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- Section 1A
- Sécurité
  - Identifier Les Consignes de Sécurité
  - Suivre Les Instructions de Sécurité
  - Le Coupage Peut Provoquer un Incendie Ou Une Explosion
  - Les Chocs Électriques Peuvent Être Fatals
  - L'électricité Statique Peut Endommager Les Cartes de Circuits Imprimés
  - Les Vapeurs Toxiques Peuvent Provoquer des Blessures Ou la Mort
  - L'arc Plasma Peut Provoquer des Blessures Ou des Brûlures
  - Les Rayons de L'arc Peuvent Brûler Les Yeux Et la Peau
  - Mise À la Masse Et À la Terre
  - Sécurité des Bouteilles de Gaz Comprimé
  - Les Bouteilles de Gaz Comprimé Peuvent Exploser en Cas de Dommages
  - Le Bruit Peut Provoquer des Problèmes Auditifs
  - Pacemakers Et Prothèses Auditives
  - Un Arc Plasma Peut Endommager Les Tuyaux Gelés
  - Étiquettes de Sécurité
Español
- Seguridad
  - Section 1B SEGURIDAD
  - Reconocimiento de Información de Seguridad
  - Siga las Instrucciones de Seguridad
  - Los Cortes Pueden Provocar Incendios O Explosiones
  - El Choque Eléctrico Puede Provocar la Muerte
  - Electricidad Estática Puede Dañar Tablillas de Circuito
  - Humos Tóxicos Pueden Causar Lesiones O Muerte
  - El Arco de Plasma Puede Causar Lesiones y Quemaduras
  - Los Rayos del Arco Pueden Producir Quemaduras en Los Ojos y en la Piel
  - Seguridad de Toma a Tierra
  - Seguridad de Los Equipos de Gas Comprimido
  - Los Cilindros de Gas Pueden Explotar si Están Dañados
  - El Ruido Puede Deteriorar la Audición
  - Operación de Marcapasosy de Audífonos
  - Un Arco Plasma Puede Dañar Tubos Congelados
  - Etiquetas de Advertencia
- Specifications
  - Section 2 SPECIFICATIONS
  - System Description
    
    General
    
    Power Supply
    
    Ignition Console
    
    Gas Console
    
    Off-Valve Assembly
    
    Torch
    
    Off-Valve
  - Specifications
    
    System Gas Requirements
    
    Power Supply
    
    Ignition Console - 078172
    
    Gas Console - 078170
    
    Off-Valve - 129816
    
    Torch - 128818
- Installation
  - Section 3 INSTALLATION
  - Upon Receipt
  - Claims
  - Installation Requirements
  - Noise Levels
  - Placement of System Components
    
    Torque Specifications
  - Installation Requirements
    
    System Components
    
    Cables and Hoses
    
    Supply Gas Hoses
    
    Customer Supplied Power Cable
  - Recommended Grounding and Shielding Practices
  - Introduction
    
    Types of Grounding
    
    Steps to Take
    
    Placement of the Power Supply
    
    Install the Ignition Console
    
    Placement of the Gas Console
    
    Install the Off-Valve
  - Power Supply to Ignition Console Leads
    
    Pilot Arc Lead
    
    Negative Lead
    
    Ignition Console Power Cable
    
    Ignition Console Coolant Hoses
  - Power Supply to Gas Console Cables
    
    Control Cable
    
    Power Cable
  - Gas Console to Off-Valve Connections
    
    Cable and Gas Hose Assembly
    
    Gas Console to Off-Valve Cable
    
    Off-Valve Cable
  - Power Supply to CNC Interface Cable
    
    Optional Multi-System CNC Interface Cable
    
    Notes to CNC Interface Cable Run List
    
    Examples of Output Circuits
    
    Examples of Input Circuits
  - Remote On/Off Switch
  - Torch Lead Assembly
  - Work Lead
  - Torch Connections
    
    Connect the Torch to the Torch Lead Assembly
    
    Connect the Torch to the Quick-Disconnect
  - Torch Mounting and Alignment
    
    Mounting the Torch
    
    Torch Alignment
  - Torch Lifter Requirement
  - Power Requirements
    
    General
    
    Line Disconnect Switch
    
    Power Cable
  - Connect the Power
  - Torch Coolant Requirements
    
    Standard Installation
    
    Coolant for Cold Operating Temperatures
    
    Coolant for Hot Operating Temperatures
  - Water Purity Requirements
  - Fill the Power Supply with Coolant
  - Gas Requirements
    
    Setting the Supply Regulators
  - Gas Regulators
  - Supply Gas Plumbing
    
    Connect the Supply Gases
  - Supply Gas Hoses
- Operation
  - Section 4 OPERATION
  - Daily Start-Up
    
    Check Torch
  - Controls and Indicators
    
    General
    
    Main Power Switch
    
    Power Indicators
  - Manual Gas Console Operation
  - Consumable Selection
    
    Mild Steel
    
    Stainless Steel
    
    Aluminum
  - Install Consumables
  - Cut Charts
    
    Bevel Cutting
    
    Marking
    
    Consumables for Mirror-Image Cutting
    
    Estimated Kerf Width Compensation
  - Changing Consumable Parts
    
    Remove Consumables
    
    Inspect Consumables
    
    Inspect Torch
    
    Inspect Electrode Pit Depth
  - Replace Torch Water Tube
  - Common Cutting Faults
  - How to Optimize Cut Quality
    
    Tips for Table and Torch
    
    Plasma Set-Up Tips
    
    Maximize the Life of Consumable Parts
    
    Additional Factors of Cut Quality
    
    Additional Improvements
- Maintenance
  - Section 5 MAINTENANCE
  - Introduction
  - Routine Maintenance
  - System Description
    
    Control and Signal Cables
  - Sequence of Operation
  - Gas System Valve Usage
  - Gas System Purge Cycle
  - Error Codes
    
    Error Code Troubleshooting - 10 of 10
    
    Error Code Troubleshooting - 1 of 10
    
    Error Code Troubleshooting - 2 of 10
    
    Error Code Troubleshooting - 3 of 10
    
    Error Code Troubleshooting - 4 of 10
    
    Error Code Troubleshooting - 5 of 10
    
    Error Code Troubleshooting - 6 of 10
    
    Error Code Troubleshooting - 7 of 10
    
    Error Code Troubleshooting - 8 of 10
    
    Error Code Troubleshooting - 9 of 10
    
    Error Code Troubleshooting
  - Power Supply States
  - Plasma System Operation with Pump Timeout
  - CNC Operation with Pump Timeout
  - Initial Checks
  - Power Measurement
  - Power Supply Coolant System Servicing
    
    Draining the Coolant System
  - Coolant System Filter
    
    Filter Replacement
  - Coolant Flow Troubleshooting Chart
  - Coolant Flow Tests
    
    Before Testing
    
    Using the Hypertherm Flow Meter
    
    Manual Pump Operation
    
    Test 1 - Return Line
    
    Test 2 - Supply Line at Ignition Console
    
    Test 3 - Change the Torch
    
    Test 4 - Supply Line to the Torch Receptacle
    
    Test 5 - Return Line from the Torch Receptacle
    
    Test 6 - Bucket Test at the Pump
    
    Test 7 - Bypass the Check Valve
    
    Pump and Motor Troubleshooting
    
    Testing the Flow Switch
  - Gas Leak Tests
  - Power Supply Control Board PCB3
  - Power Supply Power Distribution Board PCB2
  - Start Circuit PCB1
    
    Operation
    
    Start Circuit Functional Schematic
    
    Start Circuit Troubleshooting
    
    Pilot Arc Current Levels
  - Gas Console Control Board PCB2
  - Gas Console Power Distribution Board PCB1
  - Gas Console AC Valve-Driver Board PCB3
  - Chopper Tests
  - Phase-Loss Detection Test
  - Torch Lead Test
  - Preventive Maintenance
  - Cooling System
  - Power Supply
  - Section 6 PARTS LIST
  - Power Supply
  - Ignition Console
  - Gas Console - 1 of 2
  - Gas Console - 2 of 2
  - Off-Valve
  - Hyperformance Torch
    
    Torch Assembly
    
    Torch Leads
  - Consumable Parts Kit - 228027
  - Consumables for Mirror-Image Cutting
  - Recommended Spare Parts
- Wiring Diagrams
  - Introduction
- Appendix A BEN ZOTRIAZOLE / PROPYLENE G LYCOL SAFETY DATA
  - Section 1 Chemical Product and Company Identification
  - Section 2 Composition / Information on Ingredients
  - Section 3 Hazards Identification
  - Chemical Product and Company Identification
  - Information on Ingredients
  - Hazards Identification
  - Section 4 First Aid Measures
  - Section 5 Fire Fighting Measures
  - Section 6 Accidental Release Measures
  - Section 7 Handling and Storage
  - First Aid Measures
  - Fire Fighting Measures
  - Accidental Release Measures
  - Handling and Storage
  - Section 8 Exposure Controls / Personal Protection
  - Section 9 Physical and Chemical Properties
  - Section 10 Stability and Reactivity
  - Section 11 Toxicological Information
  - Exposure Controls / Personal Protection
  - Physical and Chemical Properties
  - Stability and Reactivity
  - Toxicological Information
  - Section 12 Ecological Information
  - Section 13 Disposal Considerations
  - Section 14 Transport Information
  - Section 15 Regulatory Information
  - Section 16 Other Information
  - Ecological Information
  - Disposal Considerations
  - Transport Information
  - Regulatory Information
  - Other Information
  - Freezing Point of Propylene Glycol Solution
- Functional Description of Software
- Appendix B FUNCTIONAL de SCRI PTION of SOFTWARE
- Appendix Cbevel CUTTING
  - Bevel Torch Dimensions
  - Bevel Cutting Definitions
  - Cut Charts
  - Torch Connections
    
    Connect the Torch Lead Assembly to the Quick-Disconnect Assembly
  - Parts List
    
    Consumables
    
    Part Selection

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HyPerformance

Plasma HPR260

Manual gas

Instruction manual

804940 – Revision 4

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Table of Contents

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Summary of Contents for Hypertherm HyPerformance Plasma HPR260

Page 1 HyPerformance ® ® Plasma HPR260 Manual gas Instruction manual 804940 – Revision 4...
Page 2 Register your new Hypertherm system Register your product on-line at www.hypertherm.com/registration for easier technical and warranty support. You can also receive updates on new Hypertherm products and a free gift as a token of our appreciation. For your records Serial number:...
Page 3 4 – April, 2008 Hypertherm, Inc. Hanover, NH USA www.hypertherm.com © Copyright 2008 Hypertherm, Inc. All Rights Reserved Hypertherm, HyPerformance, HyDefinition, LongLife and CommandTHC are trademarks of Hypertherm, Inc. and may be registered in the United States and/or other countries...
Page 4 65 6 841 2490 Fax HYPERTHERM BRASIL LTDA. 65 6 841 2489 (Technical Service) Avenida Doutor Renato de Andrade Maia 350 Hypertherm (Shanghai) Trading Co., Ltd. Parque Renato Maia Unit 1308-09, Careri Building CEP 07114-000 432 West Huai Hai Road...
Page 5: Electromagnetic Compatibility (Emc
EMC Introduction h. Time of day that cutting or other activities are to be carried out. Hypertherm’s CE-marked equipment is built in compliance with standard EN60974-10. The equipment should be The size of the surrounding area to be considered will...
Page 6 Arc Welding Equipment Installation and Use. Screening and shielding Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference. Screening of the entire plasma cutting installation may be considered for special applications. Hypertherm 8-06...
Page 7: Warranty
Once the product has left the Hypertherm factory, the General certification test marks are invalidated if any of the following Hypertherm, Inc. warrants that its Products shall be free...
Page 8 It is your responsibility to dispose of any In no event shall Hypertherm be liable to any person Hypertherm product or component part in an or entity for any incidental, consequential, indirect,...
Page 9: Table Of Contents
TABLE OF CONTENTS Electromagnetic Compatibility (EMC) ...........................i Warranty......................................ii 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......................................1-5...
Page 10 TABLE OF CONTENTS Seguridad de toma a tierra ..................................1b-5 Seguridad de los equipos de gas comprimido ..........................1b-6 Los cilindros de gas pueden explotar si están dañados.........................1b-6 El ruido puede deteriorar la audición ..............................1b-6 Operación de marcapasos y de audífonos ............................1b-6 Un arco plasma puede dañar tubos congelados ..........................1b-6 Etiquetas de advertencia..................................1b-7 Section 2...
Page 11 TABLE OF CONTENTS 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...
Page 12 TABLE OF CONTENTS General.......................................4-3 Main power switch ..................................4-3 Power indicators .....................................4-3 Manual gas console operation ................................4-4 Consumable selection....................................4-5 Mild steel......................................4-5 Stainless steel....................................4-6 Aluminum ......................................4-6 Install consumables....................................4-7 Cut charts........................................4-8 Bevel cutting .....................................4-8 Marking.......................................4-8 Consumables for mirror-image cutting............................4-8 Estimated kerf width compensation ............................4-9 Changing consumable parts .................................4-33 Remove consumables ..................................4-33 Inspect consumables..................................4-34...
Page 13 Filter replacement..................................5-27 Coolant flow troubleshooting chart ..............................5-28 Coolant flow tests....................................5-29 Before testing....................................5-29 Using the Hypertherm flow meter..............................5-29 Manual pump operation ................................5-30 Test 1 – return line..................................5-31 Test 2 – supply line at ignition console ..........................5-31 Test 3 – change the torch.................................5-32 Test 4 –...
Page 14 TABLE OF CONTENTS Torch assembly ....................................6-10 Torch leads......................................6-10 Consumable parts kit – 228027 ...............................6-11 Consumables for mirror-image cutting ...............................6-12 Recommended spare parts ...................................6-13 Section 7 WIRING DIAGRAMS............................7-1 Introduction ........................................7-1 Wiring Diagrams ......................................7-5 Appendix A BENZOTRIAZOLE / PROPYLENE GLYCOL SAFETY DATA ...............a-1 Section 1 Chemical Product and Company Identification......................a-2 Section 2 Composition / Information on Ingredients ........................a-2 Section 3 Hazards Identification................................a-2...
Page 15: Safety
Grounding safety ..............................1-5 Compressed gas equipment safety ..........................1-6 Gas cylinders can explode if damaged ........................1-6 Noise can damage hearing ............................1-6 Pacemaker and hearing aid operation........................1-6 A plasma arc can damage frozen pipes........................1-6 Additional safety information.............................1-6 Warning labels ................................1-7 Hypertherm Plasma Systems 8-06...
Page 16: Recognize Safety Information
• Do not cut pressurized cylinders, pipes, or any table to eliminate the possibility of hydrogen closed container. detonation. Refer to the Appendix section of this • Do not cut containers that have held combustible manual for aeration manifold details. materials. Hypertherm Plasma Systems 11-98...
Page 17: Electric Shock Can Kill
This switch allows the operator to turn off the power supply quickly in • Each Hypertherm plasma system is designed to be an emergency situation. used only with specific Hypertherm torches. Do not substitute other torches which could overheat and •...
Page 18: Toxic Fumes Can Cause Injury Or Death
Empty and properly clean the container first. and regulations. • 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. Hypertherm Plasma Systems 8-06...
Page 19: A Plasma Arc Can Cause Injury And Burns
Fasten the retaining nut tightly. local electrical codes. • Tighten all electrical connections to avoid excessive heating. Hypertherm Plasma Systems 5-02...
Page 20: Compressed Gas Equipment Safety
Protection Association, 470 Atlantic Avenue, Boston, MA 02210 Hazardous Substances, American Welding Society 10. OSHA, Safety and Health Standards, 29FR 1910 550 LeJeune Road, P.O. Box 351040, Miami, FL 33135 U.S. Government Printing Office, Washington, D.C. 20402 Hypertherm Plasma Systems 11-98...
Page 21 SAFETY WARNING LABEL This warning label is affixed to some power supplies. It is important that the operator and maintenance technician understand the intent of these warning symbols as described. Hypertherm Plasma Systems 8-99...
Page 22: Warning Labels
Use welding helmet with correct shade of filter. Wear complete body protection. 6. Become trained and read the instructions before working on the machine or cutting. 7. Do not remove or paint over (cover) warning labels. Hypertherm Plasma Systems 8-99...
Page 23: Section 1A
Les bouteilles de gaz comprimé peuvent exploser en cas de dommages .............1a-6 Le bruit peut provoquer des problèmes auditifs......................1a-6 Pacemakers et prothèses auditives ........................1a-6 Un arc plasma peut endommager les tuyaux gelés....................1a-6 Étiquettes de sécurité .............................1a-7 Hypertherm Systèmes plasma 1a-1 8-06...
Page 24: Identifier Les Consignes De Sécurité
• Ne pas couper de récipients contenant des matières Se référer à l’annexe du manuel pour plus de combustibles. renseignements sur les collecteurs d’aération. 1a-2 Hypertherm Systèmes plasma 11-98...
Page 25: Les Chocs Électriques Peuvent Être Fatals
Ce dispositif permet à la prise de terre appropriée. l’opérateur d’arrêter rapidement la source de courant en • Chaque système plasma Hypertherm est conçu pour être cas d’urgence. utilisé uniquement avec des torches Hypertherm •...
Page 26: Les Vapeurs Toxiques Peuvent Provoquer Des Blessures Ou La Mort
• Contrôler ou éprouver la qualité de l’air au site selon les besoins. • Consulter un expert local pour mettre en œuvre un plan du site afin d’assurer une qualité de l’air sûre. 1a-4 Hypertherm Systèmes plasma 8-06...
Page 27: L'arc Plasma Peut Provoquer Des Blessures Ou Des Brûlures
Table de travail Raccorder la table de travail à la terre, terre par-dessus. Bien serrer l’écrou de retenue. conformément aux codes de sécurité locaux ou nationaux • S’assurer que toutes les connexions sont bien serrées appropriés. pour éviter la surchauffe. Hypertherm Systèmes plasma 1a-5 5-02...
Page 28: Sécurité Des Bouteilles De Gaz Comprimé
• Ne pas s’enrouler le faisceau de la torche ou le câble de Les tuyaux gelés peuvent être endommagés ou éclater si retour autour du corps. l'on essaie de les dégeler avec une torche plasma. • Se tenir le plus loin possible de la source de courant. 1a-6 Hypertherm Systèmes plasma 11-98...
Page 29 SÉCURITÉ Étiquette de sécurité Cette étiquette est affichée sur la source de courant. Il est important que l’utilisateur et le technicien de maintenance comprennent la signification des symboles de sécurité. Hypertherm Systèmes plasma 1a-7 8-99...
Page 30: Étiquettes De Sécurité
6. Se former à la technique du coupage et lire les instructions avant de manipuler l’équipement ou de procéder au coupage. 7. Ne pas retirer ou peindre (recouvrir) les étiquettes de sécurité. 1a-8 Hypertherm Systèmes plasma 8-99...
Page 31: Seguridad
Los cilindros de gas pueden explotar si están dañados ..................1b-6 El ruido puede deteriorar la audición ........................1b-6 Operación de marcapasos y de audífonos ......................1b-6 Un arco plasma puede dañar tubos congelados ....................1b-6 Etiquetas de advertencia ............................1b-7 Hypertherm Sistemas plasma 1b-1 8-06...
Page 32: Reconocimiento De Información De Seguridad
Consulte la sección del apéndice de este • No corte depósitos que hayan contenido materiales manual para conocer detalles acerca del múltiple de combustibles. aireación. 1b-2 Hypertherm Sistemas plasma 11-98...
Page 33: El Choque Eléctrico Puede Provocar La Muerte
Prevención ante el electrochoque cortando. Deje la pieza en su lugar o sobre la mesa de Todos los sistemas por plasma de Hypertherm usan alto trabajo con el cable de trabajo conectado en todo voltaje en el proceso de corte (son comunes los voltajes CD momento.
Page 34: Humos Tóxicos Pueden Causar Lesiones O Muerte
• 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. 1b-4 Hypertherm Sistemas plasma 8-06...
Page 35: El Arco De Plasma Puede Causar Lesiones Y Quemaduras
Ajuste firmemente la tuerca buena toma de tierra, de conformidad con los códigos de retención. eléctricos nacionales o locales apropiados. • Asegúrese de que todas las conexiones eléctricas están firmemente realizadas para evitar sobrecalentamientos. Hypertherm Sistemas plasma 1b-5 5-02...
Page 36: Seguridad De Los Equipos De Gas Comprimido
• Manténgase tan lejos de la fuente de energía como sea posible. Se puede hacer daño a los tubos congelados, o se los puede reventar, si uno trata de descongelarlos con una antorcha por plasma. 1b-6 Hypertherm Sistemas plasma 11-98...
Page 37: Etiquetas De Advertencia
Esta etiqueta de advertencia se encuentra adherida a la fuente de energía. Es importante que el operador y el técnico de mantenimiento comprendan el sentido de estos símbolos de advertencia según se describen. El texto numerado corresponde a los cuadros numerados de la etiqueta. Hypertherm Sistemas plasma 1b-7 8-99...
Page 38 Proteja su cuerpo completamente. 6. Antes de trabajar en la máquina o de proceder a cortar, capacítese y lea las instrucciones completamente. 7. No retire las etiquetas de advertencia ni las cubra con pintura. 1b-8 Hypertherm Sistemas plasma 8-99...
Page 39: Specifications
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 – 078170...................................2-8 Off-valve – 129816..................................2-9 Torch –...
Page 40 SPECIFICATIONS HPR260 Manual Gas Instruction Manual...
Page 41: System Description
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 260-amp, 150-VDC constant-current supply. It contains the circuitry to ignite a torch, a heat exchanger and pump to cool the torch.
Page 42: Specifications
SPECIFICATIONS Specifications System gas requirements Gas quality and pressure requirements Quality Grade** Pressure +/- 10% Flow rate Oxygen* 99.5% pure 827 kPa / 8.3 bar 4250 l/h 150 scfh Clean, dry, oil-free 120 psi Nitrogen* 99.99% pure 827 kPa / 8.3 bar 9910 l/h 350 scfh Clean, dry, oil-free 120 psi...
Page 43: Power Supply
SPECIFICATIONS Power supply General Maximum OCV (U 311 VDC Maximum output current (I 260 Amps Output voltage (U 50 – 175 VDC Duty cycle rating (X) 100% @ 45.5 kw, 40° C (104° F) Ambient temperature/Duty cycle Power supplies will operate between -10° C and +40° C (+14° and 104° F) Power factor(cosϕ) 0.98 @ 260 ADC output Cooling...
Page 44: Ignition Console - 078172
SPECIFICATIONS Ignition console – 078172 • The ignition console may be mounted locally on the power supply (LHF) or remotely on the cutting table’s bridge (RHF). See Installation section for details. • Maximum cable length from the ignition console to the torch lifter station is 20 m (65 ft). Allow room to remove the top for servicing.
Page 45 SPECIFICATIONS LHF mounting (local) RHF mounting (remote) Mounted on table Horizontal mounting Vertical mounting HPR260 Manual Gas Instruction Manual...
Page 46: Gas Console - 078170
SPECIFICATIONS Gas console – 078170 • Maximum cable length from the power supply to the gas console is 75 m (250 ft). • Maximum cable length from the gas console to the off-valve assembly is 20 m (65 ft). • Mount the gas console on top of the power supply or near the CNC on the cutting table. Allow room to open the top for servicing.
Page 47: Off-Valve - 129816
SPECIFICATIONS Off-valve – 129816 • Maximum cable length from the off-valve to the torch lifter station is 1.8 m (6 ft). • Mount the off-valve assembly to the torch carriage on larger tables. On smaller tables it can be mounted to a bracket just above the bridge.
Page 48: Torch - 128818
SPECIFICATIONS Torch – 128818 • The outside diameter of the torch mounting sleeve is 50.8 mm (2.0 in). • The maximum bend radius for the torch leads is 152.4 mm (6.0 in). 1.8 m 27 mm 1.07" 193 mm 116 mm 7.59"...
Page 49: Installation
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...
Page 50 INSTALLATION 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..........................3-34 Torch mounting and alignment................................3-35 Mounting the torch ..................................3-35 Torch alignment....................................3-35...
Page 51: Upon Receipt
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.
Page 52: Installation Requirements
INSTALLATION Installation requirements HPR260 Manual Gas Instruction Manual...
Page 53: System Components
INSTALLATION System components Power supply Ignition console Gas console Off-valve assembly Torch Cables and hoses Pilot arc lead Negative lead Ignition console power cable Ignition console coolant hoses Gas control cable Gas power cable Gas console to off-valve hose and lead assembly CNC interface cable Optional CNC interface cable for systems with multiple power supplies Torch lead assembly...
Page 54: Recommended Grounding And Shielding Practices
INSTALLATION Recommended grounding and shielding practices DANGER ELECTRIC SHOCK CAN KILL 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.
Page 55: Steps To Take
9. Each Hypertherm component, as well as any other CNC or motor-drive cabinet or enclosure, must have a separate ground cable to the common (star) point on the table. This includes the ignition console, even if it is bolted to the power supply or to the cutting machine.
Page 56 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).
Page 57 INSTALLATION Cable to ground Component bus on the cutting table ground cables 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.
Page 58 Metering Gas/Selection Command console console console console Bus bar Gantry Command Bus bar Ground rod Cutting table Positive DC Plasma power supply The lifter assembly and the RHF console each require a separate path to the cutting table Chassis and RFI ground AC earth/service ground ground bus bar.
Page 59: Placement Of The Power Supply
INSTALLATION Placement of the power supply DANGER ELECTRICAL SHOCK CAN KILL Remove all electrical connections to power supply before moving or positioning. Transporting 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.
Page 60: Install The Ignition Console
INSTALLATION Install the ignition console • Mount the ignition console on the gantry (bridge) for the RHF configuration. • Mount the ignition console on the power supply for the LHF configuration. • Allow room to remove the top for servicing. 32 mm 184 mm 1.25"...
Page 61 INSTALLATION Horizontal RHF mounting Vertical RHF mounting LHF mounting HPR260 Manual Gas Instruction Manual 3-13...
Page 62: Placement Of The Gas Console
INSTALLATION Placement of the gas console • Mount the gas console near the cutting table. Allow room to remove the top and right side cover for servicing. Preferred orientation is shown in the figure below. The maximum length of cables between the power supply and gas console is 75 m (250 ft).
Page 63: Install The Off-Valve
INSTALLATION Install the off-valve • Mount the off-valve assembly near the torch lifter station. The maximum length of the gas hoses between the off-valve assembly and the torch is 1.8 m (6 ft). Off-valve grounding 157 mm 6.18" 19 mm .075"...
Page 64: Power Supply To Ignition Console Leads
INSTALLATION Power supply to ignition console leads Pilot arc lead I/O board Ignition console Part no. Length Part no. Length 123683* 1.5 m (5 ft) 123823 20 m (65 ft) 123820 3 m (10 ft) 123735 25 m (82 ft) 123821 4.5 m (15 ft) 123668...
Page 65 INSTALLATION Work lead Negative lead Pilot arc lead Pilot arc lead Negative lead HPR260 Manual Gas Instruction Manual 3-17...
Page 66: Ignition Console Power Cable
INSTALLATION Ignition console power cable Cable signal list – power supply to ignition console Power supply end Ignition console end Pin # I/O Description Pin # I/O Function 120Vac Hot Part no. Length Part no. Length 120Vac Return 123865* 2.1 m (7 ft) 123836 20 m (65 ft) Ground...
Page 67: Ignition Console Coolant Hoses
INSTALLATION Ignition console coolant hoses Green Part no. Length Part no. Length 228031* 1.1 m (3.8 ft) 128984 20 m (65 ft) 028652 3 m (10 ft) 128078 25 m (82 ft) 028440 4.5 m (15 ft) 028896 35 m (115 ft) 028441 7.5 m (25 ft) 028445...
Page 68: Power Supply To Gas Console Cables
INSTALLATION Power supply to gas console cables Control cable Part no. Length Part no. Length 123784 3 m (10 ft) 123737 25 m (82 ft) 123839 4.5 m (15 ft) 123738 35 m (115 ft) 123691 7.5 m (25 ft) 123739 45 m (150 ft) 123840...
Page 69 INSTALLATION J300 J103 Male Female HPR260 Manual Gas Instruction Manual 3-21...
Page 70: Gas Console To Off-Valve Connections
INSTALLATION Gas console to off-valve connections Cable and gas hose assembly Part no. Length 128989 3 m (10 ft) 128990 4.5 m (15 ft) 128782 7.5 m (25 ft) 128967 10 m (35 ft) 128786 15 m (50 ft) Female end at off-valve Male end at gas console 128991 20 m (65 ft)
Page 71 INSTALLATION HPR260 Manual Gas Instruction Manual 3-23...
Page 72: Power Supply To Cnc Interface Cable
INSTALLATION Power supply to CNC interface cable Part no. Length Part no. Length 123210 3 m (10 ft) 123741 25 m (82 ft) 123211 4.5 m (15 ft) 123742 35 m (115 ft) 123022 7.5 m (25 ft) 123220 45 m (150 ft) To J 300 123214 10 m (35 ft)
Page 73: Notes To Cnc Interface Cable Run List
INSTALLATION Notes to CNC interface cable run list Note 1. Inputs are optically isolated. They require 24 VDC at 7.3 mA, or dry-contact closure. The external relay’s life may be improved by adding a metallized-polyester capacitor (0.022µF 100V or higher) in parallel with the relay contacts.
Page 74: Examples Of Output Circuits
INSTALLATION Examples of output circuits 1. Logic interface, active-high 5VDC-24VDC CNC/PLC – (optional) High-impedance (≤10mA) 2. Logic interface, active-low 5VDC-24VDC (optional) CNC/PLC – High-impedance (≤10mA) 3. Relay interface CNC +24V +24VDC CNC +24V °t Install a Jumper J304 108056 CNC/PLC –...
Page 75: Examples Of Input Circuits
INSTALLATION Examples of input circuits Note: The external relay's life may be improved by adding a metallized-polyester capacitor (0.022µF 100V or higher) in parallel with the relay contacts. 1. Relay interface +24 VDC Output from CNC/PLC External relay (AC or DC) Power ground 2.
Page 76: Remote On/Off Switch
INSTALLATION Remote ON/OFF switch (provided by customer) WARNING ELECTRIC SHOCK CAN KILL 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 location 2.
Page 77: Torch Lead Assembly
INSTALLATION Torch lead assembly Part no. Length 128986 2 m (6 ft) 128935 3 m (10 ft) 128934 4.5 m (15 ft) 128784 7.5 m (25 ft) 128987 10 m (35 ft) 128785 15 m (50 ft) 128988 20 m (65 ft) Grey Plasma-gas vent hose...
Page 78: Work Lead
INSTALLATION Work lead Power supply Work table Part no. Length Part no. Length 123816 3 m (10 ft) 123775 25 m (82 ft) 123817 4.5 m (15 ft) 123776 35 m (115 ft) 123773 7.5 m (25 ft) 123777 45 m (150 ft) 123818 10 m (35 ft) 123778...
Page 79: Torch Connections
INSTALLATION 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.
Page 80 INSTALLATION 5. Connect the pilot arc lead. Note: Be careful not to damage or remove the small slotted metal band at the end of the pilot arc cable. 5a. Pull the sleeve back until the connector is exposed. 5b. Screw the connector onto the pilot arc connection from the torch. Tighten by hand until it is firmly seated. 5c.
Page 81 INSTALLATION 7. Connect the coolant return hose (red). 8. Connect the plasma gas hose. 9. Connect the shield gas hose. 10. Slide the torch sleeve over connections and screw it onto the torch body. 11. 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.
Page 82: Connect The Torch To The Quick-Disconnect
INSTALLATION Connect the torch to the quick-disconnect Apply a thin film of silicone lubricant to each o-ring Torch body Torch quick-disconnect receptacle 220162 220163 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.
Page 83: Torch Mounting And Alignment
INSTALLATION Torch mounting and alignment Mounting the torch Installation Install the torch (with torch leads attached) in the torch mounting bracket. Upper torch sleeve Position the torch below mounting bracket, so that the bracket is around the lower portion of the torch sleeve Torch mounting touching the torch quick-disconnect.
Page 84: Power Requirements
INSTALLATION Power requirements General All switches, slow-blow fuses and power cables are customer-supplied and must be chosen as outlined by applicable national or local electrical codes. Installation must be performed by a licensed electrician. Use a separate primary line disconnect switch for the power supply. Note: 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.
Page 85: Connect The Power
INSTALLATION Connect the power DANGER ELECTRICAL SHOCK CAN KILL The line disconnect switch must be in the OFF position before making the power cable connections. In the U.S., use a “lock-out/tag-out” procedure until installation is complete. In other countries, follow appropriate national or local safety procedures. 1.
Page 86: Torch Coolant Requirements
Standard installation Use Hypertherm premixed coolant (028872) when operating in a temperature range of 0° C to 40° C (32° F to 104° F). Refer to the non-standard installation recommendations, if temperatures during operation are ever outside of this range.
Page 87: Coolant For Cold Operating Temperatures
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.
Page 88: Coolant For Hot Operating Temperatures
INSTALLATION Coolant for hot operating temperatures (above 38° C / 100° F) Use a custom coolant mix when operating in temperatures above 38° C (100° F). Treated water (with no propylene glycol) can only be used as coolant when operating temperatures are never below 0°...
Page 89: Fill The Power Supply With Coolant
INSTALLATION Fill the power supply with coolant The system will take 11.4 – 15.1 liters (3 to 4 gallons) of coolant depending on the length of the torch leads and if the system has a local or remote ignition console. Caution: Using the wrong coolant can cause damage to the system.
Page 90: Gas Requirements
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.
Page 91: Gas Regulators
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 or local codes.
Page 92: Supply Gas Plumbing
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.
Page 93: Supply Gas Hoses
INSTALLATION Supply gas hoses Oxygen hose Part no. Length Part no. Length 024607 3 m (10 ft) 024738 25 m (82 ft) 024204 4.5 m (15 ft) 024450 35 m (115 ft) 024205 7.5 m (25 ft) 024159 45 m (150 ft) 024760 10 m (35 ft) 024333...
Page 94: Operation
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 Mild steel......................................4-5 Stainless steel....................................4-6 Aluminum ......................................4-6 Install consumables....................................4-7 Cut charts........................................4-8 Bevel cutting .....................................4-8 Marking.......................................4-8 Consumables for mirror-image cutting............................4-8 Estimated kerf width compensation ............................4-9...
Page 95: Daily Start-Up
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. Check torch WARNING Before operating this system, you must read the Safety section thoroughly! Turn OFF the power supply’s main disconnect switch before proceeding with the following steps.
Page 96: Controls And Indicators
OPERATION Controls and indicators General The main power switch for the HyPerformance plasma system is located on the gas console. There is no power switch on the power supply. The gas console controls all systems functions. Error codes are shown in the LED display over the current select knob.
Page 97: Manual Gas Console Operation
OPERATION Manual gas console operation The term “position number” refers to the numbers on the front panel of the gas console. 3-digit display* Position number 1. Turn ON the power. 2. Follow instructions below using the settings provided in the Cut charts. Position # Instruction Select PLASMA GAS.
Page 98: Consumable Selection
OPERATION Consumable selection Mild steel Inner Shield Nozzle Electrode Retaining cap retaining cap Swirl ring 220194 220313 220193 220180 220192 220555 220313 220554 220553 220552 220173 220189 220176 220188 220179 220187 130A 220183 220176 220182 220179 220181 200A 220356 220355 220354 220353 220352...
Page 99: Stainless Steel
OPERATION Stainless steel Inner Shield Nozzle Electrode Retaining cap retaining cap Swirl ring 220202 220304 220201 220180 220308 220338 220304 220337 220179 220339 220173 130A 220198 220304 (H35) 220197 220179 220307 220176 (N 200A 220345 220344 220343 220342 220307 260A 220398 220407 220344...
Page 100: Install Consumables
OPERATION Install consumables Apply a thin film of silicone lubricant on each o-ring. Clean the current ring using a cotton swab with water or 3% hydrogen peroxide. Do not overtighten parts! Only tighten until mating parts are seated. Install the nozzle and Install the electrode Install the swirl ring swirl ring...
Page 101: Cut Charts
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.
Page 102: Estimated Kerf Width Compensation
OPERATION Estimated kerf-width compensation The widths in the chart below are for reference. Differences between installations and material composition may cause actual results to vary from those shown in the table. Metric Thickness (mm) Process 260A O / Air 2.54 2.79 3.43 3.81...
Page 103 OPERATION Estimated kerf-width compensation – continued English Thickness (in) Process 0.060" 0.135" 1/4" 3/8" 1/2" 3/4" 1" 1-1/4" 1-1/2" 260A O / Air 0.100 0.110 0.135 0.150 0.170 0.175 200A O / Air 0.086 0.089 0.116 130A O / Air 0.071 0.080 0.083...
Page 104 OPERATION Mild steel Flow rates – lpm/scfh Plasma / O Shield Preflow 0 / 0 46 / 97 30 A Cutting Cutflow 22 / 46 0 / 0 Note: Air must be connected to use this process. It is used as the preflow gas 220173 220194 220313...
Page 105 OPERATION Mild steel Flow rates – lpm/scfh Plasma / O Shield Preflow 0 / 0 43 / 90 50 A Cutting Cutflow 25 / 52 0 / 0 Note: Air must be connected to use this process. It is used as the preflow gas 220173 220555 220313...
Page 106 OPERATION Mild steel Flow rates – lpm/scfh Plasma / Air Shield Preflow 0 / 0 76 / 161 80 A Cutting Cutflow 23 / 48 41 / 87 220173 220189 220176 220188 220179 220187 Metric Select Material Torch-to-Work Cutting Initial Pierce Pierce Delay Gases Preflow...
Page 107 OPERATION Mild steel Flow rates – lpm/scfh Plasma / Air Shield Preflow 0 / 0 102 / 215 130 A Cutting Cutflow 33 / 70 45 / 96 220173 220183 220176 220182 220179 220181 Metric Select Material Torch-to-Work Cutting Initial Pierce Pierce Delay Gases Preflow...
Page 108 OPERATION Mild steel Flow rates – lpm/scfh Plasma / Air Shield Preflow 0 / 0 128 / 270 200 A Cutting Cutflow 39 / 82 48 / 101 220398 220356 220355 220354 220353 220352 Metric Select Torch-to-Work Cutting Initial Pierce Pierce Delay Material Gases...
Page 109 OPERATION Mild steel Flow rates – lpm/scfh @ 3/4" setting Plasma / Air Shield Preflow 0 / 0 130 / 275 260 A Cutting Cutflow 42 / 88 104 / 220 220398 220440 220433 220439 220436 220435 Metric Select Torch-to-Work Cutting Initial Pierce Pierce Delay...
Page 110 OPERATION Stainless steel Flow rates – lpm/scfh Plasma / N Shield Preflow 24 / 51 45 A Cutting Cutflow 75 / 159 220173 220202 220304 220201 220180 220308 Metric Select Material Torch-to-Work Cutting Initial Pierce Pierce Delay Gases Preflow Cutflow Thickness Voltage Distance...
Page 111 OPERATION Stainless steel Flow rates – lpm/scfh F5 Plasma / N Shield Preflow 0 / 0 43 / 91 45 A Cutting Cutflow 8 / 17 65 / 138 220173 220202 220304 220201 220180 220308 Metric Select Torch-to-Work Cutting Initial Pierce Pierce Delay Material Gases...
Page 112 OPERATION Stainless steel Flow rates – lpm/scfh F5 Plasma / N Shield Preflow 0 / 0 67 / 142 80 A Cutting Cutflow 31 / 65 55 / 116 220173 220338 220304 220337 220179 220339 Metric Select Material Torch-to-Work Cutting Initial Pierce Pierce Delay Gases...
Page 113 OPERATION Stainless steel Flow rates – lpm/scfh Plasma / N Shield Preflow 97 / 205 130 A Cutting Cutflow 79 / 168 220176 220173 220198 220197 220179 220307 Metric Select Material Torch-to-Work Cutting Initial Pierce Pierce Delay Gases Preflow Cutflow Thickness Voltage Distance...
Page 114 OPERATION Stainless steel Flow rates – lpm/scfh H35 Plasma / N Shield Preflow 0 / 0 76 / 160 130 A Cutting Cutflow 26 / 54 68 / 144 220173 220198 220304 220197 220179 220307 Metric Select Material Torch-to-Work Cutting Initial Pierce Pierce Delay Gases...
Page 115 OPERATION Stainless steel Flow rates – lpm/scfh H35 Plasma / N Shield Preflow 0 / 0 116 / 245 200 A Cutting Cutflow 30 / 63 104 / 220 220398 220345 220344 220343 220342 220307 Metric Select Material Torch-to-Work Cutting Initial Pierce Pierce Delay Gases...
Page 116 OPERATION Stainless steel Flow rates – lpm/scfh Plasma / N Shield Preflow 111 / 235 200 A Cutting Cutflow 137 / 290 220398 220345 220344 220343 220342 220307 Metric Select Material Torch-to-Work Cutting Initial Pierce Pierce Delay Gases Preflow Cutflow Thickness Voltage Distance...
Page 117 OPERATION Stainless steel Flow rates – lpm/scfh H35 Plasma / N Shield Preflow 0 / 0 127 / 270 260 A Cutting Cutflow 40 / 84 122 / 260 220398 220407 220344 220406 220405 220307 Metric Select Material Torch-to-Work Cutting Initial Pierce Pierce Delay Gases...
Page 118 OPERATION Stainless steel Flow rates – lpm/scfh Plasma / Air Shield Preflow 127 / 270 0 / 0 260 A Cutting Cutflow 54 / 114 116 / 245 220398 220407 220344 220406 220405 220307 Metric Select Material Torch-to-Work Cutting Initial Pierce Pierce Delay Gases Preflow...
Page 119 OPERATION Aluminum Flow rates – lpm/scfh Air Plasma / Air Shield Preflow 45 / 95 45 A Cutting Cutflow 78 / 165 220173 220202 220176 220201 220180 220308 Metric Select Material Torch-to-Work Cutting Initial Pierce Pierce Delay Gases Preflow Cutflow Thickness Voltage Distance...
Page 120 OPERATION Aluminum Flow rates – lpm/scfh Air Plasma / Air Shield Preflow 73 / 154 130 A Cutting Cutflow 78 / 165 220173 220198 220176 220197 220179 220181 Metric Select Material Torch-to-Work Cutting Initial Pierce Pierce Delay Gases Preflow Cutflow Thickness Voltage Distance...
Page 121 OPERATION Aluminum Flow rates – lpm/scfh H35 Plasma / N Shield Preflow 0 / 0 76 / 160 130 A Cutting Cutflow 26 / 54 68 / 144 220173 220198 220304 220197 220179 220307 Metric Select Material Torch-to-Work Cutting Initial Pierce Pierce Delay Gases Preflow...
Page 122 OPERATION Aluminum Flow rates – lpm/scfh H35 Plasma / N Shield Preflow 0 / 0 113 / 240 200 A Cutting Cutflow 34 / 72 90 / 190 220398 220345 220347 220346 220342 220307 Metric Select Material Torch-to-Work Cutting Initial Pierce Pierce Delay Gases Preflow...
Page 123 OPERATION Aluminum Flow rates – lpm/scfh Plasma / N Shield Preflow 113 / 240 200 A Cutting Cutflow 135 / 287 220398 220345 220347 220346 220342 220307 Metric Select Material Torch-to-Work Cutting Initial Pierce Pierce Delay Gases Preflow Cutflow Thickness Voltage Distance Speed...
Page 124 OPERATION Aluminum Flow rates – lpm/scfh H35 Plasma / N Shield Preflow 0 / 0 127 / 270 260 A Cutting Cutflow 33 / 70 118 / 250 220398 220407 220344 220406 220405 220307 Metric Select Material Torch-to-Work Cutting Initial Pierce Pierce Delay Gases Preflow...
Page 125 OPERATION Aluminum Flow rates – lpm/scfh Plasma / Air Shield Preflow 125 / 265 0 / 0 260 A Cutting Cutflow 50 / 105 113 / 240 220398 220407 220344 220406 220405 220307 Metric Select Material Torch-to-Work Cutting Initial Pierce Pierce Delay Gases Preflow...
Page 126: Changing Consumable Parts
OPERATION Changing consumable parts WARNING The system is designed to go into an idle mode if the retaining cap is removed. However, DO NOT CHANGE CONSUMABLE PARTS WHILE IN THE IDLE MODE! Always disconnect power to the power supply before inspecting or changing torch consumable parts. Use gloves when removing consumables.
Page 127: Inspect Consumables
OPERATION Inspect consumables Part Check for Action Erosion, missing material Replace cap Cracks Replace cap Burned Replace cap Nozzle Erosion or missing material Replace nozzle* Blocked gas holes Replace nozzle* Center hole 1. Must be round Replace nozzle if hole is no longer round* 2.
Page 128: Inspect Torch
OPERATION Inspect torch Bullet connectors Water Shield gas tube Plasma vent Pilot arc Current ring Plasma gas Coolant in Coolant return Inspect Check for Action All surfaces Dirt or debris Clean surfaces Erosion, missing material Replace torch Cracks Replace torch Internal burn or arcing marks Replace torch Current ring...
Page 129: Inspect Electrode Pit Depth
OPERATION Inspect electrode pit depth Electrode pit depth gauge (004630) Part Check for Action Electrode Center surface Wear Replace electrode if pit is deeper than 1 mm (0.040 in.)* *Always replace the nozzle and electrode as a set. 4-36 HPR260 Manual Gas Instruction Manual...
Page 130: Replace Torch Water Tube
OPERATION Replace torch water tube WARNING The system is designed to go into an idle mode if the retaining cap is removed. However, DO NOT REMOVE CONSUMABLE PARTS WHILE IN THE IDLE MODE. Always disconnect power to the power supply before removing torch consumable parts. Use gloves when removing consumables. The torch might be hot.
Page 131: Common Cutting Faults
OPERATION Common cutting faults • Torch pilot arc will initiate, but will not transfer. Causes can be: 1. Work cable connection on the cutting table is not making good contact. 2. Malfunction in the system. See Section 3. Torch-to-work distance is too high. •...
Page 132: How To Optimize Cut Quality
Maximize the life of consumable parts ® Hypertherm’s LongLife process automatically “ramps up” the gas and current flows at the start and ramps them down at the end of each cut, to minimize erosion of the electrode’s center surface. The LongLife process also requires that cuts start and stop on the workpiece.
Page 133: Additional Factors Of Cut Quality
OPERATION Additional factors of cut quality Cut angle A cut part whose 4 sides average less than 4° of cut angle is considered acceptable. Note: The squarest cut angle will be on the right side with respect to the forward motion of the torch. Note: To determine whether a cut-angle problem is being caused by the plasma system or the drive system, make a test cut and measure the angle of each side.
Page 134: Additional Improvements
• In some Hypertherm systems, the shield gas pressure automatically increases during pierce delay. • If the above steps do not solve the problem, increasing the setting of the shield gas pressure may help blow the molten metal away during piercing.
Page 135: Maintenance
Filter replacement..................................5-27 Coolant flow troubleshooting chart ..............................5-28 Coolant flow tests....................................5-29 Before testing....................................5-29 Using the Hypertherm flow meter..............................5-29 Manual pump operation ................................5-30 Test 1 – return line..................................5-31 Test 2 – supply line at ignition console ..........................5-31 Test 3 – change the torch.................................5-32 Test 4 –...
Page 136 MAINTENANCE Test 7 – bypass the check valve .............................5-33 Pump and motor troubleshooting..............................5-34 Testing the flow switch.................................5-35 Gas leak tests......................................5-36 Power supply control board PCB3..............................5-37 Power supply power distribution board PCB2..........................5-38 Start circuit PCB1....................................5-39 Operation ......................................5-39 Start circuit functional schematic ..............................5-39 Start circuit troubleshooting ...............................5-39 Pilot arc current levels ..................................5-41 Gas console control board PCB2 ...............................5-42...
Page 137: Introduction
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.
Page 138: System Description
MAINTENANCE System description Control and signal cables Power Cable: Provides 120 VAC to the Gas Console. 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 for the off-valve assembly.
Page 139: Sequence Of Operation
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.
Page 140: Gas System Valve Usage
MAINTENANCE Gas system purge cycle When the system is turned on, or the operator changes from one process to another, the system automatically goes through a purge process. The purge process has 2 stages; a preflow purge and a cutflow purge. The preflow gas is turned on for 8 seconds with an auto gas console, or 12 seconds with a manual gas console.
Page 141 MAINTENANCE Gas console AC valve driver board – LEDs process Valve Gas console Off-valve location number Preflow SV11 SV17 SV18 Cutflow SV11 SV14 SV16 SV19 F5/N Gas console AC valve driver board – LEDs process Valve Gas console Off-valve location number Preflow SV12...
Page 142 MAINTENANCE Air/Air Gas console AC valve driver board – LEDs process Valve Gas console Off-valve location number Preflow SV17 SV18 Cutflow SV14 SV16 SV19 Marking Gas console AC valve driver board – LEDs process Valve Gas console Off-valve location number Preflow SV11 SV17 SV18...
Page 144: Error Codes
MAINTENANCE Error codes HyPerformance plasma system error codes Error codes are displayed in the 3-digit LED display on the gas console. 5-10 HPR260 Manual Gas Instruction Manual...
Page 145: Error Code Troubleshooting - 10 Of 10
MAINTENANCE Error code troubleshooting – 1 of 10 Error code Name Description Corrective action number No error System is ready to run. None needed. Pump output has Pump over 1. Verify that coolant filters are in good condition. exceeded 13.79 bar pressure 2.
Page 146: Error Code Troubleshooting - 1 Of 10
MAINTENANCE Error code troubleshooting – 2 of 10 Error code Name Description Corrective action number 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.
Page 147: Error Code Troubleshooting - 2 Of 10
MAINTENANCE Error code troubleshooting – 3 of 10 Error code Name Description Corrective action number 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 7.58 bar 4.
Page 148: Error Code Troubleshooting - 3 Of 10
MAINTENANCE Error code troubleshooting – 4 of 10 Error code Name Description Corrective action number 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.
Page 149: Error Code Troubleshooting - 4 Of 10
MAINTENANCE Error code troubleshooting – 5 of 10 Error code Name Description Corrective action number Coolant flow is less than 1. Verify that the correct consumables are properly installed. Low coolant the required 2.3 lpm 2. Perform the coolant flow test procedure in the Maintenance flow (0.6 gpm).
Page 150: Error Code Troubleshooting - 5 Of 10
MAINTENANCE Error code troubleshooting – 6 of 10 Error code Name Description Corrective action number 1. Verify that all 4 fans in the coolant heat exchanger are running. 2. Blow dust out of the system, especially from the heat exchanger. 3.
Page 151: Error Code Troubleshooting - 6 Of 10
MAINTENANCE Error code troubleshooting – 7 of 10 Error code Name Description Corrective action number 1. Verify that there is not a short on the I/O PCB, between the A current greater than work lead and the negative lead. High current 35 amps has been 2.
Page 152: Error Code Troubleshooting - 7 Of 10
MAINTENANCE Error code troubleshooting – 8 of 10 Error code Name Description Corrective action number 1. Verify that LED D17 or D18 illuminates on the AC valve MV1 error Motor valve 1 did not driver PCB in the selection console. If either illuminates, move into position within Auto Gas replace the motor valve.
Page 153: Error Code Troubleshooting - 8 Of 10
MAINTENANCE Error code troubleshooting – 9 of 10 Error code Name Description Corrective action number 1. Verify that the wiring between CS2 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).
Page 154: Error Code Troubleshooting - 9 Of 10
MAINTENANCE Error code troubleshooting – 10 of 10 Error code Name Description Corrective action number Internal flash Communication problem error to the flash chip on 1. Replace the control board. the gas console control Manual Gas Only board. Internal flash Communication problem error to the flash chip on...
Page 155: Power Supply States
MAINTENANCE Power supply states Set switch 8 on the gas console to the status position to view ID numbers. State Name code Idle Purge Idle 2 Preflow Pilot arc Transfer Ramp-up Steady state Ramp-down Final ramp-down Auto off Test cutflow Shutdown Reset Maintenance...
Page 156: Plasma System Operation With Pump Timeout
MAINTENANCE Plasma system operation with pump timeout 5-22 HPR260 Manual Gas Instruction Manual...
Page 157: Cnc Operation With Pump Timeout
MAINTENANCE CNC operation with pump timeout HPR260 Manual Gas Instruction Manual 5-23...
Page 158: Initial Checks
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.
Page 159: Power Measurement
MAINTENANCE Power measurement DANGER There is line voltage at the contactor after the line disconnect switch is ON, even if the the circuit breaker on the power supply is OFF. Use extreme care when measuring primary power in these areas. Voltages present at the terminal block and contactors can cause injury or death.
Page 160: Power Supply Coolant System Servicing
MAINTENANCE Power supply coolant system servicing Draining the coolant system 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.
Page 161: Coolant System Filter
MAINTENANCE Caution: Coolant will flow from the filter when its housing is removed. Drain coolant before servicing the filter. Coolant system filter Filter replacement 1. Turn OFF all power to the system. 2. Remove housing. 3. Remove and discard filter element. 4.
Page 162: Coolant Flow Troubleshooting Chart
Coolant flow troubleshooting chart...
Page 163: Coolant Flow Tests
An in-line flow meter is the most accurate way to measure the flow rate, but can not be used with all the tests described. An in-line flow meter (part number 128933) is available from Hypertherm. The following “bucket” tests give a good idea of the flow rate.
Page 164: Manual Pump Operation
MAINTENANCE Manual pump operation If the LED display on the gas console shows coolant flow error 093, the pump must be turned on manually within 12 seconds of turning on the power supply, or the power will have to be turned off and then on again. 1.
Page 165: Test 1 - Return Line
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.
Page 166: Test 3 - Change The Torch
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.
Page 167: Test 6 - Bucket Test At The Pump
1. Turn OFF the power. Remove the pump outlet, coolant line, 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”).
Page 168: Pump And Motor Troubleshooting
MAINTENANCE Test 7 – continued 5. Turn ON the power supply, and note the coolant flow rate shown on the LED display on the gas console. If the flow shown on the LED display is more than 0.8 gpm, replace the check valve. Coolant will drain out of the torch during every consumable change if the check valve is bypassed.
Page 169: Testing The Flow Switch
MAINTENANCE Testing the flow switch 1. Turn ON the power. 2. Measure the VDC between TP210 and TP206. TP206 is common on PCB3. TP210 provides a filtered, 67% scaled, voltage from the flow switch. 0.45 VDC (0.67 VDC at the flow switch) equals 2.3 lpm (0.6 gpm). If the TP210 voltage reading is below 0.45 VDC and the flow is equal to or above 3.0 lpm (1 gpm), replace the flow switch.
Page 170: Gas Leak Tests
MAINTENANCE Gas leak tests The system has two automatic leak test modes. The leak test mode is activated by switching the shield gas selector switch (2) to the TEST position and then switching the RUN/SET switch (7) to either SET PREFLOW or SET CUTFLOW to begin the leak test.
Page 171: Power Supply Control Board Pcb3
MAINTENANCE Power supply control board PCB3 Control PC board LED list Control PCB3 firmware list Signal Notes Item Part Number D100 +5 VDC U104 081107 EVEN D101 +3.3 VDC U105 081107 ODD D113 CAN TX Constant blinking D114 CAN RX Constant blinking = HPR130 Note: see wiring...
Page 172: Power Supply Power Distribution Board Pcb2
MAINTENANCE Power supply power distribution board PCB2 Power distribution PC board LED list Output Color Contactor Pilot arc relay 120 VAC (switched) Green HF ignition Surge select 24 VAC (switched) Green 240 VAC (switched) Green + 24 VDC Pump motor Green + 5 VDC - 15 VDC...
Page 173: Start Circuit Pcb1
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.
Page 174 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.
Page 175: Pilot Arc Current Levels
MAINTENANCE Pilot arc current levels The pilot arc current level will change depending on the chosen process and arc current level. See table below. Pilot arc current Plasma gas 30-amps 45-amps 50-amps 80-amps 130-amps 200-amps 260-amps Transfer current Plasma gas 30-amps 45-amps 50-amps...
Page 176: Gas Console Control Board Pcb2
MAINTENANCE Gas console control board PCB2 Control PCB2 firmware list Item Part Number 081109 ODD 081109 EVEN Gas console control board LEDN list Gas console control board LED list LEDN Signal name Color Signal name Color LEDN1 Plasma preflow, left digit + 5 VDC Green LEDN2...
Page 177: Gas Console Power Distribution Board Pcb1
MAINTENANCE Gas console power distribution board PCB1 Signal Name Color 120 VAC (switched) Green + 5 VDC + 24 VDC HPR260 Manual Gas Instruction Manual 5-43...
Page 178: Gas Console Ac Valve-Driver Board Pcb3
MAINTENANCE Gas console, AC valve-driver board PCB3 Signal Name Color Signal Name Color SV11 SV12 SV13 SV14 SV15 (not used) SV16 SV17 SV18 SV19 SV10 SV20 SV14 SV13 SV19 SV18 SV10 SV20 SV16 SV17 SV11 Off-valve SV12 5-44 HPR260 Manual Gas Instruction Manual...
Page 179: Chopper Tests
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.
Page 180 MAINTENANCE Troubleshooting high-current error codes 103 and 104 1. Verify that the current sensors (CS1 and CS2) and cables are not damaged. 2. Exchange CS1 and CS2. Replace the faulty sensor if the error the code is not displayed again. 3.
Page 181: Phase-Loss Detection Test
MAINTENANCE Phase-loss detection test 1. Turn OFF all power to the system and remove the cover from CON1. 2. Inspect the condition of the 3 contacts for excessive wear. If one of more of the contacts are worn excessively, replace CON1 and restart the system. If the error remains, perform the following steps. Excessive wear 3.
Page 182: Torch Lead Test
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. Torch lead test 1. Turn OFF all power to the system. 2.
Page 183: Preventive Maintenance
80% of the cost of cutting, improved productivity can reduce cutting costs dramatically. Preventive maintenance protocol The following protocol covers the basic elements of all Hypertherm HyPerformance plasma systems. If inspection suggests that a component is worn and might require replacement, and you would like confirmation of your decision, please contact Hypertherm's Technical Service department.
Page 184: Cooling System
B. At the ignition console; and C. At the torch main body. Also, check the coolant tank for dirt and particulates. Verify that proper Hypertherm coolant is being used. Proper Hypertherm coolant (028872) is a red liquid. Torch main body 7.
Page 185 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.
Page 186 MAINTENANCE Preventive Maintenance Master Schedule Daily: • Verify proper inlet gas pressure. • Verify proper gas flow settings. – Mandatory at every consumable change. • Inspect torch and replace consumables as needed. Weekly: Week March April June July Sept • Clean power supply with dry, oil free compressed air, or a vacuum cleaner. •...
Page 187: Power Supply
Preventive Maintenance Protocol Checklist Customer: Hypertherm system: Location: System serial #: Contact: System arc hours: Date: (if equipped with an hour meter) Comments P – Performed NP – Not present on system Power supply Gas flows – continued 1. Inspect for particulates and blow out 16.
Page 188 MAINTENANCE Service parts replacement schedule – 1 of 2 228016 – annual preventive maintenance parts kit This kit includes all the parts in the shaded boxes below Timeline Component Part number Qty. Coolant filter element 027664 Coolant solution 70/30 028872 6 months or 300 arc hours Torch kit 128879...
Page 189 MAINTENANCE Service parts replacement schedule – 2 of 2 Timeline Component Part number Qty. 027664 Coolant filter element 028872 Coolant solution 70/30 003217 Main contactor 220162 Torch main body 003149 Pilot arc relay 5 Years or 3000 arc hours 129854 High voltage transformer 041802 Power distribution board...
Page 190: Section 6 Parts List
Section 6 PARTS LIST 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......................................6-10 Consumable parts kit – 228027 ...............................6-11 Consumables for mirror-image cutting ...............................6-12 Recommended spare parts ...................................6-13 HPR260 Manual Gas Instruction Manual...
Page 191: Power Supply
PARTS LIST Power supply Part Item Number Description Designator Qty. 078187 HyPerformance Plasma power supply: 200/208 volt 078202 HyPerformance Plasma power supply: 220 volt 078188 HyPerformance Plasma power supply: 240 volt 078192 HyPerformance Plasma power supply: 380 volt 078186 HyPerformance Plasma power supply: 400 volt 078190 HyPerformance Plasma power supply: 480 volt 078189...
Page 192 PARTS LIST Power supply Part Item Number Description Designator Qty. 027634 Filter housing 027664 Filter element 127014 Cap: coolant reservoir 229034* EMI filter: 80 amp, 50-60 HZ 129792 Chopper assembly CH1, CH2 127039 6" fan :230 CFM, 115 VAC 50-60 HZ 027079 10"...
Page 193 PARTS LIST Power supply Part Item Number Description Designator Qty. 003149 Relay: pilot arc, 120 VAC 041837 PCB: I/O PCB6 003217 Contactor CON1 129791 Start circuit assembly PCB1 109483 Current sensor: hall 200 amp, 4 volt 109004 Current sensor: hall 100 amp, 4 volt 109004 Current sensor: hall 100 amp, 4 volt 108263...
Page 194 PARTS LIST Power supply Part Item Number Description Designator Qty. 008551* Fuse: 7.5 amp, 600 volt F1, F2 008709** Fuse: 20 amp, 500 volt F1, F2 041909 Control PCB PCB3 041802 Power distribution PCB PCB2 027926 Filter assembly: 1/2" NPT low profile 129793 Flow switch assembly 229066...
Page 195 PARTS LIST Power supply Part Item Number Description Designator Qty. 109393 Temperature sensor 109524 Pressure transducer 006132 Check valve: 1/4" NPT, 200 psi 006075 Check valve: 1/4" FPT 006046 Solenoid valve assembly: 3/8", 240 volt CLT SOL 228171 Kit: Pump with clamp 228230 Kit: Motor with clamp HPR260 Manual Gas Instruction Manual...
Page 196: Ignition Console
PARTS LIST Ignition console Part Item Number Description Designator Qty. 078172 Ignition Console 129831 Coil assembly 041817 HFHV Ignition PCB PCB IGN 129854 Transformer HPR260 Manual Gas Instruction Manual...
Page 197: Gas Console - 1 Of 2
PARTS LIST Gas console – 1 of 2 Part Item Number Description Designator Qty. 078170 Gas Console 041805 Power distribution PCB PCB1 041822 Valve driver PCB PCB3 005263 Pressure sensor PT1-PT4 006109 Solenoid valve SV1-SV14 006112 Replacement solenoid coil 005262 Illuminated power switch HPR260 Manual Gas Instruction Manual...
Page 198: Gas Console - 2 Of 2
PARTS LIST Gas console – 2 of 2 Part Item Number Description Designator Qty. 041912 Control PCB PCB2 229128 Regulator assembly with elbow fitting PR1, PR3, PR4 229129 Regulator assembly with elbow and tee fitting 228147 Kit: regulator upgrade (replaces all 4 regulators) Off-valve Part Item...
Page 199: Hyperformance Torch
PARTS LIST HyPerformance torch Torch assembly Part Item Number Description 128818 HPR machine torch assembly 220162 Quick-disconnect torch 220340 Water tube 220163 Quick-disconnect receptacle 220232 Torch mounting sleeve assembly 104269 2” spanner wrench 128879 Torch kit: bullet plugs, o-rings, water tube and seal 128880 Quick disconnect kit: o-ring and connector See Appendix C of this manual for bevel cutting part numbers.
Page 200: Consumable Parts Kit - 228027
PARTS LIST Consumable parts kit – 228027 (also includes HPR130 kit number 128878) Note: See Consumable selection or Cut charts for specific applications Part Number Description Qty. 220307 Electrode 220342 Swirl ring 220343 Nozzle 220344 Inner retaining cap 220345 Shield 220346 Nozzle 220347...
Page 201: Consumables For Mirror-Image Cutting
PARTS LIST Consumables for mirror-image cutting Mild steel Inner Shield retaining cap Nozzle Electrode Retaining cap Swirl ring 220194 220314 220193 220306 220192 220555 220314 220554 220549 220552 220173 220189 220304 220188 220305 220187 130A 220183 220304 220182 220305 220181 200A 220356 220351...
Page 202: Recommended Spare Parts
PARTS LIST Recommended spare parts Power supply Part Number Description Designator Qty. 129633 Green power lamp assembly 027634 Filter housing 027664 Filter element 129792 Chopper assembly 127039 6" fan :230 CFM, 115 VAC 50-60 HZ 027079 10" fan :450-550 CFM, 120 VAC 50-60 HZ 003149 Relay: pilot arc, 120 VAC 041837...
Page 203: Wiring Diagrams
Section 7 WIRING DIAGRAMS Introduction This section contains the wiring diagrams for the system. When tracing a signal path or ref er enc ing with the Parts List or Troubleshooting sections, please be aware of the following format to assist you in un der stand ing the wiring diagrams' organization: •...
Page 204 Push Button, Battery Fuse Normally Closed Push Button, Ground Clamp Cap, polarized Normally Open Receptacle Ground, Chassis Cap, non-polarized Relay, Coil Ground, Earth Cap, feed-thru Relay, Normally Closed IGBT Circuit breaker Relay, Normally Open Inductor Coax shield Relay, Solid State, AC Current Sensor Relay, Solid State, DC Lamp...
Page 205 Time Delay Open, Switch, Flow Torch Symbols NC/On Switch, Level, Time Delay Closed, Normally Closed NO/Off Electrode Switch, Pressure, Normally Closed Transformer Switch, Pressure, Normally Open Nozzle Transformer, Air Core Switch, 1 Pole, 1 Throw Transformer Coil Switch, 1 Pole, 2 Throw Shield Switch, 1 Pole, 1 Throw, Triac...
Page 210 7-10...
Page 211 7-11...
Page 212 7-12...
Page 213 7-13...
Page 214 7-14...
Page 215 7-15...
Page 216 7-16...
Page 217 7-17...
Page 218 7-18...
Page 219 7-19...
Page 220 7-20...
Page 221 Dipswitch setting example: Switch 1 is in the ON position. Switches 2-8 are in the OFF position. 7-21...
Page 222 Dipswitch setting example: Switch 1 is in the ON position. Switches 2-8 are in the OFF position. 7-22...
Page 223 Dipswitch setting example: Switch 1 is in the ON position. Switches 2-8 are in the OFF position. 7-23...
Page 224 Appendix A HYPERTHERM TORCH COOLANT SAFETY DATA 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...
Page 225: Section 1 Chemical Product And Company Identification
MATERIAL SAFETY DATA SHEET SECTION 1 – CHEMICAL PRODUCT AND COMPANY IDENTIFICATION PRODUCT NAME Hypertherm Torch Coolant Latest Revision 09-02-2004 Date EMERGENCY TELEPHONE NUMBERS ISSUE DATE 03-10-2005 Product Information: (603) 643-3441 DISTRIBUTOR: Hypertherm, Inc. Etna Road Hanover, N.H. 03755 SECTION 2 – COMPOSITION / INFORMATION ON INGREDIENTS...
Page 226: Section 4 First Aid Measures
MSDS Page 2 of 4 Product CODE Hypertherm Torch Coolant SECTION 4 – FIRST AID MEASURES Ingestion Never give anything by mouth to an unconscious person. Give several glasses of water. If vomiting is not spontaneous, induce vomiting. Keep airway clear. Get medical attention.
Page 227: Section 8 Exposure Controls / Personal Protection
MSDS Page 3 of 4 Product CODE Hypertherm Torch Coolant SECTION 8 – EXPOSURE CONTROLS / PERSONAL PROTECTION Hygienic practices Normal procedures for good hygiene. Good general ventilation. Eye wash station in immediate area of use. Engineering controls M.E.L./O.E.S Nil.
Page 228: Section 12 Ecological Information
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. Hypertherm Plasma systems...
Page 229: Freezing Point Of Propylene Glycol Solution
% of Propylene Glycol Freezing Point of Propylene Glycol Solution Hypertherm Plasma systems 9/2/04...
Page 230: Functional Description Of Software
Appendix B FUNCTIONAL DESCRIPTION OF SOFTWARE 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. –...
Page 231 SOFTWARE FUNCTIONAL DESCRIPTION • After delay, wait for CAN watchdog message from the gas console. • After CAN watchdog messages have been received, send a CAN reset message to the gas console and go to the Purge state. Error checking •...
Page 232 SOFTWARE FUNCTIONAL DESCRIPTION • If chopper current = 1⁄2 of pilot arc current, turn off HF and go to Transfer state. • If no chopper current after 10 HF pulses, go to Auto Off state with error code (020), “No pilot arc. ” Error checking •...
Page 233 SOFTWARE FUNCTIONAL DESCRIPTION • Check for coolant flow at power-up (093) 10. Final ramp-down • Chopper setpoints = 0 Error checking • Check for coolant flow at power-up (093) 11. Auto-off • Turn off pilot arc relay, pilot arc controller, HF, and machine motion outputs. •...
Page 234 Appendix C BEVEL CUTTING In this appendix: Bevel torch dimensions .....................................c-2 Bevel cutting definitions....................................c-3 Cut charts........................................c-4 Torch connections....................................c-10 Connect the torch lead assembly to the quick-disconnect assembly ................c-10 Parts list........................................c-12 Consumables....................................c-12 Part selection....................................c-13 HPR260 Manual Gas Instruction Manual...
Page 235: Appendix Cbevel Cutting
APPENDIX C – BEVEL CUTTING Bevel torch dimensions 42 ° 51 mm 57 mm 51 mm 2.0" 2.25" 2.0" 122 mm 4.8" 154 mm 6.1" 280.5 mm 11.0" HPR260 Manual Gas Instruction Manual...
Page 236: Bevel Cutting Definitions
APPENDIX C – BEVEL CUTTING Bevel cutting definitions Bevel angle The angle between the center line of the torch and a line that is perpendicular to the workpiece. If the torch is perpendicular to the workpiece, the bevel angle is zero. The maximum bevel angle is 45°.
Page 237: Cut Charts
APPENDIX C – BEVEL CUTTING Cut charts Initial pierce heights and pierce delay times listed in the cut charts are for straight cuts. Edge start indicates that the material thickness is outside the range that can be pierced. These thicknesses can only be cut by using an edge start. Mild steel bevel cutting Flow rates –...
Page 238 APPENDIX C – BEVEL CUTTING Mild steel bevel cutting Flow rates – lpm/scfh @ 3/4" setting Plasma / Air Shield Preflow 0 / 0 130 / 275 260 A Cutflow 42 / 88 104 / 220 220398 220545 220603 220542 220436 220541 Notes:...
Page 239 APPENDIX C – BEVEL CUTTING Stainless steel bevel cutting Flow rates – lpm/scfh H35 Plasma / N Shield Preflow 0 / 0 90 / 190 130 A Cutflow 26 / 54 114 / 240 220398 220609 220608 220656 220179 220606 Notes: Bevel angle range is 0°...
Page 240 APPENDIX C – BEVEL CUTTING Stainless steel bevel cutting Flow rates – lpm/scfh Plasma / N Shield Preflow 97 / 205 130 A Cutflow 125 / 260 220398 220609 220608 220656 220179 220606 Notes: Bevel angle range is 0° to 45°. Water tube 220571 must be used with these consumables.
Page 241 APPENDIX C – BEVEL CUTTING Stainless steel bevel cutting Flow rates – lpm/scfh @ 3/4" setting H35 Plasma / N Shield Preflow 0 / 0 127 / 270 260 A Cutflow 40 / 84 122 / 260 220398 220609 220608 220607 220405 220606...
Page 242 APPENDIX C – BEVEL CUTTING Stainless steel bevel cutting Flow rates – lpm/scfh @ 3/4" setting Plasma / Air Shield Preflow 127 / 270 0 / 0 260 A Cutflow 54 / 114 116 / 245 220398 220609 220608 220607 220405 220606 Notes:...
Page 243: Torch Connections
APPENDIX C – BEVEL CUTTING Torch connections Connect the torch lead assembly to the quick-disconnect assembly 1. Uncoil the first 2 meters (6.5 feet) of lead assembly on a flat surface. 2. Hold the torch assembly and remove the mounting sleeve from the torch quick-disconnect assembly. 3.
Page 244 APPENDIX C – BEVEL CUTTING 6. Connect the plasma vent hose (white). Note: The connectors in steps 6–9 are push-to-connect fittings. To make a connection, slide the hose fitting into the appropriate connector until it 7. Connect the coolant return hose (red). stops.
Page 245: Parts List
APPENDIX C – BEVEL CUTTING Parts list Consumables Mild steel Inner Retaining retaining Swirl Electrode Water tube Shield Nozzle ring 130A 220700 220645 220603 220646 220179 220649 220398 260A 220545 220603 220542 220436 220541 220571 220398 Stainless steel Inner Retaining retaining Swirl Electrode...
Page 246: Part Selection
APPENDIX C – BEVEL CUTTING Part selection Note: Standard consumables can be used for bevel cutting, but are not optimized for bevel cutting. Water tube 220571 or 220700 must be installed in the HPR torch when using consumables specifically designed for bevel cutting.
Page 247 APPENDIX C – BEVEL CUTTING 1. Leads for use with the standard quick-disconnect (220163) All leads have standard fittings that are identical to the hoses listed in the Installation section in this manual. The only difference is that the gas leads have been extended to 2.5 m (8.17 ft). Part number Overall length Gas lead length...
Page 248 Changed Description of change for revision 4 (date of change - 4/2008) Page Updated EMC and Warranty information to the latest version and new format. Updated table of contents to i - x reflect changes for the new revision. Added information to the gas quality and pressure requirements table. Added notes below the table. Changed the format of the table to include the power supply part numbers.
Page 249 Changed Description of change for revision 6 (date of change - 12/2007) Page Listed the 3 current sensors separately (5, 6a, and 6b) to identify their designators. 108263 (items 7a and 7b - fuse) was a 150 amp fuse and is now 175 amps (page 6-13 also). Fuses listed separately to identify their designators.
Page 250 Changed Page Description IM804940 Rev 1 to 3 5/15/06 Revision 2 was never printed. Printed manuals went from Revision 1 to 3. Updated the "Gas purity and pressure requirements" table to add grade information. Also changed the maximum ﬂow rate for Nitrogen and Air from 7080 l/h 250 scfh to 9910 l/h 350 scfh. Update table to include part numbers, add 220V and 380V power supplies and add regulatory approvals.
Page 251 Changed Page Description IM804940 Rev 0 to 1 8/05/05 Updated art for step number 5 to show the new pilot arc connector. Added text to step number 5 " 3.29 Tighten by hand only". Corrected recommended cable size for 200/208V, rated for 90 degrees C. It was (2 AWG) and is 3.33 now (2/0 AWG).

Hypertherm HyPerformance Plasma HPR260 Instruction Manual

English

Electromagnetic Compatibility (EMC

Warranty

Safety

Français

Section 1A

Sécurité

Español

Seguridad

Specifications

Installation

Operation

Maintenance

Wiring Diagrams

Appendix A BEN ZOTRIAZOLE / PROPYLENE G LYCOL SAFETY DATA

Functional Description of Software

Appendix B FUNCTIONAL de SCRI PTION of SOFTWARE

Appendix Cbevel CUTTING