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Welding System
HPR130 Manual Gas
Hypertherm HPR130 Manual Gas User Manual
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INST
ALLA
TION
3-4
H
P
R130 Manual G
as
Instruction Manual
5
Installation requirements
A
B
C
D
1
2
3
4
5
6
7
8
9
10
11
13
E
15
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14
12
37
39
Table of Contents
English
6
Electromagnetic Compatibility (EMC
4
Warranty
5
General
5
Patent Indemnity
5
Limitation of Liability
5
Liability Cap
5
Insurance
5
National and Local Codes
5
Transfer of Rights
5
Table of Contents
6
Safety
11
Recognize Safety Information
12
Follow Safety Instructions
12
Cutting Can Cause Fire or Explosion
12
Electric Shock Can Kill
13
Cutting Can Produce Toxic Fumes
13
A Plasma Arc Can Cause Injury and Burns
14
Arc Rays Can Burn Eyes and Skin
14
Grounding Safety
14
Compressed Gas Equipment Safety
15
Gas Cylinders Can Explode if Damaged
15
Noise Can Damage Hearing
15
Pacemaker and Hearing Aid Operation
15
A Plasma Arc Can Damage Frozen Pipes
15
Additional Safety Information
15
Warning Label
16
Français
18
Section 1A
18
Sécurité
18
Danger Avertissement Précaution
19
Risque D'explosion Argon-Hydrogène Et Méthane
19
Détonation de L'hydrogène Lors du Coupage de L'aluminium
19
Les Chocs Électriques Peuvent Être Fatals
20
Le Coupage Peut Produire des Vapeurs Toxiques
20
Prévention des Chocs Électriques
20
L'arc Plasma Peut Provoquer des Blessures Ou des Brûlures
21
Mise À la Masse Et À la Terre
21
Les Rayons de L'arc Peuvent Brûler Les Yeux Et la Peau
21
Torches À Allumage Instantané
21
Sécurité des Bouteilles de Gaz Comprimé
22
Les Bouteilles de Gaz Comprimé Peuvent Exploser en Cas de Dommages
22
Le Bruit Peut Provoquer des Problèmes Auditifs
22
Pacemakers Et Prothéses Auditives
22
Un Arc Plasma Peut Endommager Les Tuyaux Gelés
22
Identifier Les Consignes de Sécurité
19
Le Coupage Peut Provoquer un Incendie Ou Une Explosion
19
Suivre Les Instructions de Sécurité
19
Pacemakers Et Prothèses Auditives
22
Étiquette de Sécurité
23
Specifications
25
Section 2 SPECIFICATIONS
25
System Description
27
General
27
Power Supply
27
HPR130 Manual Gas Instruction Manual
27
Ignition Console
27
Gas Console
27
Off-Valve
27
Torch
27
Specifications
28
System Gas Requirements
28
Power Supply
29
Ignition Console - 078172
30
Gas Consol - 078170
32
Gas Console - 078170
32
Off-Valve - 129816
33
Torch - 128818
34
Installation
35
Section 3 INSTALLATION
35
Upon Receipt
37
Claims
37
Installation Requirements
37
Noise Levels
37
Placement of System Components
37
Torque Specifications
37
Installation Requirements
38
System Components
39
Cables and Hoses
39
Supply Gas Hoses
39
Customer Supplied Power Cable
39
System Grounding Requirements
40
Suggested Ground Cable Routing
40
Power Supply
40
Equipment Grounding
40
Work Table Grounding
41
Placement of the Power Supply
43
Install the Ignition Console
44
Placement of the Gas Console
46
Install the Off-Valve
47
Power Supply to Ignition Console Leads
48
Pilot Arc Lead
48
Negative Lead
48
Ignition Control Cable
50
Ignition Console Coolant Hoses
51
Power Supply to Gas Console Cables
52
Control Cable
52
Power Cable
52
Gas Console to Off-Valve Connections
54
Cable and Gas Hose Assembly
54
Gas Console to Off-Valve Cable
54
Off-Valve Cable
54
Power Supply to CNC Interface Cable
56
Optional Multi-System CNC Interface Cable
56
Notes to CNC Interface Cable Run List
57
Examples of Output Circuits
58
Examples of Input Circuits
59
Remote On/Off Switch
60
Torch Lead Assembly
61
Work Lead
62
Torch Connections
63
Connect the Torch to the Torch Lead Assembly
63
Connect the Torch to the Quick-Disconnect
65
Torch Mounting and Alignment
66
Torch Lifter Requirement
66
Power Requirements
67
General
67
Line Disconnect Switch
67
Power Cable
67
Connect the Power
68
Torch Coolant Requirements
69
Water Purity Requirements
69
Fill the Power Supply with Coolant
70
Gas Requirements
71
Setting the Supply Regulators
71
Gas Regulators
72
Supply Gas Plumbing
73
Connect the Supply Gases
73
Supply Gas Hoses
74
Operation
75
Section 4 OPERATION
75
Daily Start-Up
76
Check Torch
76
Controls and Indicators
77
General
77
Main Power Switch
77
Power Indicators
77
Manual Gas Console Operation
78
Consumable Selection
79
Mild Steel
79
Stainless Steel
79
Aluminum
80
Install Consumables
81
Cut Charts
82
Marking
82
Consumables for Mirror-Image Cutting
82
Estimated Kerf Width Compensation
83
Changing Consumable Parts
95
Remove Consumables
95
Inspect Consumables
96
Inspect Torch
97
Inspect Electrode Pit Depth
98
Replace Torch Water Tube
99
Common Cutting Faults
100
How to Optimize Cut Quality
101
Tips for Table and Torch
101
Plasma Set-Up Tips
101
Maximize the Life of Consumable Parts
101
Additional Factors of Cut Quality
102
Additional Improvements
103
Maintenance
104
Section 5 MAINTENANCE
104
Introduction
105
Routine Maintenance
105
System Description
106
Control and Signal Cables
106
Sequence of Operation
107
Error Codes
109
Error Code Troubleshooting - 1 of 6
110
Error Code Troubleshooting - 2 of 6
111
Error Code Troubleshooting - 3 of 6
112
Error Code Troubleshooting - 4 of 6
113
Error Code Troubleshooting - 5 of 6
114
Error Code Troubleshooting - 6 of 6
115
Power Supply States
116
Plasma System Operation with Pump Timeout
117
CNC Operation with Pump Timeout
118
Initial Checks
119
Power Measurement
120
Power Supply Coolant System Servicing
121
Draining the Coolant System
121
Coolant System Filter and Strainer
122
Filter Replacement
122
Pump Strainer Cleaning
122
Coolant Flow Test Procedure
123
Testing the Flow Switch
124
Gas Leak Test Procedure
125
Power Supply Control Board PCB3
126
Power Supply Power Distribution Board PCB2
127
Start Circuit PCB1
128
Operation
128
Start Circuit Functional Schematic
128
Start Circuit Troubleshooting
128
Pilot Arc Current Levels
130
Gas Console Control Board PCB2
131
Gas Console Power Distribution PCB1
132
Gas Console AC Valve-Driver PCB3
133
Chopper Module Test Procedure
134
Phase-Loss Detection Test
136
Torch Lead Test
137
Preventive Maintenance
138
Power Supply
142
Section 6 PARTS LIST
145
Power Supply
146
Ignition Console
150
Gas Console - 1 of 2
151
Gas Console - 2 of 2
152
Off-Valve
152
Hyperformance Torch
153
Torch Assembly
153
Torch Leads
153
Consumable Parts Kit - 128878
154
Consumables for Mirror-Image Cutting
155
Recommended Spare Parts
156
Wiring Diagrams
157
Introduction
157
Section 7 WIRING DIAGRAMS
157
Software Functional Description
179
Appendix A SOFTWARE FUNCTIONAL DESCRIPTION
182
Propylene Glycol Safety Data / Benzotriazole Safety Data
182
Appendix B PROPYLENE GLYCOL SAFETY DATA / BENZOTRIAZOLE SAFETY DATA
183
Section 1 Chemical Product and Company Identification
183
Section 2 Composition / Information on Ingredients
183
Section 3 Hazards Identification
183
Section 4 First Aid Measures
184
Section 5 Fire Fighting Measures
184
Section 6 Accidental Release Measures
184
Section 7 Handling and Storage
184
Section 8 Exposure Controls / Personal Protection
185
Section 9 Physical and Chemical Properties
185
Section 10 Stability and Reactivity
185
Section 11 Toxicological Information
185
Section 12 Ecological Information
186
Section 13 Disposal Considerations
186
Section 14 Transport Information
186
Section 15 Regulatory Information
186
Section 16 Other Information
186
Freezing Point of Propylene Glycol Solution
187
4
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Hypertherm HPR130 Manual Gas Specifications
General
Brand
Hypertherm
Model
HPR130 Manual Gas
Category
Welding System
Language
English
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