas 2 (50 psi) for non-mixing, or 1. Verify that gas pressure transducer P4 is between 3.45 bar pressure less than 1.38 bar (20 psi) (50 psi) and 9.65 bar (140 psi). Increase or decrease the Auto Gas when mixing or greater than inlet gas pressure to correct the problem. Only 9.65 bar (140 psi) for nonmixing and mixing. Coolant flow is less than Low the required 2.3 lpm coolant flow (0.6 gpm). 1. Verify that the correct consumables are properly installed. 2. Perform the coolant flow test procedure in the Maintenance section of the manual.
058
060
061
1. Auto 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. Manual gas - the selector knob (2) may be set between not receiving signals from positions. Reset the knob. No plasma the gas selector knob. 3. Verify that there is power to the console by looking to see if gas type any LED on any board in the selection console (auto) or gas Auto gas - The selection console (manual) is illuminated. If no LED is illuminated, console is not receiving the verify that the fuse on the power distribution PCB is in plasma gas type signal. proper working condition. 4. If the problem still exists, replace the control board.
5-16
062
1. Auto 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. Manual gas - the selector knob (2) may be set between not receiving signals from positions. Reset the knob. No shield gas the gas selector knob. 3. Verify that there is power to the console by looking to see if type any LED on any board in the selection console (auto) or Auto gas - The selection gas console (manual) is illuminated. If no LEDs are console is not receiving the illuminated, verify that the fuse on the power distribution shield gas type signal. 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. 3. Verify that the voltage on rear side of J3.202, pins 2 and 3 Chopper 1 has overheated. on PCB3, is less than or equal to 2.9 VDC. 4. If the voltage is low, verify correct wiring between chopper 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 sink of chopper. 3. Verify that the voltage on rear side of J3.202, pins 5 and 6 Chopper 2 has overheated. on PCB3, is less than or equal to 2.9 VDC. 4. If the voltage is low, verify correct wiring between chopper 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. 1. Verify that all the large fans are operating properly. Spinning fan blades should be difficult to see. 2. Blow dust out of system especially from fans and large power transformer. 3. Verify that the voltage on the rear side of J3.202 pins 14 and 15, is equal to or less than 3.2 VDC. 4. If voltage is low or near 0 VDC, inspect wiring between the transformer's temperature sensor and J3.202 pins 13 and 14. Look for shorts between wires or to ground. 5. If wiring is good, the transformer has overheated. Allow the power supply to idle with the fans running for a minimum of 30 minutes to cool the large power transformer. 6. Replace the transformer's temperature sensor if it is open or shorted. Replacement kit part number is 228309.
065
Chopper 1 overtemp
066
067
Magnetics overtemp
5-17
071
Coolant overtemp
072
Auto gas, control board Control board has overtemp exceeded 90 C (194 F). Auto Gas Only
073
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. 3. Verify that the voltage on rear side of J3.202, pins 8 and 9 Chopper 3 has overheated. on PCB3, is less than or equal to 2.9 VDC. 4. If the voltage is low, verify correct wiring between chopper 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 sink of chopper. 3. Verify that the voltage on rear side of J3.202, pins 11 and Chopper 4 has overheated. 12 on PCB3, is less than or equal to 2.9 VDC. 4. If the voltage is low, verify correct wiring between chopper 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. A current less than 10 amps has been detected by current sensor 3. A current less than 10 amps has been detected by current sensor 4.
074
075
Low current on CS3 HPR400 Only Low current on CS4 HPR400 Only
076
5-18
093
1. If this is a new system, follow start procedure. 2. Verify that the coolant filter is in good condition. No coolant Coolant flow signal was 3. Perform coolant flow tests (Maintenance section). flow lost or never was satisfied. 4. Verify that the CNC drives the plasma start signal for at least 10 seconds to allow the timed-out pump to turn on again. High current on CS4 HPR400 Only A current greater than 35 amps has been detected by current sensor 4.
095
099
1. Verify that the temperature sensor for the chopper has not Chopper 1 been bypassed or that the wires to the temperature switch Chopper 1 is indicating an overtemp at are shorted out in the harness, or that the sensor is open. overtemp at power-up. power-up 2. If no jumper is present, the chopper is overheated and needs time to cool to 83 C (181.4 F). Chopper 2 1. Verify that the temperature sensor for the chopper has not overtemp at been bypassed or that the wires to the temperature switch power-up Chopper 2 is indicating an are shorted out in the harness, or that the sensor is open. HPR260 overtemp at power-up. 2. If no jumper is present, the chopper is overheated and HPR400 needs time to cool to 83 C (181.4 F). Only 1. Verify that the transformer temperature sensor has not been bypassed or the wires to the temperature sensor are not shorted out in the harness. 2. Verify that the sensor is not open or shorted, if it is not open or shorted, the main transformer is overheated and needs time to cool to 150 C (302 F). See wiring diagrams in section 7
100
101
102
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
A current greater than High current 35 amps has been on CS1 detected by current sensor 1. High current on CS2 HPR260 HPR400 Only A current greater than 35 amps has been detected by current sensor 2.
104
105
A current less than Low current 10 amps has been on CS1 detected by current sensor 1.
5-19
106
107
108
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 PCB 3 if connections are correct and not damaged. 3. Verify that the main contactor (CON1) is not welded closed, or closing at power-up. 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. 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).
109
Coolant flow OK signal Coolant flow is active during power-up at power-up and before pump motor is activated. Coolant Coolant is indicating an overtemp at overtemp at power-up. power-up
111
116
Watchdog interlock
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 D2 (+3.3 VDC) are illuminated on PCB2 inside the gas An error occurred with the console. These LEDs indicate power to PCB2. CAN communication 3b. (Auto gas console) Verify that D17 (+5 VDC) and D18 system. (+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. Motor valve 1 did not move into position within 60 seconds. 1. Verify that LED D17 or D18 illuminates on the AC valve driver PCB in the selection console. If either illuminates, replace the motor valve. If they do not illuminate, replace PCB3.
123
5-20
124
133
1. Verify that the part numbers of PCB2 and PCB3 are correct. 2. 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. The power supply control 3. Verify that cable number 6 (power supply-to-gas console board does not recognize power cable) is not damaged and is properly connected Unknown gas the gas console that is inside the power supply and to the rear of the gas console. console type installed or has not 4. Verify that D1 (+5 VDC) and D2 (+3.3 VDC) are received a CAN message. illuminated on PCB2 inside the gas console. These LEDs indicate power to PCB2. 5. 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.
134
Chopper 1 overcurrent
1. Verify that the wiring between CS1 and PCB3 is correct and not damaged. 2. Measure voltage across current sensor. a) Red to black = +15 VDC, Green to black = -15 VDC, white to black = 0 VDC at idle and varies with current output (4 VDC = 100 amps). b) If possible, take a voltage reading on current sensor while trying to cut. Ratio is 4 VDC = 100 amps. c) If the current sensor voltage is approximately 6.4 VDC or greater at idle, replace the current sensor. 3. Remove connector JA.1 from the chopper and verify that LED1 is extinguished. a) If LED1 is extinguished with the connector removed, then reconnect JA.1 and try to fire the torch. If the chopper still goes into overcurrent, replace the chopper. b) If the chopper does not go into overcurrent, replace PCB3.
5-21
138
139
This is a warning for a possible gas restriction in the leads. 1. Verify that there are no restrictions in the plasma and shield Purge The purge cycle did not hoses. time-out error complete within 3 minutes. 2. Verify that the inlet gas pressures are set to the proper levels. Pressure transducer 1or 8 error Auto Gas Only Pressure transducer 2 or 7 error Auto Gas Only Pressure transducer 3 or 5 error Auto Gas Only Pressure transducer 4 or 6 error Auto Gas Only Faulty transducer or control board in the metering console or the selection console. 1. Verify that transducer P1 in the selection console is working properly. Replace if necessary. 2. Verify that transducer P8 in the metering console is working properly. Replace if necessary. 3. Verify that the control boards in the metering and selection consoles are working properly. Replace if necessary. 1. Verify that transducer P2 in the selection console is working properly. Replace if necessary. 2. Verify that transducer P7 in the metering console is working properly. Replace if necessary. 3. Verify that the control boards in the metering and selection consoles are working properly. Replace if necessary. 1. Verify that transducer P3 in the selection console is working properly. Replace if necessary. 2. Verify that transducer P5 in the metering console is working properly. Replace if necessary. 3. Verify that the control boards in the metering and selection consoles are working properly. Replace if necessary. 1. Verify that transducer P4 in the selection console is working properly. Replace if necessary. 2. Verify that transducer P6 in the metering console is working properly. Replace if necessary. 3. Verify that the control boards in the metering and selection consoles are working properly. Replace if necessary.
140
141
Faulty transducer or control board in the metering console or the selection console.
142
Faulty transducer or control board in the metering console or the selection console.
143
Faulty transducer or control board in the metering console or the selection console.
5-22
145
146
1. Verify that the temperature sensor for the chopper has not been bypassed or that the wires to the temperature switch Chopper 3 is indicating an are shorted out in the harness, or that the sensor is open. overtemp at power-up. 2. If no jumper is present, the chopper is overheated and needs time to cool to 83 C (181.4 F). 1. Verify that the temperature sensor for the chopper has not been bypassed or that the wires to the temperature switch Chopper 4 is indicating an are shorted out in the harness, or that the sensor is open. overtemp at power-up. 2. If no jumper is present, the chopper is overheated and needs time to cool to 83 C (181.4 F).
147
151
Software has detected an Software fail incorrect state or 1. Replace power supply control board. condition. Communication problem Internal flash to the flash chip on error the power supply control board. EEPROM memory on PS EEPROM power supply control error board not working.
152
153
1. Replace the control board. 1. Verify that the wiring between CS3 and PCB3 is correct and not damaged. 2. Measure voltage across current sensor. a) Red to black = +15 VDC, Green to black = -15 VDC, white to black = 0 VDC at idle and varies with current output (4 VDC = 100 amps). b) If possible, take a voltage reading on current sensor while trying to cut. Ratio is 4 VDC = 100 amps. c) If the current sensor voltage is approximately 6.4 VDC or greater at idle, replace the current sensor. 3. Remove connector JC.1 from the chopper and verify that LED1 is extinguished. a) If LED1 is extinguished with the connector removed, then reconnect JC.1 and try to fire the torch. If the chopper still goes into overcurrent, replace the chopper. b) If the chopper does not go into overcurrent, replace PCB3.
154
5-23
155
156
See wiring diagrams in section 7 Chopper 3 current at power-up HPR400 Only Chopper 3 current signal is active at power-up 1. Verify that the voltage at CS3 is correct. 2. Verify that the wiring between CS3 and PCB3 is correct and not damaged. 3. Swap CS3 with CS2. If the error code changes to 156, replace the original CS3.
157
See wiring diagrams in section 7 Chopper 4 current at power-up HPR400 Only Chopper 4 current signal is active at power-up 1. Verify that the voltage at CS4 is correct. 2. Verify that the wiring between CS4 and PCB3 is correct and not damaged. 3. Swap CS4 with CS2. If the error code changes to 156, replace the original CS4.
158
5-24
159
1. Verify that the circuit breaker on PCB7 has not tripped. If it has tripped, reset the breaker by pressing the button until it is even with the top of the circuit breaker. If the circuit breaker is not tripped and there is no power to PCB7, verify that the fuse on PCB2 in the power supply is good. 2. If D32 illuminates, the solenoid valve and motor are drawing too much current. D32 will only illuminate for a short time, and extinguishes after the outputs from the pump-motordrive turn-off in response to the fault condition. Verify the wiring to the solenoid valve and the motor. Verify that the pump spins freely and is properly mounted to the motor. Look for obstructions in the torch, consumables, coolant lines, and in-line filter. Verify that the solenoid valve is operating. Any of these can cause the motor or solenoid valve to draw excessive current. Test for low coolant flow by using the coolant flow test on page 5-33. 3. If D32 illuminates immediately at power-up, and all the items above have been verified, replace PCB7. 4. If D30 illuminates, the IGBT drive has encountered an overcurrent condition. D30 will only illuminate for a short time, and extinguishes after the outputs from the pump motor-drive turn off. Follow the same steps for D32 above. 5. If D31 illuminates, the heatsink thermistor is indicating that the heatsink is too hot. Wait 10 minutes for it to cool. If the error remains, verify that the wires from heatsink on PCB7 are properly connected to the J6 connector on PCB7. If the error still remains, turn OFF all power to the system and measure the resistance on the J6 connector between pins 1 and 2. At 25 C (77 F) the resistance should be 10k.
160
Communication between the control board (PCB3 HPR coolers in the power supply) and CAN fault the cooler sensor board HPR400 (PCB1 in the cooler) was Only interrupted for more than 1 second.
1. Verify that the cable connections from the power supply to the cooler are good. 2. Verify that D1 (+ 5 VDC) and D2 (+3.3 VDC) are illuminated on PCB1 inside the cooler. 3. Verify that the CAN bus LEDs, D7 and D8 are blinking.
5-25
180
1. Verify that the power supply-to-selection console CONTROL and POWER cables are not damaged and are properly connected to PCB3, and the rear of the selection console. 2. Verify that D17 (+5 VDC) and D18 (+3.3 VDC) are illuminated on PCB2 inside the selection console. These Selection LEDs indicate power to PCB2. Also verify that D26 (CAN The power supply did not console CAN RX) and D27 (CAN - TX) are illuminated on PCB2 inside receive a CAN message timeout the selection console. These LEDs indicate communication from the selection console Auto Gas between the selection console and the power supply. within 1 second. Only 3. If power is present at PCB2 and PCB3 and both selection console cables are good, then PCB2 or PCB3 has failed. Use the CAN tester to verify which board needs to be replaced. 4. Verify that the gas console control PCB and power distribution PCBs are securely mounted to the chassis at all four corners.
181
1. Verify that the power supply-to-metering console CONTROL and POWER cables are not damaged and are properly connected to PCB3, and the rear of the metering console. 2. Verify that D17 (+5 VDC) and D18 (+3.3 VDC) are illuminated on PCB2 inside the metering console. These LEDs indicate power to PCB2. Also verify that D26 (CAN Metering The power supply did not RX) and D27 (CAN - TX) are illuminated on PCB2 inside console CAN receive a CAN message the metering console. These LEDs indicate communication timeout from the metering console between the metering console and the power supply. Auto Gas within 1 second. 3. If power is present at PCB2 and PCB3 and both metering Only console cables are good, then PCB2 or PCB3 has failed. Use the CAN tester to verify which board needs to be replaced. 4. Verify that the gas console control PCB and power distribution PCBs are securely mounted to the chassis at all four corners.
5-26
MAINTENANCE
State Name code 00 02 03 04 05 06 07 08 09 10 11 12 14 15 16 20 22 23 24 Power -up (idle) Purge Ready for start (Idle 2) Preflow Pilot arc Transfer Ramp-up Steady state Ramp-down Final ramp-down Cycle complete (Auto off) Test cutflow Shutdown Reset Maintenance Test preflow Manual pump control Inlet leak check System leak check
5-27
MAINTENANCE
Yes
No
System is in IDLE state waiting for a START signal, NOT READY FOR START signal is inactive If 30 minutes has passed since the last start, turn OFF the pump START signal removed
START signal No
Yes
Yes
If the pump has timed out, turn on the NOT READY FOR START signal and turn on the pump
No
5-28
MAINTENANCE
Assert the PLASMA START and HOLD signals to all plasma systems
Yes
Is the NOT READY FOR START signal active on any plasma system No
5-29
MAINTENANCE
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.
1. Disconnect line power by turning OFF the main disconnect switch. 2. Remove the power supplys 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.
5-30
MAINTENANCE
Power measurement
DANGER
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
U V W
Note:
Check lines in the following order: U to V U to W V to W Check each line to ground. If one line is 10% or higher than the other 2, put that leg on U.
5-31
MAINTENANCE
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.
5-32
MAINTENANCE
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).
5-33
MAINTENANCE
Caution:
Coolant will flow from the filter when its housing is removed. Drain coolant before servicing the filter.
Strainer Nut
5-34
Go to steps to take before testing on the next page Flow rate from flow tube < 0.8 gpm
Go to pump/motor troubleshooting
No flow
Go to test 1
Go to test 2
Go to test 6
Flow rate from flow tube > 0.8 gpm Flow rate from CNC > 0.8 gpm
Go to test 7
Replace the torch If the flow shown On the CNC is > 0.9 gpm
Go to test 3
Order a replacement Check valve or your Coolant will drain out at Each consumable change
Check your power supply outlet hose for kinks. If there are no kinks, replace the bypass valve and the hose set between the power supply and the high frequency console.
Go to test 4 Replace the flow switch Flow rate from bucket test > 0.9 gpm Flow rate from bucket test > 0.9 gpm Flow rate from bucket test < 0.9 gpm Flow rate from bucket test < 0.9 gpm There is a kink or clog between the high frequency console and the power supply. If there is not a kink, replace the leads.
MAINTENANCE
There is a kink in the return hose to the power supply. If there is not a kink, replace the hose.
Go to test 5
There is a kink in the leads between the high frequency console and the torch. If there is not a kink, replace the leads.
MAINTENANCE
Before testing
Note: Coolant must be drained from the system before the in-line lter is cleaned (step 1 below). The coolant in the system will drain out as soon as the in-line lter is removed.
1. Clean the filter/strainer. 2. Replace the filter on the rear of the power supply. 3. Verify that the system has the correct level of coolant, when refilling the system after completing steps 1 and 2.
Filter/Strainer Nut
1.2 1.0
Float
.8 .6 .4 .2
Flow direction
5-36
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. Note: A ow diagram can be found on schematic 013375, sheet 15 of 19
5-37
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). If the flow rate is 0.8 gpm or more, go to test 7. If the flow rate is less than 0.8 gpm, go to test 2. If there is no flow, go to pump and motor troubleshooting.
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 container is full in 65 seconds or less, go to test 3. If it takes more than 65 seconds to fill the container, go to test 6.
5-38
Caution:
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. If it takes more than 65 seconds to fill the container, there is an obstruction in the torch receptacle. Replace the torch receptacle. If the container is full in 65 seconds or less, there is an obstruction in the return coolant line (from the RHF/LHF console to the power supply). Replace the return coolant line.
5-39
1. Turn OFF the power. Remove the hose from the relief valve.
5-40
Note:
The check valve must be oriented correctly. The arrow points up, as shown.
5-41
TP 206
TP 210
041993
5-42
MAINTENANCE
5-43
MAINTENANCE
Control PCB3 firmware list Item U104 U105 Part number 081169 EVEN 081169 ODD
Notes
= HPR130 = HPR260 Note: See wiring diagrams for other dipswitch settings
LED D321 D322 D323 D324 D325 D326 D327 D328 D329 D330
Control PCB LED list Output Input Machine motion Error Rampdown error Not ready Spare Pilot arc enable Hold Pierce Corner current Plasma start
Notes
Control PCB LED list Output Input HV transformer Pump motor enable Contactor Pilot arc relay Spare Surge select Phase loss
Notes
Not used
5-44
MAINTENANCE
D1
D2
D5
D7
D25
Power distribution PC board LED list LED D1 D2 D3 D5 D7 D12 D23 D25 D26 D31 D32 D33 D35 Output Contactor Pilot arc relay 120 VAC (switched) HF ignition Surge select 24 VAC (switched) 240 VAC (switched) + 24 VDC Pump motor + 5 VDC 15 VDC + 15 VDC 24 VAC Color Red Red Green Red Red Green Green Red Green Red Red Red Green
D23
D26
D31
D32
5-45
MAINTENANCE
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.
Choke
Diode
Pilot arc
Start circuit
5-46
MAINTENANCE
D2 should always be illuminated. D1 illuminates as soon as the torch fires and will extinguish as soon as the arc transfers to the workpiece. If arc transfer is immediate, the LED will not illuminate. If there is no arc at the torch or if the arc will not transfer: 1. Turn OFF all power to the system. 2. Remove wires from H8 (WORK) and H9 (NOZZLE) studs on the board. 3. Verify a resistance of about () 5.5 k between H8 and D50 (). If the resistance value is not correct, replace the board. Note: Resistance value may slowly increase to the correct value due to the capacitance in the circuit. 4. Verify a resistance of about () 15 k between snubber and H8. The work lead should not have any cuts or breaks. Verify a resistance of 1 or less. The work lead connection to the cutting table should be clean and have good contact to the table. Verify that LED-D2 is illuminated. If it is not illuminated, the board may need to be replaced or the board may not be receiving power. Fire the torch in the air and verify that D1 is illuminated. If it is not illuminated, but a pilot arc is established, the board may need to be replaced. Verify a resistance of about () 1 across the R1 resistor.
D1 D2
15k or
H8 WORK
H9 NOZZLE
5.5k
R1
5-47
MAINTENANCE
Transfer current
Plasma gas O2 N2 H35 F5 Air 30-amps 10 10 10 10 10 45-amps 10 10 10 10 10 50-amps 10 10 10 10 10 80-amps 10 10 10 10 10 130-amps 15 15 15 15 15
5-48
MAINTENANCE
Control PCB2 firmware list Item U17 U18 Part number 081109 EVEN 081109 ODD
LEDN LEDN1 LEDN2 LEDN3 LEDN4 LEDN5 LEDN6 LEDN7 LEDN8 LEDN9 LEDN10 LEDN11
Gas console control board LEDN list Signal name Plasma preflow, left digit Plasma preflow, right digit Plasma cutflow, left digit Plasma cutflow, right digit Shield preflow, left digit Shield preflow, right digit Shield cutflow, left digit Shield cutflow, right digit Current, left digit Current, center digit Current, right digit
Color Red Red Red Red Red Red Red Red Red Red Red
Gas console control board LED list LED Signal name Color D1 D2 D4 D6 D8 D9 D10 D11 + 5 VDC + 3.3 VDC Coolant error Pressure error CAN TX CAN RX Voltage error Temperature error Green Green Yellow Yellow Green Green Yellow Yellow
5-49
MAINTENANCE
Gas console control board LED list LED Signal name Color D1 D7 D9 120 VAC (switched) + 5 VDC + 24 VDC Green Red Red
5-50
MAINTENANCE
LED D1 D2 D3 D4 D5 D6 D7 D8 D9 D10
Signal name SV1 SV2 SV3 SV4 SV5 SV6 SV7 SV8 SV9 SV10
Color Red Red Red Red Red Red Red Red Red Red
SV14 SV13
LED D11 D12 D13 D14 D15 D16 D17 D18 D19 D20
Signal name SV11 SV12 SV13 SV14 SV15 SV16 SV17 SV18 SV19 SV20
Color Red Red Red Red Red Red Red Red Red Red
SV16 SV17
Off-valve
SV5 SV1
5-51
MAINTENANCE
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.
LED display
Troubleshooting low-current error code 105 1. Verify that the current sensors (CS1 and CS3) and cables are not damaged. 2. Exchange CS1 and CS3. Replace the faulty sensor if the error code is not displayed again. 3. Measure the resistance between wire 38 and wire 39 on PCB6 with a meter. The value should be increasing as the capacitor charges. Replace PCB6 if a constant value is seen. 4. Check for loose wires or shorts from the chopper to PCB6. 5. Check for 220 VAC to 1A, 1B, and 1C on the chopper when the contactor closes.
CS3
CS1
5-52
MAINTENANCE
Troubleshooting high-current error code 103 1. Verify that the current sensors (CS1 and CS3) and cables are not damaged. 2. Exchange CS1 and CS3. 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.
5-53
MAINTENANCE
2. Inspect the condition of the 3 contacts for excessive wear. If one or more of the contacts are worn excessively, replace CON1 and restart the system. If the error remains, perform the following steps.
OK
Excessive wear
3. Test the fuses F5, F6, and F7 on the power distribution board (PCB2). If any of the fuses are blown, replace PCB2.
D1
D2
D5
D7
D25
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-tophase 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.
5-54
D23
D26
D31
D32
MAINTENANCE
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.
3. Install a temporary jumper wire between H8 (work) and H9 (nozzle) on the start circuit PCB1.
D1 D2
H8 WORK
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.
5-55
MAINTENANCE
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.
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 roughened, black surface. Replace if necessary.
5-56
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.
5-57
MAINTENANCE
16. If the gas line pressures hold steady, perform a system gas leak test as specified in this manual. 17. Check for hose restrictions, as follows: A. Check all hoses to verify that they have no kinks or sharp bends, which can restrict gas flow. B. If the cutting table uses a power track system to support leads from the power supply to the gas console or torch, check the position of the leads in the power track to ensure the leads do not twist or kink, causing a possible restriction.
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 connection because a poor connection may cause arc-transfer problems. 24. Complete the Preventive Maintenance worksheet on the next page, for future reference.
5-58
MAINTENANCE
Weekly:
Week 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. Jan Feb March April May June July Aug Sept Oct Nov Dec
Semi-Annually:
Year 1st service 2nd service
Annually:
Year Replace service parts per the Service Part Replacement Schedule.
5-59
Comments
Power supply
P P P P NP NP NP NP
1. Inspect for particulates and blow out 2. Inspect wiring harnesses 3. Inspect main contactor 4. Inspect pilot arc relay
Coolant system
P P NP NP
5. Inspect filter element 6. Perform coolant flow test A. Coolant flow checked at _________ gallons per minute ( _________ l/min)
16. Perform gas leak test A. Oxygen pressure drop at ____________ psi in 10 minutes ( ____________ bar) B. Nitrogen pressure drop at ____________ psi in 10 minutes ( ____________ bar) NP 17. Inspect for hose restrictions P NP A. Motor valve hoses P NP B. Gas console to motor valve P NP C. Off-valve to torch body P NP D. Hoses in power track
NP
Cable connections
P NP P P P
7. Inspect water tube 8. Inspect current ring 9. Clean threads on torch front end 10. Inspect Vespel torch insulator 11. Inspect torch and consumable o-rings 12. Verify proper fit of retaining or shield cap 13. Inspect hose fittings 14. Inspect torch-to-torch-lead connections
18. Inspect cables NP A. CommandTHC NP B. Control cable from off-valve to gas console NP C. From ignition console and gas console to power supply
Ignition console
P P NP NP NP
Gas flows
P NP P P P P P P
15. Inspect plumbing from gas supply NP A. Oxygen NP B. Nitrogen or argon NP C. Air NP D. Nitrogen-Hydrogen (F5) NP E. Argon-Hydrogen (H35) NP F. Inspect compressed air filter system
19. Inspect for moisture, dust and particulates 20. Inspect spark gap subassembly 21. Inspect torch leads
System grounding
P P NP NP
22. Inspect for proper system component grounding 23. Inspect connection from cutting table to workpiece (+) lead
MAINTENANCE
Timeline
Component
Coolant filter element Coolant solution 70/30 Torch kit Quick-disconnect kit Air filter element Coolant filter element Coolant solution 70/30 Main contactor Torch main body Pilot arc relay Air filter element Coolant filter element Coolant solution 70/30 Torch kit Quick-disconnect kit Air filter element Coolant filter element Coolant solution 70/30 Main contactor Torch main body Pilot arc relay Coolant pump kit Torch leads Air filter element Coolant filter element Coolant solution 70/30 Torch kit Quick-disconnect kit Air filter element Coolant filter element Coolant solution 70/30 Main contactor Torch main body Pilot arc relay Cooling fan 6" Cooling fan 10" Air filter element Coolant filter element Coolant solution 70/30 Torch kit Quick-disconnect kit Air filter element
Part number
027664 028872 128879 128880 011110 027664 028872 003139 220162 003149 011110 027664 028872 128879 128880 011110 027664 028872 003139 220162 003149 228170 System dependant 011110 027664 028872 128879 128880 011110 027664 028872 003139 220162 003149 127039 027079 011110 027664 028872 128879 128880 011110
Qty.
1 4 1 1 1 1 4 1 1 1 1 1 4 1 1 1 1 4 1 1 1 1 1 1 1 4 1 1 1 1 4 1 1 1 4 3 1 1 4 1 1 1
5-61
MAINTENANCE
Part number
027664 028872 003139 220162 003149 228170 System dependant 228538 011110 027664 028872 128879 128880 011110 027664 028872 003139 220162 003149 129854 041802 078535 System dependant System dependant 011110 027664 028872 128879 128880 011110 027664 028872 003139 220162 003149 228170 System dependant 127039 027079 011110
Qty.
1 4 1 1 1 1 1 1 1 1 4 1 1 1 1 4 1 1 1 1 1 1 1 1 1 1 4 1 1 1 1 4 1 1 1 1 1 4 3 1
5-62
In this section:
Power supply ..............................................................................................................................................................................................6-2 Ignition console...........................................................................................................................................................................................6-7 Gas console 1 of 2 ................................................................................................................................................................................6-8 Gas console 2 of 2 ................................................................................................................................................................................6-9 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...............................................................................................................................................6-13 Recommended spare parts...................................................................................................................................................................6-14
6-1
PARTS LIST
Power supply
2 1
3 6 4
Item 1
Part Number 078538 078539 078540 078541 078542 078543 078544 078545 228328 075241 228532 228531 129633
Description HyPerformance Plasma power supply: 200/208 volt HyPerformance Plasma power supply: 220 volt HyPerformance Plasma power supply: 240 volt HyPerformance Plasma power supply: 380 volt HyPerformance Plasma power supply: 400 volt HyPerformance Plasma power supply: 440 volt HyPerformance Plasma power supply: 480 volt HyPerformance Plasma power supply: 600 volt Panel: Top, with label Sheet metal screws Panel: Right or left side, with label Panel: Front, with label Green power lamp assembly
Designator
Qty.
2 3 4 5 6
1 1 1 1 1
6-2
PARTS LIST
Power supply
2 3
6
Item 1 2 3 4 5 6 Part Number 027634 027664 127014 129792 127039 027079 014283 014284 014282 014303 014283 014284 014282 014281 228309 Description Filter housing Filter element Cap: Coolant reservoir Chopper assembly 6" fan: 230 CFM, 115 VAC 50-60 HZ 10" fan: 450-550 CFM, 120 VAC 50-60 HZ 200 volt main transformer: 19.5 KW, 3 ph, 50 HZ 220 volt main transformer: 19.5 KW, 3 ph, 50-60HZ 240 volt main transformer: 19.5 KW, 3 ph, 60 HZ 380 volt main transformer: 19.5 KW, 3 ph, 50 HZ 400 volt main transformer: 19.5 KW, 3 ph, 50 HZ 440 volt main transformer: 19.5 KW, 3 ph, 50-60 HZ 480 volt main transformer: 19.5 KW, 3 ph, 60 HZ 600 volt main transformer: 19.5 KW, 3 ph, 60 HZ Kit: Thermistor replacement for main transformer Designator Qty. 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1
CH1
T2
6-3
PARTS LIST
Power supply
4 3 5
6a
6b
Item 1 2 3 4 5 6a 6b 7
Part Number 003149 041837 003139 109036* 229238 109004 109004 014280
Description Relay: Pilot arc, 120 VAC PCB: I/O Contactor EMI filter: 60 amp, 440 VAC 3PH Start circuit assembly Current sensor: Hall 100 amp, 4 volt Current sensor: Hall 100 amp, 4 volt Inductor: 4MH
Qty. 1 1 1 1 1 1 1 1
6-4
PARTS LIST
Power supply
4
5 3
1 7
8
10
9
Item 1 2 3 4 5 6 7 8 9 10 Part Number 008551* 008709** 228548 041802 109393 229206 027978 027185 006075 228170 006046 228538 Description Fuse: 7.5 amp, 600 volt Fuse: 20 amp, 500 volt Control PCB Power distribution PCB Temperature sensor Flow switch assembly Heat exchanger assembly 4" fan Check valve: 1/4" FPT Kit: Pump with clamp Solenoid valve assembly: 3/8", 240 volt Kit: Motor with clamp Designator F1, F2 F1, F2 PCB3 PCB2 T2 FLS Qty. 2 2 1 1 1 1 1 2 1 1 1 1
CLT SOL
* 380, 400, 440, 480 and 600 volt power supplies ** 200/208 and 240 volt power supplies
6-5
PARTS LIST
Power supply
Item 1
Part Number 129786 229117 129966 229094 129787 229013 129967 129989
Description Control transformer: 200/208 volt, 50-60 HZ Control transformer: 220 volt, 50-60 HZ Control transformer: 240 volt, 60 HZ Control transformer: 380 volt, 50 HZ Control transformer: 400 volt, 50-60 HZ Control transformer: 440 volt, 50-60 HZ Control transformer: 480 volt, 50-60 HZ Control transformer: 600 volt, 50-60 HZ
Designator T2
Qty. 1 1 1 1 1 1 1 1
6-6
PARTS LIST
Ignition console
2 3
Item 1 2 3 4
Qty. 1 1 1
6-7
PARTS LIST
Gas console
1
2 3 4
7
Part Number 078532 041805 041822 005263 006109 006112 006136 005262
Item 1 2 3 4 5 6 7
Description Gas Console Power distribution PCB Valve driver PCB Pressure sensor Solenoid valve Replacement solenoid coil Solenoid valve Illuminated power switch
Designator PCB1 PCB3 PT1-PT4 SV2, SV3, SV4, SV6, SV8-SV14 SV1, SV5, SV7 SW1
Qty. 1 1 4 11 3 1
6-8
PARTS LIST
Gas console
2 3
4 1
Item 1 2 3 4
Description Control PCB Regulator assembly with elbow fitting Regulator assembly with elbow and tee fitting Kit: Regulator upgrade (replaces all 4 regulators) Filter assembly Filter element
Qty. 1 3 1 1 1
Off-valve
Item 1 2 Part Number 078534 006109 006112 123748 Description Off valve assembly Solenoid valve Replacement solenoid coil Off-valve cable Designator V16-V20 Qty. 1 5 5 1
PARTS LIST
HyPerformance torch
Torch assembly 1
6
Part Number 228520 220706 220571 220705 220789 220788 220790 104269 128879 128880
Item 1 2 3 4 5
Description HPR130XD machine torch assembly Quick-disconnect torch Water tube Quick-disconnect receptacle Torch mounting sleeve assembly: Standard, 181 mm (7 in) Torch mounting sleeve assembly: Short, 114 mm (4.5 in) Torch mounting sleeve assembly: Long, 248 mm (9.75 in) 2" spanner wrench Torch kit: o-rings, water tube and seal Quick disconnect kit: o-ring and connector
6-10
Part no. 228291 228292 228293 228294 228295 228296 228297 228547
Length 2 m (6 ft) 3 m (10 ft) 4.5 m (15 ft) 6 m (20 ft) 7.5 m (25 ft) 10 m (35 ft) 15 m (50 ft) 20 m (65 ft)
Ohmic contact wire (Not part of the HPR130XD system. Shown for reference only)
Part no. 123983 123984 123985 123986 123987 123988 123989 123990 123991 Length 3 m (10 ft) 6 m (20 ft) 7.5 m (25 ft) 9 m (30 ft) 12 m (40 ft) 15 m (50 ft) 23 m (75 ft) 30 m (100 ft) 45 m (150 ft)
6-11
PARTS LIST
6-12
PARTS LIST
30 A
220194 220810 220193 220306 220192
50 A
220555 220810 220554 220549 220552 220340 220747
80 A
220189 220755 220188 220305 220187
130 A
220183 220755 220182 220305 220181
6-13
PARTS LIST
CH1
CLT SOL
Ignition console
Part Number 041817 129854 Description HFHV Ignition PCB Transformer Designator T1 Qty. 1 1
Gas console
Part Number 041805 041822 005263 006109 005262 Description Power distribution PCB Valve driver PCB Pressure sensor Solenoid valve Illuminated power switch Designator PCB1 PCB3 PT1-PT3 SV1-SV14 SW1 Qty. 1 1 1 2 1
Off-valve
Part Number 006109 Description Solenoid valve Designator V16-V19 Qty. 1
6-14
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 numbers are located in the lower right-hand corner. Page-to-page referencing is done in the following manner:
SHEET 4-D3
Source Connection
Destination Sheet #
Destination Coordinates
SHEET 4-D3
Source Sheet #
Source Coordinates
Destination Coordinates
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).
7-1
7-2
Fuse Ground Clamp Ground, Chassis Ground, Earth IGBT Inductor LED Lamp MOV Pin Socket Plug PNP Transistor Potentiometer Relay, Coil Relay, Normally Closed Relay, Normally Open Relay, Solid State, AC Relay, Solid State, DC Relay, Solid State, Dry Resistor SCR Shield Shunt Spark Gap Receptacle Push Button, Normally Open Push Button, Normally Closed
Battery
Cap, polarized
WIRING DIAGRAMS
Cap, non-polarized
Cap, feed-thru
Circuit breaker
Coax shield
Current Sensor
Current sensor
DC supply
Diode
Door interlock
Fan
Feedthru LC
Filter, AC
Switch, Flow
Torch Symbols
Switch, Level, Normally Closed Time Delay Closed, NO/Off Electrode Transformer
Nozzle
Terminal Block
WIRING DIAGRAMS
7-3
WIRING DIAGRAMS
7-4
7-5
WIRING DIAGRAMS
7-6
Negative Lead HF/PS Cable Atm Vent Plasma Preow Shield Preow Plasma Cutow Shield Cutow
3X3
1X3
2X1
C
Gas Power Cable Gas Control Cable Work Lead
1X1 1X2
Torch Workpiece
Unit 5
1X4 Plasma Interface Cable
A
7-7
RED RED/BLK
C SHEET 4-D4 D SHEET 4-C1 WHT BLU T SHEET 3-B4 A SHEET 4-C1 RED/BLK RED BLK RED SHLD WHT E SHEET 3-C1 J4.1 J1
RED/BLK 20 19 RED
C1 350UF K1
W A4 B4 C4 CON1
RED RED/BLK
TB1 1 W 2 V 3 U 4 PE
3 2 1
YEL/BLK YEL
SHEET AA 3-A4 PE L1 L2 L3
U SHEET 3-B4
AF SHEET 8-A4
J11 1 2
J1
BLU
()NEGATIVE
L1 L2 L3
L1 L2 L3
L1 38
K1 A1
A2 K2
R5 100K
C3 .22UF
1 2 3 4
1A 1B 1C
R2 10 R3 100R4 10 J3 (++)POSITIVE
BLK L2 BLK L3
T1
SHOWN WIRED FOR 480V SEE PAGES 6 AND 7 FOR OTHER CONFIGURATIONS F2
.022UF CS3 G SHEET 4-C1 + .22UF 1 2 3 4 H9 J10 RED GRN WHT BLK SHIELD CR1 21 H9 BLK 39 22 40 BLK
C2 R7 10K J2 C4 R6 10K
F1
(+)POSITIVE
B
BLK BLK
H8
T2
CONTROL TRANSFORMER
SHEET 4-B1
F SHEET 3-D4
H9 H8 J1.4 J4 J1 J1.1 1 RED 1 2 2 ENABLE 3 RED/BLK 3 PCB1 4 PILOT ARC CONTROLLER 229238
SHEET 3-C1
A
7-8
4
J2.15 J15 1A 1 2 1B BLK 3 4 BLK 1C 5 SHEET BC 6 9-D4 RED/BLK SHEET A RED J2.B J4 2-A4 J2.4 J2.A 1 1 YEL 24VAC 24VAC YEL 24VAC 2 2 HARNESS: 229329 3 3 FOR ARCGLIDE THC ONLY RED 120VAC RED 120VAC 120VAC 4 4 5 5 ORN 240VAC ORN 240VAC 240VAC 6 6 BLK SHEET M 5-D4 J2.14 J14 BLU 1 WHT 2 3 BLU 4 WHT 5 RED 6 BLK 7 YEL 8 SHEET B 2-C3 F5 F6 F7
O SHEET 4-B4 J5 1 2 1 2
CLT SOL
F2
F4
240VAC HOT
J11 J2.11 BLK 1 2 3 4 WHT 5 6 J1 J2.1 RED/BLK 1 RED/BLK 2 RED/BLK 3 RED 4 RED 5 RED 6 RED/BLK 7 RED/BLK 8 RED/BLK 9 RED 10 RED 11 RED 12 RED/BLK 13 RED/BLK 14 15 RED 16 RED 17 18 J13 1 2
BLK WHT
C
SHEET L 4-B4
REMOTE ON/OFF
120VAC RTN
PUMP MOTOR
240VAC HOT
CON PAR HF
SS
240VAC COM
SIGNAL COM
24VAC HOT
24VAC RTN
B
J3 J2.3 SHEET T 2-D4 SHEET U 2-D1 RED/BLK RED RED/BLK RED RED/BLK RED RED RED/BLK SHEET AA 2-A1 RED RED/BLK 1 2 3 4 5 6 7 8 9 10 1112
COM 24VAC
J2.5 J5 1 2 3 4 5 6 7 8 9 10 11 12
D3 120VAC D12 24VAC D26 Pump motor signal D25 +24V D23 240VAC D31 +5V D32 -15V D33 +15V AC1 AC2
K2 F3 120VAC HOT
FAN 1 FAN 2 CHP CHP 5 6 7 FAN 8 9 FAN 2 CLT 10 FAN 1 CLT CHOPPER POWER E SHEET 2-D2 I SHEET 2-A1
K1 F1
K3
+ CONTACTOR D1 CONTACTOR + PILOT ARC RELAY D2 PILOT ARC RELAY + HV XFMR D5 HV XFMR + SURGE SELECT D7 SURGE SELECT
120VAC RTN
AC PWR LT
B
J9 6 RED 1 2 3 4 5 6 WHT RED 7 RED/BLK SHEET Y 4-D1 FLS POWER
J12 J2.12
1 2
J13 J2.13
1 2
J2 J2.2
1 2 BLU WHT
J7 J2.7
1 2
BLK WHT
BLU WHT
J8 1 2 1 2 SHEET BD 9-B4
Q SHEET 4-C1 P SHEET 4-C4 HARNESS: 229329 FOR ARCGLIDE THC ONLY
TB2 RED/BLK
1 1
2 2
3 3
4 4
5 5
6 6
7 7
REMOTE ON/OFF 7 6 5 4 3 2 1
WHT RED
RED
RED RED/BLK
A
4 3 2 1 1X3 GRN WHT BLK
HF
013375 SHEET 3 OF 19
3 2 1
A
7-9
1
J8.1 RED RED/BLK J1 J3 NO COM 3 2 1 120VAC RTN 120VAC HOT
SHEET Y 3-B1
D
J3.301 J301 RED BLK SHIELD 1 2 3 4 5 6 7 8 9 10 11 12 13 14 ARC BREAKOVER COM +5V PWM DRV A PWM DRV B SS-C SS-E PA-C PA-E PCB3 POWER SUPPLY CONTROL 041993 J201 J3.201 TP210 2 3 TP206 +24V COM COOLANT FLOW SENSOR A+3.3V COOLANT TEMP SENSOR XFMR TEMP SENSOR CHOPPER TEMP SENSOR A CHOPPER TEMP SENSOR B LINE VOLTAGE INPUT 1 2 3 4 5 6 7 8 9 10 11 12 13 14 BLK RED SHIELD BLU WHT BLU WHT BLU WHT
J8.4 J4 2 1
SHEET C 2-D3
1 2
1 2
T2
BLU WHT
SHEET P 3-A2
BLU WHT BLU WHT BLU WHT BLU WHT BLU WHT
J3.302 J302 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 +24V HF PUMP CONTACTOR PILOT ARC RELAY SPARE SURGE PHASE LOSS PWR GND
CHOPPER SENSOR B
BLU WHT
CORNER CURRENT CORNER CURRENT+ PIERCE PIERCE+ HOLD HOLD+ START START+
MOTION-E MOTION-C ERROR-E ERROR-C RDERR-E RDERR-C NOT READY-E NOT READY-C MOTION2-E MOTION2-C MOTION3-E MOTION3-C MOTION4-E MOTION4-C
CNC
J200 J3.200 RED 1 GRN 2 WHT 3 BLK 4 SHIELD 5 6 7 8 9 10 RED 11 GRN 12 WHT 13 BLK 14 15 16
G SHEET 2-B2
SHEET 2-B1
CNC +24V
PWR GND
RX+
S101
121 121 J107 J3.107 1 2 J106 J3.106 1 2 J108 1 2 3 4 5 6 7 8 9 1 20 2 21 3 22 4 23 5 24 6 25 7 26 8 27 9 2810 291130123113 32 1433 1534 16351736 183719
J300B
J304
1 2
+24V t
0
A
7-10
D
SHEET M 3-D4 J3.105 J105 1 2 3 4 5 6 7 8
C
J110 1 2 3 4 5 6 7 8 9 10 11 12 13 14
EMU0 EMU1
121
J101
1 2
J102
1 6 2 7 3 8 4 9 5
J103
1 6 2 7 3 8 4 9 5
J3.101 CANA
SHIELD
CANB
RED
A
7-11
4
INPUT POWER FROM FACILITY
2
INPUT POWER FROM FACILITY
PE L1 L2 L3
PE L1 L2 L3
TB1 1 W 2 V 3 U 4 PE L1 L2 L3
W A4 B4 C4 CON1
F1
F2
A4 A3 0 A2 A1 0 B4 B3 0 B2 B1 0 C4 C30 C2 C10
T1 1A 1B 1C 014282
TB1 1 W 2 V 3 U 4 PE L1 L2 L3
W A4 B4 C4 CON1
F1 T1
F2
A4 A3 0 A2 A1 0 B4 B3 0 B2 B1 0 C4 C30 C2 C10
T1 1A 1B 1C 014282
GRY WHT
BLK WHT
T1
T2
T2
INPUT POWER FROM FACILITY PE L1 L2 L3 TB1 1 W 2 V 3 U 4 PE L1 EMI FILTER L2 L3 L1 L2 L3 CON1 F1 F2 WIRED FOR 400V 50-60HZ
PE L1 L2 L3
W A4 B4 C4
BLU WHT
T1
BLK WHT
T1 1A 1B 1C 014283
TB1 1 W 2 V 3 U 4 PE L1 L2 L3
W A4 B4 C4 CON1
F1
F2
T1 1A 1B 1C
014283
T1
T2
T2
A
7-12
D
TB1 1 W 2 V 3 U 4 PE L1 L2 L3
PE L1 L2 L3
PE L1 L2 L3
W A4 B4 C4 CON1
A4 A3 0 A2 A1 0 B4 B3 0 B2 B1 0 C4 C30 C2 C10
T1 1A 1B 1C 014284
TB1 1 W 2 V 3 U 4 PE L1 L2 L3
W A4 B4 C4 CON1
F1
F2
F1 T1
F2
A4 A3 0 A2 A1 0 B4 B3 0 B2 B1 0 C4 C30 C2 C10
T1 1A 1B 1C 014284
BLK WHT
BRN WHT
T1
T2
PE L1 L2 L3
TB1 1 W 2 V 3 U 4 PE L1 L2 L3
PE L1 L2 L3
W A4 B4 C4 CON1
A1 0 B1 0 C1 0
T1 1A
TB1 1 W 2 V 3 U 4 PE L1 L2 L3
W A4 B4 C4 CON1
A1 0 B1 0 C1 0
T1 1A
1B
1B
F1 BLK WHT
F2
1C T1 014281
F2
T2
T2
A
7-13
D
J2A 1 20 2 21 3 22 4 23 5 24 6 25 7 26 8 27 9 28 10 29 11 30 12 31 13 32 14 33 15 34 16 35 17 36 18 37 19
CABLE: 123760 PCB3 POWER SUPPLY CONTROL 041993 RX37 RX37+ TX37 TX37+ 422 GND MOTION 1-E MOTION 1-C ERROR-E ERROR-C RDERR-E RDERR-C NOT READY-E NOT READY-C MOTION 2-E MOTION 2-C MOTION 3-E MOTION 3-C MOTION 4-E MOTION 4-C CORNER CORNER+ PIERCE PIERCE+ HOLD HOLD+ START START+ J300A J2B 1 20 2 21 3 22 4 23 5 24 6 25 7 26 8 27 9 28 10 29 11 30 12 31 13 32 14 33 15 34 16 35 17 36 18 37 19
D
J3.303A
J12.2B
TO POWER SUPPLY
SPARE OUT 1 SPARE OUT 1+ PIERCE COMPLETE OUT PIERCE COMPLETE OUT+ HOLE IGNITION OUT HOLD IGNITION OUT+ PLASMA START OUT PLASMA START OUT+
ELECTRODE
EMI GND
1 20 2 21 3 22 4 23 5 24 6 25 7 26 8 27 9 28 10 29 11 30 12 31 13 32 14 33 15 34 16 35 17 36 18 37 19 J301 1 2 t
0
B
PWR GND CNC +24V
J5
2 YEL/BLK 2
3 3
+24V
SHEET AF 2-D1
YEL
A
7-14
SHEET BC 3-D4
THC OPTION ARCGLIDE ETHERNET INTERFACE 141131 RX RX+ TX TX+ MOTION IN +5V ERROR IN +5V RAMPDOWN ERROR IN +5V NOT READY IN +5V
CABLE: 123760
J303B
D
J3.303B PCB3 POWER SUPPLY CONTROL 041993
J5
J13.5
1 2 3 4 5 6 7 8
TO ARCGLIDE MODULE(S)
TO POWER SUPPLY
CORNER OUT CORNER OUT+ PIERCE COMPLETE OUT PIERCE COMPLETE OUT+ HOLE IGNITION OUT HOLD IGNITION OUT+ PLASMA START OUT PLASMA START OUT+
B
ELECTRODE
SHEET BD 3-A2
WORK
1 20 2 21 3 22 4 23 5 24 6 25 7 26 8 27 9 28 10 29 11 30 12 31 13 32 14 33 15 34 16 35 17 36 18 37 19
1 20 2 21 3 22 4 23 5 24 6 25 7 26 8 27 9 28 10 29 11 30 12 31 13 32 14 33 15 34 16 35 17 36 18 37 19
J301
YEL/BLK 2
SHEET AF 2-D1
YEL
J7 J1 J6
MOTION 1-E MOTION 1-C ERROR-E ERROR-C RDERR-E RDERR-C NOT READY-E NOT READY-C MOTION 2-E MOTION 2-C MOTION 3-E MOTION 3-C MOTION 4-E MOTION 4-C CORNER CORNER+ PIERCE PIERCE+ HOLD HOLD+ START START+
B
PWR GND CNC +24V
J4
1 2
+24V
A
7-15
D
SHEET AB 10-B4
F1
D
PCB1 GAS CONSOLE POWER DISTRIBUTION 041805
J1.1 J1 1 2 3 4 5 6 7 8
GAS CONSOLE DC POWER 120VAC HOT D1 120VAC D7+5V D9 +24V J6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 J1.6 RED/BLK RED AC VALVE DRIVER POWER AE SHEET 12-D3
B
1A RED 2A
WHT
WHT BLK
7 6 5 4 3 2 1
WHT RED
J7 BLU WHT J2.4 J4 1 2 3 4 5 6 7 8 J2.8 J8 1 2 CABLE: 123692 BLK BLK J2.9 J9 1 2 3 4 CAN A 5 6 7 8 9 +24V +24V COM +5V +5V COM PCB2 GAS CSL CONT 041912 RXD TXD 232 COM 1 2 3 4 5 6 7 8 9
D
SHEET AC 10-C4
BLU WHT
RS-232
CANH CAN +24V TMS TRST\ TDI +5V COM +5V JTAG TDO TCK CANH CAN +24V
o
C
J3 1 2 3 4 5 6 7 8 9 10 11 12 13 14
SHEET AG 6-A4
CAN B
J10 1 2 3 4 5 6 7 8 9 J11 1 2 t
EMU0 EMU1
+24V SIG COM
SIG
SIG
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
J2
SIG
PT3-PP
PT4-PC
PT2-SP
PT1-SC
3
SHEET AE 10-C1 PCB2 GAS CSL CONT 041912 J3.1 1 2 3 J1
2
PCB3 AC VALVE DRIVER 041822 120V HOT SV4 120V RTN SV3 SV2 SV1 SV5 120V RTN 120V RTN 120V RTN SV6 120V RTN 120V RTN 120V RTN SV7 120V RTN 120V RTN 120V RTN SV8 D20 120V RTN D19 120V RTN D18 120V RTN D17 SV9 D16 120V RTN D15 120V RTN D14 120V RTN D13 SV10 D12 120V RTN D11 120V RTN D10 120V RTN D9 SV11 D8 120V HOT D7 120V HOT D6 120V HOT D5 SV12 D4 SV13 D3 SV14 D2 SPARE OUTPUT D1 J3 J3.3 RED/BLK 1 RED/BLK 2 RED/BLK 3 RED/BLK 4 RED/BLK 5 RED 6 RED 7 RED 8 RED/BLK 9 RED 10 RED 11 RED 12 RED/BLK 13 RED 14 RED 15 RED 16 RED/BLK 17 RED 18 RED 19 RED 20 RED/BLK 21 RED 22 RED 23 24 RED/BLK 25 26 27 28 RED/BLK 29 30 31 32 RED/BLK 33 RED/BLK 34 RED/BLK 35 36 J3.2 RED/BLK RED RED/BLK RED/BLK RED RED RED/BLK RED RED/BLK RED
RED/BLK RED
RED/BLK RED
SV1 RED/BLK RED SV3 RED/BLK RED SV5 RED/BLK RED SV7 RED/BLK RED SV9 RED/BLK RED SV11 RED/BLK RED SV13 RED/BLK RED
SV2
J6 NOT USED NOT USED NOT USED +5V +5V +5V SPARE 4 SPARE 3 SPARE 2 SPARE 1 SV20 SV19 SV18 SV17 SV16 SV15 SV14 SV13 SV12 SV11 SV10 SV9 SV8 SV7 SV6 SV5 SV4 SV3 SV2 SV1 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51 53 55 57 59
J2.6
J3.4
60 COND RIBBON
J4 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51 53 55 57 59
RED/BLK RED
D
SV4
RED/BLK RED
SV6
RED/BLK RED
SV8
RED/BLK RED
SV10
RED/BLK RED
C
SV12
RED/BLK RED
SV14
J2 CABLE: 123704 SV16 120V RTN SV17 120V RTN SV18 120V RTN SV19 120V RTN SV20 120V RTN 1 2 3 4 5 6 7 8 9 10
3X3 S C
1 2 12 3 4 13 5 6 14 7 8 11 9 10 1 2 12 3 4 13 5 6 14 7 8 11 9 10
CABLE: 123678
4X1
P P
A
P C RED/BLK SV19 RED 129816 OFF VALVE MANIFOLD
RED/BLK RED V V
RED/BLK RED P C
RED/BLK RED P P
RED/BLK RED S C
RED/BLK RED S P
V V
A
7-18
2X1
1 2 3 4
009045
FLTR
CATHODE BLOCK HPR HFHV IGNITION 041817 TORCH C2 0.22uF 1kVDC J4 009224 C1 0.22uF 1kVDC 009224 J1 SG1 109344 5kV SG2 109344 5kV PILOT ARC J5
B
T1 129854
COIL SECONDARY IN J6 COIL PRIMARY 2 T2 009793 COIL PRIMARY 1 COIL SECONDARY OUT NOZZLE CONNECTION
J2
A
7-19
O2 5 Micron
Air Filter
N2/Ar
H35/F5
V2
V1
V3 V12
V4
V5
V6
V7
V8
V9
V10
V11
PR1
PR2
PR3
Gas Console
P1
P2
P3
P4
C
Shield Cutow Shield Preow Plasma Preow
Plasma Cutow
V16
V17
V18
V19
V20
Vent
Shield
Plasma Vent
Torch
A
7-20
RESERVOIR
HEAT EXCHANGER
FLOW SENSOR
CHECK VALVE
MANIFOLD
RHF
TORCH
A A
A
7-21
S101
J106 1 2 J303
J107 1 2
S101
J106 1 2 J303
J107 1 2
S101
J106 1 2 J303
J107 1 2
C
S101 J106 1 2 J303 1 2 3 4 1 2 3 4 J107 1 2
1 2 3 4
1 2 3 4
1 2 3 4
1 2 3 4
1 2 3 4 1 2 3 4
1 2 3 4 1 2 3 4
1 2 3 4 1 2 3 4
Notes: 1) For single system installations set Serial ID (S100), and Machine Motion (J303) as shown in Unit 1, jumpers J106 and J107 must be closed. 2) On multi-system installations refer to the illustration. Jumpers J106 and J107 are left open on all systems except for the very last system where they are in the closed position. Termination resistors (120-ohm) or termination jumpers must be installed/set at the CNC for each of the RS-422 RX and TX signal pairs. 3) 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, 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 to the HPR power supply. See sheet 17 for more details.
1 2 3 4 5 6 7 8
1 2
Notes: 1) For single system installation set Serial ID (S100), Machine Motion (J303), J106 & J107 as shown. Relocate the white wire on TB2 from position #3 to position #2. Connect customer supplied Remote On/Off cable in series with the power supply and the gas console power switch. Connect one terminal of the Remote On/Off cable to position #2 on TB2 and the other terminal to position #3. Refer to page 3 of the wiring diagram
C
041993 CONTROL BOARD
S100
Depress the Gas Console Power switch to the closed position (on position). TB2
7 7
2) For a multi-system installation set up as described above, set jumpers as shown on the multi-system interface page RED/BLK 21 RED 3) The CNC will need a dedicated I/O for each system using the Remote On/Off feature (contact should be rated for min. 24Vac, 0.5 Amp)
S101
ON
J106
1 2
J107
1 2
RED/BLK RED
6 5 4
1 2 3 4
ON
1 2 3 4 5 6 7 8
J300A
J300B
1X1
Serial ID Dipswitch
WHT
76
RED
* If a Hypertherm Automation controller is being used, and there are intermittent communication failures (PS Link Failure), try removing the jumnpers on J104 and J105 on the control board, 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 to the HPR power supply. See gure below for details.
J1 SV
3 2
RIBBON CABLE
B
Remote On/Off Customer Supplied CNC Interface Cable
AMD J3
BTR J7
RS-232 J9 J10
RS-232
ATR J8
1 2 3 4 5 6 7 8
RS-422
RS-422
S101
J106
1 2
J107
1 2
Torch
Workpiece
C
S100
ON 1 2 3 4
J303
1 2 3 4 1 2 3 4
C
CNC Interface Cable Pendant Ext. Cable
1 2 3 4 5 6 7 8
Command I/O Cable-Second THC Command I/O Cable-Third THC Command I/O Cable-Fourth THC
Notes: 1) For a single system installation set Serial ID (S100), Machine Motion (J303), J106 & J107 as shown above. 2) For a two system installation duplicate a second power supply and Command THC as illustrated for a single system, set Serial ID as shown for the second system. 3) For a three system installation set up as described above, set Serial ID as shown for the third system. 4) For a four system installation set up as described above, set Serial ID as shown for the fourth system. 5) All machine interface cables (Pwr. supply-CNC) used for serial communication between Pwr. supply-CNC will have a common connection node with the CNC. 6) The CNC will need a dedicated I/O port for each Command THC. 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, 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 to the HPR power supply. See gure on Sheet 19 for details.
ON
1 2 3 4 5 6 7 8 ON
1 2 3 4 5 6 7 8 ON
1 2 3 4 5 6 7 8
Unit 1
Unit 2
Unit 3
Unit 4
5 67
5 67
5 67
5 67
1 23
UNIT ADDRESS J5 J1
1 23
1 23
1 23
SW1
UNIT ADDRESS J5 J1
UNIT ADDRESS J5 J1
UNIT ADDRESS J5 J1
CNC Interface Cable ArcGlide Ethernet Cable ArcGlide Ethernet Cable Dipswitch setting example:
Notes: 1) For the 041993 control board, set Serial ID (S100), and Machine Motion (J303) as shown. Jumpers J106 and J107 should be installed. All 041993 DIPSWITCH and jumper settings are the same; serial IDs are determined by the 141131 board setting. 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. 4) For a three system installation, set SW1 on the 141131 boards as shown in Units 1 through 3. 5) For a four system installation, set SW1 on the 141131 boards as shown in Units 1 through 4.
S100
ON
ON
1 2
1 2 3 4 5 6 7 8
In this section:
Section 1 Chemical Product and Company Identification .........................................................................................................a-2 Section 2 Information on Ingredients ..............................................................................................................................................a-2 Section 3 Hazards Identification.......................................................................................................................................................a-2 Section 4 First Aid Measures ............................................................................................................................................................a-3 Section 5 Fire Fighting Measures ....................................................................................................................................................a-3 Section 6 Accidental Release Measures........................................................................................................................................a-3 Section 7 Handling and Storage ......................................................................................................................................................a-3 Section 8 Exposure Controls / Personal Protection ....................................................................................................................a-4 Section 9 Physical and Chemical Properties ................................................................................................................................a-4 Section 10 Stability and Reactivity.....................................................................................................................................................a-4 Section 11 Toxicological Information .................................................................................................................................................a-4 Section 12 Ecological Information......................................................................................................................................................a-5 Section 13 Disposal Considerations .................................................................................................................................................a-5 Section 14 Transport Information........................................................................................................................................................a-5 Section 15 Regulatory Information .....................................................................................................................................................a-5 Section 16 Other Information ..............................................................................................................................................................a-5 Freezing Point of Propylene Glycol Solution........................................................................................................................................a-6
a-1
4/06/07
Nov. 7, 2008
Product Information:
(603) 643-3441
CAS No.
95-14-7 57-55-6
% by wt.
<1,0 <50,0
a-2
11/7/2008
MSDS
Product
CODE
Page 2 of 4
If affected, remove from exposure. Restore breathing. Keep warm and quiet. Seek medical attention. Immediately flush eye with cool running water. Remove contact lenses if applicable. Continue flushing with water for at least 15 minutes. Seek immediate medical attention. Wash with soap and water. If irritation develops or persists, seek medical attention.
Note to Physician Treatment based on judgment of the physician in response to reactions of the patient.
Flammable limits
Not Established
Product is an aqueous solution. Use Carbon Dioxide, Dry Chemical, Foam. Full protective equipment including self-contained breathing apparatus should be used. During emergency conditions overexposure to decomposition products may cause a health hazard. Symptoms may not be immediately apparent. Get medical attention. Water base solution.
a-3
11/7/2008
MSDS
Product
CODE
Page 3 of 4
Normal procedures for good hygiene. Good general ventilation. Eye wash station in immediate area of use. M.E.L./O.E.S Nil. U.K HSE EH:40 Not listed
Boiling point freezing point vapor pressure vapor density evaporation rate
May occur
Other effects
Acute Chronic
a-4
9/2/04
MSDS
Product
CODE
Page 4 of 4
Not established As reported for 100% Benzotriazole: Bluegill Sunfish (96 hr. Tlm):28mg/l; Minnow (96hr. Tlm):28mg/l; Trout (96 hr. LC 50): 39mg/l; Algae(96hr. EC 50): 15.4mg/l; Daphina magna (48 hr. LC 50): 141.6mg/l
Ecotoxicity
CODE
2 HDPE
No
Description
Not applicable
Information contained in this MSDS refers only to the specific material designated and does not relate to any process or use involving other materials. This information is based on data believed to be reliable, and the Product is intended to be used in a manner that is customary and reasonably foreseeable. Since actual use and handling are beyond our control, no warranty, express or implied, is made and no liability is assumed by Hypertherm, Inc., in connection with the use of this information.
a-5
9/2/04
C
4 -1 -7 -12
F
40 30 20 10 0 -10 -20 -30 -40 -50 -60 -70 0 10 20 30 40 50 60
Temperature
% of Propylene Glycol
a-6
8/21/08
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 dont 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. III. Main loop a. Check for serial messages from the internal UART. If valid message is received, parse the message and take action. b. Check for serial messages from the external UART. If valid message is received, parse the message and take action. c. Check for CAN message. If CAN message has arrived, parse the message and take action. d. Check for error conditions every 10 milliseconds. e. Refresh data from gas console (i.e. pressures) every 250 milliseconds. f. Update the chopper control loop every 26 microseconds. g. If an error has occurred, take action. h. Update analog inputs. i. If current setpoint has changed, update the data in the EEPROM. j. If inlet gases change, perform a purge cycle. k. Descriptions of machine states (Numbers listed below do not correspond to actual state numbers.) 1. Idle Outputs are off. Chopper setpoints = 0. 6-second delay for other processors to initialize.
b-1
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). 5. Pilot Arc Turn on pilot arc controller and pilot arc relay. Pulse HF after 50-millisecond delay to allow pilot arc relay to close.
b-2
b-3
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. 14. Test cutflow Gas console runs cutflow gases. Wait for request to go to Idle state or Test Preflow state. Error checking Check for coolant flow at power-up (093). Check for no Start signal. 15. Test preflow Gas console runs preflow gases. Wait for request to go to Idle state or Test Cutflow state. Error checking Check for coolant flow at power-up (093). Check for no Start signal.
b-4
In this section:
Components for robotic applications....................................................................................................................................................c-2 Torch leads ........................................................................................................................................................................................c-2 Rotational mounting sleeve (optional).........................................................................................................................................c-2 Leather overwrap .............................................................................................................................................................................c-2 Robotic teaching torch (laser pointer) ........................................................................................................................................c-2
c-1
Over all length 2 m (6 ft) 2.5 m (8 ft) 3 m (10 ft) 3.5 m (12 ft) 4.5 m (15 ft) 6 m (20 ft) 7.5 m (25 ft) 10 m (35 ft) 15 m (50 ft)
6 foot gas lead 228514 228515 228475 228476 228477 228478 228479 228480 228481
8 foot gas lead 228516 228517 228482 228483 228484 228485 228486 228487 228488
Length 1.5 m (5 ft) 3 m (10 ft) 4.5 m (15 ft) 6 m (20 ft) 9 m (30 ft)
Length 12 m (40 ft) 15 m (50 ft) 22.5 m (75 ft) 30 m (100 ft) 45 m (150 ft)
c-2
c-3