MAINTENANCE
5-42 HPR400XD Manual Gas Instruction Manual
Gas leak tests
The system has two automatic leak test modes. The leak test mode is activated by changing the shield gas selector
switch (2) to the TEST position and then changing the RUN/SET switch (7) to either SET PREFLOW or SET
CUTFLOW to begin the leak test.
Leak test mode 1 – With switch 7 in the SET PREFLOW position.
The inlet valves within the gas console will close and the off-valves will open to allow any trapped gas to escape. After
20 seconds all the off-valves will close. At this point there should be no pressure between the gas console and off-valve,
and the pressure displays should read zero.
This test is intended to identify a problem with any inlet supply valve that does not close properly in the gas console, in
which case pressure will build at the off-valve and be displayed on the gas console. This test also checks for leaks in the
supply lines.
Leak Check Mode 2 – Switch 7 in the SET CUTFLOW position.
The inlet valves will open and pressurize the gas lines between the off-valve and the gas console. After 20 seconds all
inlet valves are turned off. The pressures displayed should remain constant.
This test is intended to identify a leak between the gas console and the off-valve.
Leak test 1
1. Turn ON power to the plasma system.
2. After initial gas purge change shield selector switch (2) to TEST.
3. Select SET PREFLOW on switch 7. The off-valve opens and exhausts gas between the gas console and torch. The
inlet valves in gas console will remain closed.
4. The off-valve will close after 20 seconds.
5. Close gas supply valves.
6. Monitor the pressure displays and the gas supply pressure gauges for 20 minutes. The pressure displays should
remain at or close to zero while inlet pressures remain constant.
7. If any pressure display increases, then one or more inlet valves in the gas console are not closing properly.
8. If a gas supply pressure gauge decreases but no pressure is displayed on gas console, then there is a leak in the
supply hoses between the shut-off and the gas console.
Leak test 2
1. After performing leak test 1, turn on gas supply valves again and move switch 7 to SET CUTFLOW. The inlet valves
in the gas console will open for 20 seconds and then close, while the off-valve remains closed. This traps pressure
between the gas console and the off-valve.
2. Close the gas supply valves.
3. Monitor the pressure displays on the gas console and the gas supply pressure gauges for 20 minutes. Pressure
displays and gas supply gauges should remain constant.
4. If any pressure displays decrease, then there is a leak in a gas line between the gas console and the off-valve.
5. If a gas supply pressure gauge decreases then there is a leak in the supply hoses between the shut-off and the gas
console.
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