HPR400XD

HyPerformance Plasma ®
HPR400XD ®
Auto gas
Instruction manual
806160 – Revision 3
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HyPerformance Plasma
HPR400XD Auto Gas
Instruction Manual
(P/N 806160)
Revision 3 – November, 2011
Hypertherm, Inc.
Hanover, NH USA
www.hypertherm.com
© 2011 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.
Hypertherm, Inc. Hypertherm Europe B.V.
Etna Road, P.O. Box 5010 Vaartveld 9
Hanover, NH 03755 USA 4704 SE
603-643-3441 Tel (Main Office) Roosendaal, Nederland
603-643-5352 Fax (All Departments) 31 165 596907 Tel
info@hypertherm.com (Main Office Email) 31 165 596901 Fax
800-643-9878 Tel (Technical Service) 31 165 596908 Tel (Marketing)
technical.service@hypertherm.com (Technical Service Email) 31 165 596900 Tel (Technical Service)
800-737-2978 Tel (Customer Service) 00 800 4973 7843 Tel (Technical Service)
customer.service@hypertherm.com (Customer Service Email)
Hypertherm Japan Ltd.
Hypertherm Automation Level 9, Edobori Center Building
5 Technology Drive, Suite 300 2-1-1 Edobori, Nishi-ku
West Lebanon, NH 03784 USA Osaka 550-0002 Japan
603-298-7970 Tel 81 6 6225 1183 Tel
603-298-7977 Fax 81 6 6225 1184 Fax
Hypertherm Plasmatechnik GmbH Hypertherm Brasil Ltda.

Technologiepark Hanau Avenida Doutor Renato de
Rodenbacher Chaussee 6 Andrade Maia 350
D-63457 Hanau-Wolfgang, Deutschland Parque Renato Maia
49 6181 58 2100 Tel CEP 07114-000
49 6181 58 2134 Fax Guarulhos, SP Brasil
49 6181 58 2123 (Technical Service) 55 11 2409 2636 Tel
55 11 2408 0462 Fax
Hypertherm (S) Pte Ltd.
82 Genting Lane Hypertherm México, S.A. de C.V.
Media Centre Avenida Toluca No. 444, Anexo 1,
Annexe Block #A01-01 Colonia Olivar de los Padres
Singapore 349567, Republic of Singapore Delegación Álvaro Obregón
65 6841 2489 Tel México, D.F. C.P. 01780
65 6841 2490 Fax 52 55 5681 8109 Tel
65 6841 2489 (Technical Service) 52 55 5683 2127 Fax
Hypertherm (Shanghai) Trading Co., Ltd. Hypertherm Korea Branch

Unit A, 5th Floor, Careri Building #3904 Centum Leaders Mark B/D,
432 West Huai Hai Road 1514 Woo-dong, Haeundae-gu, Busan
Shanghai, 200052 Korea, 612-889
PR China 82 51 747 0358 Tel
86-21 5258 3330/1 Tel 82 51 701 0358 Fax
86-21 5258 3332 Fax
03/08/11
Electromagnetic compatibility (EMC)
ElEctRomAgNEtIc comPAtIbIlIty (Emc)
Introduction a. Other supply cables, control cables, signaling and

telephone cables; above, below and adjacent to the
Hypertherm’s CE-marked equipment is built in cutting equipment.
compliance with standard EN60974-10. The equipment
should be installed and used in accordance with b. Radio and television transmitters and receivers.
the information below to achieve electromagnetic
compatibility. c. Computer and other control equipment.
The limits required by EN60974-10 may not be d. Safety critical equipment, for example guarding of
adequate to completely eliminate interference when the industrial equipment.
affected equipment is in close proximity or has a high
degree of sensitivity. In such cases it may be necessary e. Health of the people around, for example the use of
to use other measures to further reduce interference. pacemakers and hearing aids.
This cutting equipment is designed for use only in an f. Equipment used for calibration or measurement.
industrial environment.
g. Immunity of other equipment in the environment. User
Installation and use shall ensure that other equipment being used in the
environment is compatible. This may require additional
The user is responsible for installing and using the protection measures.
plasma equipment according to the manufacturer’s
instructions. h. Time of day that cutting or other activities are to be
carried out.
If electromagnetic disturbances are detected then it shall
be the responsibility of the user to resolve the situation The size of the surrounding area to be considered
with the technical assistance of the manufacturer. In will depend on the structure of the building and other
some cases this remedial action may be as simple activities that are taking place. The surrounding area
as earthing the cutting circuit, see Earthing of the may extend beyond the boundaries of the premises.
work piece. In other cases, it could involve constructing
an electromagnetic screen enclosing the power source
and the work complete with associated input filters. In all methods of reducing emissions
cases, electromagnetic disturbances must be reduced to mains supply
the point where they are no longer troublesome.
Cutting equipment must be connected to the
mains supply according to the manufacturer’s
Assessment of area recommendations. If interference occurs, it may be
Before installing the equipment, the user shall make an necessary to take additional precautions such as filtering
assessment of potential electromagnetic problems in of the mains supply.
the surrounding area. The following shall be taken into
account:
Compliance Information EMC-1

Compliance Information Emc-1
7/10
7/10
ElEctRomAgNEtIc comPAtIbIlIty
Consideration should be given to shielding the supply Earthing of the workpiece

cable of permanently installed cutting equipment,
in metallic conduit or equivalent. Shielding should Where the workpiece is not bonded to earth for
be electrically continuous throughout its length. The electrical safety, nor connected to earth because of its
shielding should be connected to the cutting mains size and position, for example, ship’s hull or building
supply so that good electrical contact is maintained steel work, a connection bonding the workpiece to earth
between the conduit and the cutting power source may reduce emissions in some, but not all instances.
enclosure. Care should be taken to prevent the earthing of the
workpiece increasing the risk of injury to users, or
damage to other electrical equipment. Where necessary,
maintenance of cutting equipment the connection of the workpiece to earth should be
The cutting equipment must be routinely maintained made by a direct connection to the workpiece, but
according to the manufacturer’s recommendations. All in some countries where direct connection is not
access and service doors and covers should be closed permitted, the bonding should be achieved by suitable
and properly fastened when the cutting equipment is in capacitances selected according to national regulations.
operation. The cutting equipment should not be modified
in any way, except as set forth in and in accordance with Note: The cutting circuit may or may not be earthed for
the manufacturer’s written instructions. For example, safety reasons. Changing the earthing arrangements
the spark gaps of arc striking and stabilizing devices should only be authorized by a person who is competent
should be adjusted and maintained according to the to assess whether the changes will in crease the risk of
manufacturer’s recommendations. injury, for example, by allowing parallel cutting current
return paths which may damage the earth circuits of
other equipment. Further guidance is provided in
cutting cables IEC 60974-9, Arc Welding Equipment, Part 9:
The cutting cables should be kept as short as possible Installation and Use.
and should be positioned close together, running at or
close to the floor level. Screening and shielding
Selective screening and shielding of other cables
Equipotential bonding and equipment in the surrounding area may alleviate
Bonding of all metallic components in the cutting problems of interference. Screening of the entire plasma
installation and adjacent to it should be considered. cutting installation may be considered for special
applications.
However, metallic components bonded to the workpiece
will increase the risk that the operator could receive a
shock by touching these metallic components and the
electrode (nozzle for laser heads) at the same time.
The operator should be insulated from all such bonded

metallic components.
Emc-2 Compliance Information

7/10
warranty
wARRANty
Attention Hypertherm provides repair, replacement or adjustment

of the Product as the sole and exclusive remedy, if
Genuine Hypertherm parts are the factory- and only if the warranty set forth herein properly is
recommended replacement parts for your Hypertherm invoked and applies. Hypertherm, at its sole option,
system. Any damage or injury caused by the use of other shall repair, replace, or adjust, free of charge, any
than genuine Hypertherm parts may not be covered by defective Products covered by this warranty which
the Hypertherm warranty, and will constitute misuse of shall be returned with Hypertherm’s prior authorization
the Hypertherm Product. (which shall not be unreasonably withheld), properly
packed, to Hypertherm’s place of business in Hanover,
You are solely responsible for the safe use of the New Hampshire, or to an authorized Hypertherm repair
Product. Hypertherm does not and cannot make any facility, all costs, insurance and freight pre paid by the
guarantee or warranty regarding the safe use of the customer. Hypertherm shall not be liable for any repairs,
product in your environment. replacement, or adjustments of Products covered by this
warranty, except those made pursuant to this paragraph
general and with Hypertherm’s prior written consent.
Hypertherm, Inc. warrants that its Products shall be The warranty set forth above is exclusive and is in
free from defects in materials and workmanship for the lieu of all other warranties, express, implied, statutory,
specific periods of time set forth herein and as follows: or otherwise with respect to the Products or as to
if Hypertherm is notified of a defect (i) with respect to the results which may be obtained therefrom, and
the power supply within a period of two (2) years from all implied warranties or conditions of quality or of
the date of its delivery to you, with the exception of merchantability or fitness for a particular purpose or
Powermax brand power supplies, which shall be within against infringement. The foregoing shall constitute the
a period of three (3) years from the date of delivery to sole and exclusive remedy for any breach by Hypertherm
you, and (ii) with respect to the torch and leads within of its warranty.
a period of one (1) year from its date of delivery to you,
and with respect to torch lifter assemblies within a Distributors/OEMs may offer different or additional
period of one (1) year from its date of delivery to you, warranties, but Distributors/OEMs are not authorized to
and with respect to laser heads within a period of one give any additional warranty protection to you or make
(1) year from its date of delivery to you, and with respect any representation to you purporting to be binding upon
to Automation products one (1) year from its date of Hypertherm.
delivery to you, with the exception of the EDGE Pro
and MicroEDGE Pro CNCs and ArcGlide THC, which
shall be within a period of two (2) years from the date of
delivery to you.
This warranty shall not apply to any Powermax brand

power supplies that have been used with phase
converters. In addition, Hypertherm does not warranty
systems that have been damaged as a result of poor
power quality, whether from phase converters or
incoming line power. This warranty shall not apply to any
Product which has been incorrectly installed, modified,
or otherwise damaged.
Compliance Information W-1

Compliance Information w-1
8/10
9/10
wARRANty
Patent indemnity Insurance

Except only in cases of products not manufactured by At all times you will have and maintain insurance in such
Hypertherm or manufactured by a person other than quantities and types, and with coverage sufficient and
Hypertherm not in strict conformity with Hypertherm’s appropriate to defend and to hold Hypertherm harmless
specifications and in cases of designs, processes, in the event of any cause of action arising from the use
formulae, or combinations not developed or purported of the products.
to be developed by Hypertherm, Hypertherm will have
the right to defend or settle, at its own expense, any transfer of rights
suit or proceeding brought against you alleging that
the use of the Hypertherm product, alone and not in You may transfer any remaining rights you may have
combination with any other product not supplied by hereunder only in connection with the sale of all or
Hypertherm, infringes any patent of any third party. You substantially all of your assets or capital stock to a
shall notify Hypertherm promptly upon learning of any successor in interest who agrees to be bound by all of
action or threatened action in connection with any such the terms and conditions of this Warranty. Within thirty
alleged infringement (and in any event no longer than (30) days before any such transfer occurs, you agree to
fourteen (14) days after learning of any action or threat notify in writing Hypertherm, which reserves the right of
of action), and Hypertherm’s obligation to defend shall approval. Should you fail timely to notify Hypertherm and
be conditioned upon Hypertherm’s sole control of, and seek its approval as set forth herein, the Warranty set
the indemnified party’s cooperation and assistance in, forth herein shall be null and void and you will have no
the defense of the claim. further recourse against Hypertherm under the Warranty
or otherwise.
limitation of liability
In no event shall Hypertherm be liable to any
person or entity for any incidental, consequential
direct, indirect, punitive or exemplary damages
(including but not limited to lost profits)
regardless of whether such liability is based on
breach of contract, tort, strict liability, breach
of warranty, failure of essential purpose, or
otherwise, and even if advised of the possibility
of such damages.
National and local codes

National and local codes governing plumbing and
electrical installation shall take precedence over any
instructions contained in this manual. In no event shall
Hypertherm be liable for injury to persons or property
damage by reason of any code violation or poor work
practices.
liability cap
In no event shall Hypertherm’s liability, if any,
whether such liability is based on breach of
contract, tort, strict liability, breach of warranties,
failure of essential purpose or otherwise, for
any claim, action, suit or proceeding (whether
in court, arbitration, regulatory proceeding or
otherwise) arising out of or relating to the use of
the Products exceed in the aggregate the amount
paid for the Products that gave rise to such claim.
w-2 Compliance Information

9/10
Table of Contents
Electromagnetic compatibility (EMC)..........................................................................................................EMC-1

warranty.............................................................................................................................................................................W-1
Section 1
SAFETY.......................................................................................................................................................................................1-1
Recognize safety information...................................................................................................................................................................1-2
Follow safety instructions..........................................................................................................................................................................1-2
Electrical hazards........................................................................................................................................................................................1-2
Electric shock can kill.................................................................................................................................................................................1-3
Cutting can cause fire or explosion........................................................................................................................................................1-4
Toxic fumes can cause injury or death...................................................................................................................................................1-5
Static electricity can damage circuit boards........................................................................................................................................1-6
Compressed gas equipment safety........................................................................................................................................................1-6
Grounding safety........................................................................................................................................................................................1-6
Gas cylinders can explode if damaged..................................................................................................................................................1-6
A plasma arc can cause injury and burns..............................................................................................................................................1-7
Arc rays can burn eyes and skin..............................................................................................................................................................1-7
Noise can damage hearing.......................................................................................................................................................................1-8
Pacemaker and hearing aid operation...................................................................................................................................................1-8
A plasma arc can damage frozen pipes................................................................................................................................................1-8
Dry dust collection information................................................................................................................................................................1-9
Laser radiation.......................................................................................................................................................................................... 1-10
Symbols and marks................................................................................................................................................................................. 1-11
Additional safety information................................................................................................................................................................. 1-11
Warning labels.......................................................................................................................................................................................... 1-12
Section 1a
SÉCURITÉ................................................................................................................................................................................1a-1
Identifier les consignes de sécurité..................................................................................................................................................... 1a-2
Suivre les instructions de sécurité........................................................................................................................................................ 1a-2
Risques électriques................................................................................................................................................................................. 1a-2
Les chocs électriques peuvent être fatals.......................................................................................................................................... 1a-3
Le coupage peut provoquer un incendie ou une explosion........................................................................................................... 1a-4
Les vapeurs toxiques peuvent provoquer des blessures ou la mort............................................................................................ 1a-5
Sécurité des bouteilles de gaz comprimé.......................................................................................................................................... 1a-6
Mise à la masse et à la terre.................................................................................................................................................................. 1a-6
L’électricité statique peut endommager les cartes de circuits imprimés.................................................................................... 1a-6
Les bouteilles de gaz comprimé peuvent exploser en cas de dommages................................................................................. 1a-6
L’arc plasma peut provoquer des blessures ou des brûlures........................................................................................................ 1a-7
Les rayons de l’arc peuvent brûler les yeux et la peau.................................................................................................................... 1a-7
Le bruit peut provoquer des problèmes auditifs............................................................................................................................... 1a-8
Un arc plasma peut endommager les tuyaux gelés......................................................................................................................... 1a-8
Pacemakers et prothèses auditives..................................................................................................................................................... 1a-8
Information sur le dépoussièrage......................................................................................................................................................... 1a-9
Radiation au laser..................................................................................................................................................................................1a-10
Symboles et marquage.........................................................................................................................................................................1a-11
Étiquettes de sécurtité..........................................................................................................................................................................1a-12
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Table of Contents
Sección 1b
SEGURIDAD............................................................................................................................................................................1b-1
Reconocimiento de información de seguridad................................................................................................................................. 1b-2
Cumplimiento de instrucciones de seguridad.................................................................................................................................. 1b-2
Riesgos de electrocución...................................................................................................................................................................... 1b-2
Las descargas eléctricas pueden matar............................................................................................................................................. 1b-3
Los cortes pueden producir incendios o explosiones..................................................................................................................... 1b-4
Los vapores tóxicos pueden producir lesiones o la muerte........................................................................................................... 1b-5
Seguridad de equipos de gas comprimido....................................................................................................................................... 1b-6
Seguridad de toma a tierra.................................................................................................................................................................... 1b-6
La electricidad estática puede dañar las placas de circuitos........................................................................................................ 1b-6
Los cilindros de gas pueden explotar si están dañados................................................................................................................. 1b-6
El arco de plasma puede producir lesiones y quemaduras........................................................................................................... 1b-7
Los rayos del arco pueden quemar los ojos y la piel....................................................................................................................... 1b-7
Los ruidos pueden dañar la audición.................................................................................................................................................. 1b-8
Funcionamiento de marcapasos y audífonos.................................................................................................................................... 1b-8
El arco de plasma puede dañar las tuberías congeladas............................................................................................................... 1b-8
Información acerca de la recolección de polvo seco...................................................................................................................... 1b-9
Radiación láser.......................................................................................................................................................................................1b-10
Símbolos y marcas................................................................................................................................................................................1b-11
Etiquetas de advertencia......................................................................................................................................................................1b-12
Section 2
Specifications.....................................................................................................................................................................2-1
System description.....................................................................................................................................................................................2-3
General...............................................................................................................................................................................................2-3
Power supply.....................................................................................................................................................................................2-3
Cooler.................................................................................................................................................................................................2-3
Ignition console.................................................................................................................................................................................2-3
Selection console.............................................................................................................................................................................2-3
Metering console..............................................................................................................................................................................2-3
Torch...................................................................................................................................................................................................2-3
Specifications..............................................................................................................................................................................................2-4
System gas requirements...............................................................................................................................................................2-4
Power supply.....................................................................................................................................................................................2-5
Cooler – 078531...........................................................................................................................................................................2-6
Ignition console – 078172.............................................................................................................................................................2-7
Selection console – 078533.........................................................................................................................................................2-9
Metering console – 078535....................................................................................................................................................... 2-10
Torch – 228354............................................................................................................................................................................ 2-11
IEC symbols.............................................................................................................................................................................................. 2-12
Section 3
Installation..........................................................................................................................................................................3-1
Upon receipt................................................................................................................................................................................................3-3
Claims............................................................................................................................................................................................................3-3
Installation requirements...........................................................................................................................................................................3-3
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Table of Contents
Noise levels..................................................................................................................................................................................................3-3
Placement of system components..........................................................................................................................................................3-3
Torque specifications......................................................................................................................................................................3-3
System components........................................................................................................................................................................3-5
Cables and hoses............................................................................................................................................................................3-5
Supply gas hoses.............................................................................................................................................................................3-5
Customer-supplied power cable..................................................................................................................................................3-5
Recommended grounding and shielding practices............................................................................................................................3-6
Introduction..................................................................................................................................................................................................3-6
Types of grounding..........................................................................................................................................................................3-6
Steps to take.....................................................................................................................................................................................3-7
Grounding diagram....................................................................................................................................................................... 3-10
Placement of the power supply............................................................................................................................................................ 3-11
Lifting the power supply............................................................................................................................................................... 3-12
Install the ignition console...................................................................................................................................................................... 3-14
Placement of the cooler......................................................................................................................................................................... 3-16
Install the metering console................................................................................................................................................................... 3-17
Placement of the selection console..................................................................................................................................................... 3-18
Power supply to ignition console leads.............................................................................................................................................. 3-20
Pilot arc lead................................................................................................................................................................................... 3-20
Negative lead.................................................................................................................................................................................. 3-20
Ignition console power cable...................................................................................................................................................... 3-22
Coolant hoses........................................................................................................................................................................................... 3-23
Power supply to cooler cables............................................................................................................................................................. 3-24
Control cable.................................................................................................................................................................................. 3-24
Power cable.................................................................................................................................................................................... 3-24
Power supply to selection console cables......................................................................................................................................... 3-26
Control cable.................................................................................................................................................................................. 3-26
Power cable.................................................................................................................................................................................... 3-26
Selection console to metering console connections...................................................................................................................... 3-28
Cable and gas hose assembly................................................................................................................................................... 3-28
Power supply to CNC interface cable................................................................................................................................................ 3-30
Optional multi-system CNC interface cable........................................................................................................................... 3-30
Notes to CNC interface cable run list...................................................................................................................................... 3-31
Examples of output circuits......................................................................................................................................................... 3-32
Examples of input circuits............................................................................................................................................................ 3-33
Remote ON/OFF switch (provided by customer)............................................................................................................................ 3-34
Torch lead assembly............................................................................................................................................................................... 3-35
Work lead.................................................................................................................................................................................................. 3-36
Torch connections................................................................................................................................................................................... 3-37
Connect the torch to the torch lead assembly....................................................................................................................... 3-37
Connect the torch to the quick-disconnect............................................................................................................................ 3-41
Torch mounting and alignment............................................................................................................................................................. 3-42
Mounting the torch........................................................................................................................................................................ 3-42
Torch alignment............................................................................................................................................................................. 3-42
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Table of Contents
Torch lifter requirement.......................................................................................................................................................................... 3-43

HyperNet.................................................................................................................................................................................................... 3-43
Power requirements................................................................................................................................................................................ 3-44
General............................................................................................................................................................................................ 3-44
Line disconnect switch................................................................................................................................................................ 3-45
Main power cable.......................................................................................................................................................................... 3-45
Connect the power.................................................................................................................................................................................. 3-46
Torch coolant requirements................................................................................................................................................................... 3-47
Premixed coolant for standard operating temperatures....................................................................................................... 3-47
Custom Coolant mix for cold operating temperatures.......................................................................................................... 3-48
Custom Coolant mix for hot operating temperatures............................................................................................................ 3-49
Water purity requirements..................................................................................................................................................................... 3-49
Fill the cooler with coolant..................................................................................................................................................................... 3-50
Gas requirements.................................................................................................................................................................................... 3-51
Setting the supply regulators...................................................................................................................................................... 3-51
Gas regulators.......................................................................................................................................................................................... 3-52
Supply gas plumbing.............................................................................................................................................................................. 3-53
Connect the supply gases.......................................................................................................................................................... 3-54
Supply gas hoses.................................................................................................................................................................................... 3-55
Section 4
Operation...............................................................................................................................................................................4-1
Daily start-up................................................................................................................................................................................................4-3
Check torch.......................................................................................................................................................................................4-3
Power indicators.........................................................................................................................................................................................4-4
General...............................................................................................................................................................................................4-4
Power supply.....................................................................................................................................................................................4-4
CNC controller requirements...................................................................................................................................................................4-5
CNC screen examples...............................................................................................................................................................................4-6
Main (control) screen.......................................................................................................................................................................4-6
Diagnostic screen............................................................................................................................................................................4-7
Test screen........................................................................................................................................................................................4-8
Cut chart screen...............................................................................................................................................................................4-9
Consumable selection............................................................................................................................................................................ 4-10
Standard cutting (0°).................................................................................................................................................................... 4-10
Bevel cutting (0° to 45°).............................................................................................................................................................. 4-10
Marking............................................................................................................................................................................................ 4-10
Consumables for mirror-image cutting..................................................................................................................................... 4-10
SilverPlus electrodes.................................................................................................................................................................... 4-10
Mild steel......................................................................................................................................................................................... 4-11
Stainless steel................................................................................................................................................................................ 4-12
Aluminum......................................................................................................................................................................................... 4-13
Mild steel bevel cutting................................................................................................................................................................ 4-14
Mild steel, thick piercing, bevel cutting.................................................................................................................................... 4-14
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Stainless steel bevel cutting....................................................................................................................................................... 4-15

Install and Inspect consumables.......................................................................................................................................................... 4-16
Torch maintenance.................................................................................................................................................................................. 4-19
Routine maintenance.................................................................................................................................................................... 4-19
Quick-disconnect maintenance................................................................................................................................................. 4-19
Maintenance kit.............................................................................................................................................................................. 4-19
Replace torch water tube....................................................................................................................................................................... 4-20
Common cutting faults........................................................................................................................................................................... 4-21
How to optimize cut quality................................................................................................................................................................... 4-22
Tips for table and torch................................................................................................................................................................ 4-22
Plasma set-up tips........................................................................................................................................................................ 4-22
Maximize the life of consumable parts...................................................................................................................................... 4-22
Additional Factors of cut quality................................................................................................................................................. 4-23
Additional improvements............................................................................................................................................................. 4-25
Cut charts.................................................................................................................................................................................................. 4-26
Bevel cut charts............................................................................................................................................................................. 4-26
Bevel cutting definitions......................................................................................................................................................................... 4-27
Estimated kerf-width compensation.................................................................................................................................................... 4-28
Section 5
Maintenance.........................................................................................................................................................................5-1
Introduction..................................................................................................................................................................................................5-3
Routine maintenance.................................................................................................................................................................................5-3
Power and signal cables.................................................................................................................................................................5-4
Sequence of operation..............................................................................................................................................................................5-5
Gas system purge cycle............................................................................................................................................................................5-6
Gas system valve usage............................................................................................................................................................................5-6
Marking process...............................................................................................................................................................................5-8
Error codes...................................................................................................................................................................................................5-9
Error code troubleshooting – error codes 000 to 018...................................................................................................... 5-10
Error code troubleshooting – error codes 020 to 028, 224 to 228............................................................................... 5-11
Error code troubleshooting – error codes 116 to 133, 316............................................................................................. 5-20
Error code troubleshooting – error codes 134 to 140, 334 and 338............................................................................ 5-21
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Error code troubleshooting – error code 181, 182, and 383.......................................................................................... 5-26
Power supply states................................................................................................................................................................................ 5-27
Plasma system operation with pump time-out.................................................................................................................................. 5-28
CNC operation with pump time-out.................................................................................................................................................... 5-29
Initial checks.............................................................................................................................................................................................. 5-30
Power measurement............................................................................................................................................................................... 5-31
Air filter element replacement............................................................................................................................................................... 5-32
Coolant system servicing....................................................................................................................................................................... 5-33
Draining the coolant system........................................................................................................................................................ 5-33
Coolant system filter............................................................................................................................................................................... 5-34
Filter replacement.......................................................................................................................................................................... 5-34
Coolant flow troubleshooting chart..................................................................................................................................................... 5-35
Coolant flow tests.................................................................................................................................................................................... 5-36
Before testing................................................................................................................................................................................. 5-36
Bypass valve verification.............................................................................................................................................................. 5-37
Using the Hypertherm flow meter (128933)........................................................................................................................... 5-37
Manual pump operation............................................................................................................................................................... 5-38
Test 1 – return line...................................................................................................................................................................... 5-39
Test 2 – supply line at ignition console.................................................................................................................................. 5-39
Test 3 – change the torch......................................................................................................................................................... 5-40
Test 4 – supply line to the torch receptacle......................................................................................................................... 5-40
Test 5 – return line from the torch receptacle (remove at the ignition console).......................................................... 5-40
Test 6 – bucket test at the pump............................................................................................................................................ 5-41
Pump and motor troubleshooting.............................................................................................................................................. 5-42
Testing the flow sensor................................................................................................................................................................ 5-42
Gas leak tests........................................................................................................................................................................................... 5-43
Leak test 1 (inlet leak test).......................................................................................................................................................... 5-43
Leak test 2 (system leak test)..................................................................................................................................................... 5-44
Leak test 3 (proportional valve test in the metering console)............................................................................................. 5-44
Power supply control board PCB3..................................................................................................................................................... 5-45
Power supply power distribution board PCB2................................................................................................................................. 5-46
Start-circuit PCB1................................................................................................................................................................................... 5-47
Operation........................................................................................................................................................................................ 5-47
Start circuit functional schematic.............................................................................................................................................. 5-47
Start circuit troubleshooting....................................................................................................................................................... 5-47
Pilot arc current levels............................................................................................................................................................................ 5-49
Pump motor drive board PCB7............................................................................................................................................................ 5-50
Cooler power distribution board PCB1............................................................................................................................................. 5-51
Cooler sensor board PCB2.................................................................................................................................................................. 5-52
Selection console control board PCB2............................................................................................................................................. 5-53
Selection console power distribution board PCB1......................................................................................................................... 5-54
Selection console, AC valve-driver board PCB3............................................................................................................................. 5-55
Metering console control board PCB2............................................................................................................................................... 5-56
Metering console power distribution board PCB1.......................................................................................................................... 5-57
Chopper tests........................................................................................................................................................................................... 5-58
vi HPR400XD Auto Gas – 806160 Revision 3

Table of Contents
Phase-loss detection test...................................................................................................................................................................... 5-60

Torch lead test.......................................................................................................................................................................................... 5-61
Preventive maintenance.......................................................................................................................................................................... 5-62
Section 6
Parts List...............................................................................................................................................................................6-1
Power supply...............................................................................................................................................................................................6-2
Cooler............................................................................................................................................................................................................6-6
Ignition console ..........................................................................................................................................................................................6-8
Selection console.......................................................................................................................................................................................6-9
Metering console..................................................................................................................................................................................... 6-11
HyPerformance torch.............................................................................................................................................................................. 6-12
Torch assembly.............................................................................................................................................................................. 6-12
Torch leads..................................................................................................................................................................................... 6-13
Ohmic contact wire....................................................................................................................................................................... 6-13
Consumable parts kits............................................................................................................................................................................ 6-14
Consumables for mirror-image cutting............................................................................................................................................... 6-16
Mild steel (straight cutting)......................................................................................................................................................... 6-16
Mild steel (bevel cutting)............................................................................................................................................................. 6-17
Recommended spare parts................................................................................................................................................................... 6-18
Section 7
Wiring Diagrams................................................................................................................................................................7-1
Appendix A
Hypertherm torch coolant Safety Data......................................................................................................... a-1
1 – Identification of the substance/mixture and of the company undertaking............................................................................a-2
2 – Hazards identification.......................................................................................................................................................................a-2
3 – Composition/information on ingredients......................................................................................................................................a-3
4 – First aid measures.............................................................................................................................................................................a-3
5 – Fire-fighting measures......................................................................................................................................................................a-3
6 – Accidental release measures..........................................................................................................................................................a-3
7 – Handling and storage.......................................................................................................................................................................a-4
8 – Exposure controls/personal protection........................................................................................................................................a-4
9 – Physical and chemical properties..................................................................................................................................................a-4
10 – Stability and reactivity....................................................................................................................................................................a-5
11 – Toxicological information...............................................................................................................................................................a-5
12 – Ecological information...................................................................................................................................................................a-5
13 – Disposal considerations................................................................................................................................................................a-6
14 – Transport information.....................................................................................................................................................................a-6
16 – Other information............................................................................................................................................................................a-7
Freezing Point of Propylene Glycol Solution........................................................................................................................................a-8
Appendix B
CNC Interface Protocol.............................................................................................................................................. b-1
Interface hardware......................................................................................................................................................................................b-2
HPR400XD Auto Gas – 806160 Revision 3 vii

Table of Contents
Signal list......................................................................................................................................................................................................b-2
Signals................................................................................................................................................................................................b-2
Hardware............................................................................................................................................................................................b-3
Multi-drop wiring...............................................................................................................................................................................b-4
Multi-drop addressing.....................................................................................................................................................................b-5
Serial commands........................................................................................................................................................................................b-5
Format.................................................................................................................................................................................................b-5
Framing...............................................................................................................................................................................................b-5
Commands.........................................................................................................................................................................................b-5
Command table (1 of 14).........................................................................................................................................................................b-6
Error responses............................................................................................................................................................................. b-20
Calculating checksums................................................................................................................................................................ b-20
Error codes................................................................................................................................................................................................ b-21
Status codes............................................................................................................................................................................................. b-25
Gas type codes........................................................................................................................................................................................ b-25
CNC requirements.................................................................................................................................................................................. b-26
Auto gas console........................................................................................................................................................................... b-26
Serial interface guidelines...................................................................................................................................................................... b-27
Checksum....................................................................................................................................................................................... b-27
Message retries............................................................................................................................................................................. b-27
Cable shielding.............................................................................................................................................................................. b-27
Appendix C
robotic applications.................................................................................................................................................... c-1
Components for robotic applications.....................................................................................................................................................c-2
Torch leads........................................................................................................................................................................................c-2
Ohmic contact extension................................................................................................................................................................c-2
Rotational mounting sleeve (optional) – 220864...................................................................................................................c-3
Leather overwrap – 024866........................................................................................................................................................c-3
Robotic teaching torch (laser pointer) – 228394..................................................................................................................c-3
Torch and rotational mounting sleeve dimensions...................................................................................................................c-3
HPR400XD auto gas instruction manual revision changes (806160).................................................... 1
viii HPR400XD Auto Gas – 806160 Revision 3

Section 1
SAFETY
In this section
Recognize safety information...................................................................................................................................................................1-2
Follow safety instructions..........................................................................................................................................................................1-2
Electrical hazards........................................................................................................................................................................................1-2
Electric shock can kill.................................................................................................................................................................................1-3
Cutting can cause fire or explosion........................................................................................................................................................1-4
Toxic fumes can cause injury or death...................................................................................................................................................1-5
Static electricity can damage circuit boards........................................................................................................................................1-6
Compressed gas equipment safety........................................................................................................................................................1-6
Grounding safety........................................................................................................................................................................................1-6
Gas cylinders can explode if damaged..................................................................................................................................................1-6
A plasma arc can cause injury and burns..............................................................................................................................................1-7
Arc rays can burn eyes and skin..............................................................................................................................................................1-7
Noise can damage hearing.......................................................................................................................................................................1-8
Pacemaker and hearing aid operation...................................................................................................................................................1-8
A plasma arc can damage frozen pipes................................................................................................................................................1-8
Dry dust collection information................................................................................................................................................................1-9
Laser radiation.......................................................................................................................................................................................... 1-10
Symbols and marks................................................................................................................................................................................. 1-11
Additional safety information................................................................................................................................................................. 1-11
Warning labels.......................................................................................................................................................................................... 1-12
Hypertherm 1-1
03/10
Safety
Recognize safety danger warning caution

information Hypertherm uses American National Standards Institute
guidelines for safety signal words and symbols. A signal
The symbols shown in this section are used to identify word DANGER or WARNING is used with a safety
potential hazards. When you see a safety symbol in this symbol. DANGER identifies the most serious hazards.
manual or on your machine, understand the potential
for personal injury, and follow the related instructions • DANGER and WARNING safety labels are located
to avoid the hazard. on your machine near specific hazards.
• DANGER safety messages precede related

Follow safety instructions in the manual that will result in serious
instructions injury or death if not followed correctly.
Read carefully all safety messages in this manual and • WARNING safety messages precede related
safety labels on your machine. instructions in this manual that may result in injury
• Keep the safety labels on your machine in good or death if not followed correctly.
condition. Replace missing or damaged labels
immediately. • CAUTION safety messages precede related
instructions in this manual that may result in
• Learn how to operate the machine and how to use
minor injury or damage to equipment if not
the controls properly. Do not let anyone operate it
followed correctly.
without instruction.
• Keep your machine in proper working condition.
Unauthorized modifications to the machine may affect
safety and machine service life.
Electrical hazards
• Only trained and authorized personnel may open this • The enclosure shall be closed and the proper earth
equipment. ground continuity to the enclosure verified prior to
operating the equipment after moving, opening, or
• If the equipment is permanently connected, turn it off,
servicing.
and lock out/tag out power before the enclosure is
opened. • Always follow these instructions for disconnecting
power before inspecting or changing torch
• If power is supplied to the equipment with a cord,
consumable parts.
unplug the unit before the enclosure is opened.
• Lockable disconnects or lockable plug covers must
be provided by others.
• Wait 5 minutes after removal of power before
entering the enclosure to allow stored energy to
discharge.
• If the equipment must have power when the
enclosure is open for servicing, arc flash explosion
hazards may exist. Follow ALL local requirements
(NFPA 70E in the USA) for safe work practices and
for Personal Protective Equipment when servicing
energized equipment.
1-2 Hypertherm
03/10
Safety
Electric shock can kill
Touching live electrical parts can cause a fatal shock or • Install and ground this equipment according to the
severe burn. instruction manual and in accordance with national
• Operating the plasma system completes an electrical and local codes.
circuit between the torch and the workpiece. The • Inspect the input power cord frequently for damage
workpiece and anything touching the workpiece are or cracking of the cover. Replace a damaged power
part of the electrical circuit. cord immediately. Bare wiring can kill.
• Never touch the torch body, workpiece or the water in • Inspect and replace any worn or damaged torch
a water table when the plasma system is operating. leads.
• Do not pick up the workpiece, including the waste
Electric shock prevention
cutoff, while you cut. Leave the workpiece in place
All Hypertherm plasma systems use high voltage or on the workbench with the work cable attached
in the cutting process (200 to 400 VDC are during the cutting process.
common). Take the following precautions when • Before checking, cleaning or changing torch parts,
operating this system: disconnect the main power or unplug the power
• Wear insulated gloves and boots, and keep your body supply.
and clothing dry. • Never bypass or shortcut the safety interlocks.
• Do not stand, sit or lie on – or touch – any wet • Before removing any power supply or system
surface when using the plasma system. enclosure cover, disconnect electrical input power.
• Insulate yourself from work and ground using dry Wait 5 minutes after disconnecting the main power
insulating mats or covers big enough to prevent any to allow capacitors to discharge.
physical contact with the work or ground. If you must • Never operate the plasma system unless the power
work in or near a damp area, use extreme caution. supply covers are in place. Exposed power supply
• Provide a disconnect switch close to the power connections present a severe electrical hazard.
supply with properly sized fuses. This switch allows • When making input connections, attach proper
the operator to turn off the power supply quickly in grounding conductor first.
an emergency situation.
• Each Hypertherm plasma system is designed to be
• When using a water table, be sure that it is correctly used only with specific Hypertherm torches. Do not
connected to earth ground. substitute other torches which could overheat and
present a safety hazard.
Hypertherm 1-3
03/10
Safety
Cutting can cause fire or explosion
Fire prevention WARNING

• Be sure the area is safe before doing any cutting. Explosion Hazard
Keep a fire extinguisher nearby. Argon-Hydrogen and Methane
• Remove all flammables within 35 feet (10 m) of the
Hydrogen and methane are flammable gases that
cutting area.
present an explosion hazard. Keep flames away from
• Quench hot metal or allow it to cool before handling cylinders and hoses that contain methane or hydrogen
or before letting it touch combustible materials. mixtures. Keep flames and sparks away from the torch
• Never cut containers with potentially flammable when using methane or argon-hydrogen plasma.
materials inside – they must be emptied and
properly cleaned first.
WARNING
• Ventilate potentially flammable atmospheres
Explosion Hazard
before cutting.
Underwater Cutting with Fuel Gases
• When cutting with oxygen as the plasma gas, an
exhaust ventilation system is required. • Do not cut aluminum underwater or with water
touching the underside of the aluminum.
Explosion prevention • Cutting aluminum underwater or with the water
• Do not use the plasma system if explosive dust or touching the underside of the aluminum can result
vapors may be present. in an explosive condition that can detonate during
• Do not cut pressurized cylinders, pipes, or any plasma cutting operations.
closed container.
• Do not cut containers that have held combustible WARNING
materials. Hydrogen Detonation with
Aluminum Cutting
• Do not cut under water with fuel gases containing
hydrogen.
• Cutting under water with fuel gases containing
hydrogen can result in an explosive condition that
can detonate during plasma cutting operations.
1-4 Hypertherm
03/10
Safety
Toxic fumes can cause injury or death
The plasma arc by itself is the heat source used for • Duration of cutting or gouging.
cutting. Accordingly, although the plasma arc has not • Size, air volume, ventilation and filtration of the
been identified as a source of toxic fumes, the material work area.
being cut can be a source of toxic fumes or gases that
deplete oxygen. • Personal protective equipment.
• Number of welding and cutting systems in operation.
Fumes produced vary depending on the metal that is • Other site processes that may produce fumes.
cut. Metals that may release toxic fumes include, but
are not limited to, stainless steel, carbon steel, zinc If the workplace must conform to national or local
(galvanized), and copper. regulations, only monitoring or testing done at the
site can determine whether the site is above or below
In some cases, the metal may be coated with a allowable levels.
substance that could release toxic fumes. Toxic
coatings include, but are not limited to, lead (in some To reduce the risk of exposure to fumes:
paints), cadmium (in some paints and fillers), and • Remove all coatings and solvents from the metal
beryllium. before cutting.
• Use local exhaust ventilation to remove fumes from
Gases produced by plasma cutting vary based on the
the air.
material to be cut and the method of cutting, but may
include ozone, oxides of nitrogen, hexavalent chromium, • Do not inhale fumes. Wear an air-supplied respirator
hydrogen, and other substances if such are contained when cutting any metal coated with, containing, or
in or released by the material being cut. suspected to contain toxic elements.
• Assure that those using welding or cutting equipment,
Caution should be taken to minimize exposure to fumes as well as air-supplied respiration devices, are
produced by any industrial process. Depending upon qualified and trained in the proper use of such
the chemical composition and concentration of the equipment.
fumes (as well as other factors, such as ventilation),
• Never cut containers with potentially toxic materials
there may be a risk of physical illness, such as birth
inside. Empty and properly clean the container first.
defects or cancer.
• Monitor or test the air quality at the site as needed.
It is the responsibility of the equipment and site owner • Consult with a local expert to implement a site plan
to test the air quality in the area where the equipment is to ensure safe air quality.
used and to ensure that the air quality in the workplace
meets all local and national standards and regulations.
The air quality level in any relevant workplace depends

on site-specific variables such as:
• Table design (wet, dry, underwater).
• Material composition, surface finish, and composition
of coatings.
• Volume of material removed.
Hypertherm 1-5
03/10
Safety
Grounding safety
Work cable Attach the work cable securely to the Input power
workpiece or the work table with good metal-to-metal • Be sure to connect the power cord ground wire to
contact. Do not connect it to the piece that will fall the ground in the disconnect box.
away when the cut is complete.
• If installation of the plasma system involves
Work table Connect the work table to an earth connecting the power cord to the power supply, be
ground, in accordance with appropriate national and sure to connect the power cord ground wire properly.
local electrical codes. • Place the power cord’s ground wire on the stud
first, then place any other ground wires on top of the
power cord ground. Fasten the retaining nut tightly.
• Tighten all electrical connections to avoid excessive
heating.
Static electricity can damage circuit boards

Use proper precautions when handling printed circuit boards:
• Store PC boards in anti-static containers.
• Wear a grounded wrist strap when handling PC boards.
Compressed gas equipment

safety Gas cylinders can
explode if damaged
• Never lubricate cylinder valves or regulators with oil
or grease. Gas cylinders contain gas under high pressure.
If damaged, a cylinder can explode.
• Use only correct gas cylinders, regulators, hoses and
fittings designed for the specific application. • Handle and use compressed gas cylinders in
accordance with applicable national and local codes.
• Maintain all compressed gas equipment and
associated parts in good condition. • Never use a cylinder that is not upright and secured
in place.
• Label and color-code all gas hoses to identify the
type of gas in each hose. Consult applicable national • Keep the protective cap in place over valve except
and local codes. when the cylinder is in use or connected for use.
• Never allow electrical contact between the plasma
arc and a cylinder.
• Never expose cylinders to excessive heat, sparks,
slag or open flame.
• Never use a hammer, wrench or other tool to open a
stuck cylinder valve.
1-6 Hypertherm
03/10
Safety
A plasma arc can cause injury and burns
Instant-on torches The plasma arc will cut quickly through gloves and skin.
Plasma arc comes on immediately when the torch • Keep away from the torch tip.
switch is activated.
• Do not hold metal near the cutting path.
• Never point the torch toward yourself or others.
Arc rays can burn eyes and skin
Eye protection Plasma arc rays produce intense • Cuffless trousers to prevent entry of sparks and slag.
visible and invisible (ultraviolet and infrared) rays that • Remove any combustibles, such as a butane lighter
can burn eyes and skin. or matches, from your pockets before cutting.
• Use eye protection in accordance with applicable
national and local codes. Cutting area Prepare the cutting area to reduce
• Wear eye protection (safety glasses or goggles with reflection and transmission of ultraviolet light:
side shields, and a welding helmet) with appropriate • Paint walls and other surfaces with dark colors to
lens shading to protect your eyes from the arc’s reduce reflection.
ultraviolet and infrared rays. • Use protective screens or barriers to protect others
from flash and glare.
Skin protection Wear protective clothing to protect
• Warn others not to watch the arc. Use placards
against burns caused by ultraviolet light, sparks, and
or signs.
hot metal.
• Gauntlet gloves, safety shoes and hat.
• Flame-retardant clothing to cover all exposed areas.
Minimum protective Suggested shade

Arc current OSHA 29CFR Europe
shade number number for comfort
(amps) 1910.133(a)(5) EN168:2002
(ANSI Z49.1:2005) (ANSI Z49.1:2005)
Less than 40 A 5 5 8 9
41 to 60 A 6 6 8 9
61 to 80 A 8 8 8 9
81 to 125 A 8 9 8 9
126 to 150 A 8 9 8 10
151 to 175 A 8 9 8 11
176 to 250 A 8 9 8 12
251 to 300 A 8 9 8 13
301 to 400 A 9 12 9 13
401 to 800 A 10 14 10 N/A
Hypertherm 1-7
03/10
Safety
Pacemaker and hearing aid operation
Pacemaker and hearing aid operation can be affected To reduce magnetic field hazards:
by magnetic fields from high currents.
• Keep both the work cable and the torch lead to one
Pacemaker and hearing aid wearers should consult a side, away from your body.
doctor before going near any plasma arc cutting and
• Route the torch leads as close as possible to the
gouging operations.
work cable.
• Do not wrap or drape the torch lead or work cable
around your body.
• Keep as far away from the power supply as possible.
Noise can damage hearing
Cutting with a plasma arc can exceed acceptable noise Use ear protectors if the noise is disruptive or if there
levels as defined by local codes in many applications. is a risk of hearing damage after all other engineering
Prolonged exposure to excessive noise can damage and administrative controls have been implemented.
hearing. Always wear proper ear protection when If hearing protection is required, wear only approved
cutting or gouging, unless sound pressure level personal protective devices such as ear muffs or ear
measurements taken at the installed site have verified plugs with a noise reduction rating appropriate for the
personal hearing protection is not necessary per situation. Warn others in the area of possible noise
relevant international, regional, and local codes. hazards. In addition, ear protection can prevent hot
splatter from entering the ear.
Significant noise reduction can be obtained by adding
simple engineering controls to cutting tables such as
barriers or curtains positioned between the plasma arc
and the workstation; and/or locating the workstation
away from the plasma arc. Implement administrative
controls in the workplace to restrict access, limit
operator exposure time, screen off noisy working
areas and/or take measures to reduce reverberation
in working areas by putting up noise absorbers.
A plasma arc can damage frozen pipes
Frozen pipes may be damaged or can burst if you attempt to thaw them with a plasma torch.
1-8 Hypertherm
03/10
Safety
Dry dust collection information

At some sites, dry dust can represent a potential Note 1 – Hypertherm’s interpretation of these new
explosion hazard. requirements is that unless a site-specific evaluation
has been completed to determine that all dust
The U.S. National Fire Protection Association’s 2007
generated is not combustible, the 2007 edition of
edition of NFPA standard 68, “Explosion Protection by
NFPA 68 requires the use of explosion vents designed
Deflagration Venting,” provides requirements for the
to the worst-case Kst value (see annex F) that could be
design, location, installation, maintenance, and use of
generated from dust so that the explosion vent size and
devices and systems to vent combustion gases and
type can be designed. NFPA 68 does not specifically
pressures after any deflagration event. Consult with
identify plasma cutting or other thermal cutting
the manufacturer or installer of any dry dust collection
processes as requiring deflagration venting systems,
system for applicable requirements before you install
but it does apply these new requirements to all dry dust
a new dry dust collection system or make significant
collection systems.
changes in the process or materials used with an
existing dry dust collection system. Note 2 – Users of Hypertherm manuals should consult
and comply with all applicable federal, state, and local
Consult your local “Authority Having Jurisdiction” (AHJ)
laws and regulations. Hypertherm does not, by the
to determine whether any edition of NFPA 68 has been
publication of any Hypertherm manual, intend to urge
“adopted by reference” in your local building codes.
action that is not in compliance with all applicable
Refer to NFPA68 for definitions and explanations of regulations and standards, and this manual may never
regulatory terms such as deflagration, AHJ, adopted by be construed as doing so.
reference, the Kst value, deflagration index, and other
terms.
Hypertherm 1-9
03/10
Safety
Laser radiation
Exposure to the laser output can result in serious eye injury. Avoid direct eye exposure.
For your convenience and safety, on Hypertherm products that use a laser, one of the following laser radiation
labels has been applied on the product near where the laser beam exits the enclosure. The maximum output (mV),
wavelength emitted (nM) and, if appropriate, the pulse duration is also provided.
Additional laser safety instructions:

• Consult with an expert on local laser regulations. • Modifying the laser or product in any way can
Laser safety training may be required. increase the risk of laser radiation.
• Do not allow untrained persons to operate the laser. • Use of adjustments or performance of procedures
Lasers can be dangerous in the hands of untrained other than those specified in this manual may result in
users. hazardous laser radiation exposure.
• Do not look into the laser aperture or beam at any • Do not operate in explosive atmospheres, such as in
time. the presence of flammable liquids, gases, or dust.
• Position the laser as instructed to avoid unintentional • Use only laser parts and accessories that are
eye contact. recommended or provided by the manufacturer for
• Do not use the laser on reflective workpieces. your model.
• Do not use optical tools to view or reflect the laser • Repairs and servicing MUST be performed by
beam. qualified personnel.
• Do not disassemble or remove the laser or aperture • Do not remove or deface the laser safety label.
cover.
1-10 Hypertherm
03/10
Safety
Symbols and marks

Your Hypertherm product may have one or more of the following markings on or near the data plate. Due to differences
and conflicts in national regulations, not all marks are applied to every version of a product.
S mark symbol
The S mark symbol indicates that the power supply and torch are suitable for operations carried out in
environments with increased hazard of electrical shock per IEC 60974-1.
CSA mark
Hypertherm products with a CSA mark meet the United States and Canadian regulations for product safety.
The products were evaluated, tested, and certified by CSA-International. Alternatively the product may have
a mark by one of the other Nationally Recognized Testing Laboratories (NRTL) accredited in both the United
States and Canada, such as Underwriters Laboratories, Incorporated (UL) or TÜV.
CE marking
he CE marking signifies the manufacturer’s declaration of conformity to applicable European directives
T
and standards. Only those versions of Hypertherm products with a CE marking located on or near the
data plate have been tested for compliance with the European Low Voltage Directive and the European
Electromagnetic Compatibility (EMC) Directive. EMC filters needed to comply with the European EMC
Directive are incorporated within versions of the product with a CE marking.
GOST-R mark
CE versions of Hypertherm products that include a GOST-R mark of conformity meet the product safety
and EMC requirements for export to the Russian Federation.
c-Tick mark
E versions of Hypertherm products with a c-Tick mark comply with the EMC regulations required for sale
C
in Australia and New Zealand.
CCC mark
The China Compulsory Certification (CCC) mark indicates that the product has been tested and found
compliant with product safety regulations required for sale in China.
Additional safety information

1. ANSI Standard Z49.1, Safety in Welding and Cutting, American 6. CGA Pamphlet P-1, Safe Handling of Compressed Gases in Cylinders,
Welding Society, 550 LeJeune Road Compressed Gas Association
P.O. Box 351020, Miami, FL 33135 1235 Jefferson Davis Highway, Arlington, VA 22202
2. ANSI Standard Z49.2, Fire Prevention in the Use of Cutting and 7. CSA Standard W117.2, Code for Safety in Welding and Cutting,
Welding Processes, American National Standards Institute Canadian Standards Association Standard Sales
1430 Broadway, New York, NY 10018 178 Rexdale Boulevard, Rexdale, Ontario M9W 1R3, Canada
3. ANSI Standard Z87.1, Safe Practices for Occupation and 8. NFPA Standard 51B, Cutting and Welding Processes, National Fire
Educational Eye and Face Protection, American National Standards Protection Association
Institute, 1430 Broadway, New York, NY 10018 470 Atlantic Avenue, Boston, MA 02210
4. AWS F4.1, Recommended Safe Practices for the Preparation for 9. NFPA Standard 70–1978, National Electrical Code, National Fire
Welding and Cutting of Containers and Piping That Have Held 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
5. AWS F5.2, Recommended Safe Practices for Plasma Arc 11. AWS Safety and Health Fact Sheets, American Welding Society 550
Cutting, American Welding Society LeJeune Road, P.O. Box 351040, Miami, FL 33135
550 LeJeune Road, P.O. Box 351040, Miami, FL 33135 www.aws.org/technical/facts/
Hypertherm 1-11
03/10
Safety
Warning labels
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.
Read and follow these instructions, employer safety

practices, and material safety data sheets. Refer to WARNING AVERTISSEMENT
ANS Z49.1, “Safety in Welding, Cutting and Allied
Processes” from American Welding Society Plasma cutting can be injurious to operator and persons Le coupage plasma peut être préjudiciable pour l’opérateur et les personnes qui se
(http://www.aws.org) and OSHA Safety and Health in the work area. Consult manual before operating. Failure trouvent sur les lieux de travail. Consulter le manuel avant de faire fonctionner. Le
Standards, 29 CFR 1910 (http://www.osha.gov). to follow all these safety instructions can result in death. non respect des ces instructions de sécurité peut entraîner la mort.
1. Cutting sparks can cause explosion or fire. 1. Les étincelles de coupage peuvent provoquer une explosion
1.1 Do not cut near flammables. ou un incendie.
1.2 Have a fire extinguisher nearby and ready to use. 1.1 Ne pas couper près des matières inflammables.
1.3 Do not use a drum or other closed container as a cutting table. 1.2 Un extincteur doit être à proximité et prêt à être utilisé.
1.3 Ne pas utiliser un fût ou un autre contenant fermé comme table de coupage.
2. Plasma arc can injure and burn; point the nozzle away 2. L’arc plasma peut blesser et brûler; éloigner la buse de soi.
from yourself. Arc starts instantly when triggered. Il s’allume instantanément quand on l’amorce;
2.1 Turn off power before disassembling torch. 2.1 Couper l’alimentation avant de démonter la torche.
2.2 Do not grip the workpiece near the cutting path. 2.2 Ne pas saisir la pièce à couper de la trajectoire de coupage.
2.3 Wear complete body protection. 2.3 Se protéger entièrement le corps.
3. Hazardous voltage. Risk of electric shock or burn. 3. Tension dangereuse. Risque de choc électrique ou de brûlure.
3.1 Wear insulating gloves. Replace gloves when wet or damaged. 3.1 Porter des gants isolants. Remplacer les gants quand ils sont humides ou
3.2 Protect from shock by insulating yourself from work and ground. endommagés.
3.3 Disconnect power before servicing. Do not touch live parts. 3.2 Se protéger contre les chocs en s’isolant de la pièce et de la terre.
3.3 Couper l’alimentation avant l’entretien. Ne pas toucher les pièces sous tension.
4. Plasma fumes can be hazardous. 4. Les fumées plasma peuvent être dangereuses.
4.1 Do not inhale fumes. 4.1 Ne pas inhaler les fumées
4.2 Use forced ventilation or local exhaust to remove the fumes. 4.2 Utiliser une ventilation forcée ou un extracteur local pour dissiper les fumées.
4.3 Do not operate in closed spaces. Remove fumes with ventilation. 4.3 Ne pas couper dans des espaces clos. Chasser les fumées par ventilation.
5. Arc rays can burn eyes and injure skin. 5. Les rayons d’arc peuvent brûler les yeux et blesser la peau.
5.1 Wear correct and appropriate protective equipment to protect 5.1 Porter un bon équipement de protection pour se protéger la tête, les yeux, les
head, eyes, ears, hands, and body. Button shirt collar. Protect ears oreilles, les mains et le corps. Boutonner le col de la chemise. Protéger les oreilles
from noise. Use welding helmet with the correct shade of filter. contre le bruit. Utiliser un masque de soudeur avec un filtre de nuance appropriée.
6. Become trained. Only qualified personnel should operate this 6. Suivre une formation. Seul le personnel qualifié a le droit de faire
equipment. Use torches specified in the manual. Keep non-qualified fonctionner cet équipement. Utiliser exclusivement les torches indiquées dans le
personnel and children away. manual. Le personnel non qualifié et les enfants doivent se tenir à l’écart.
7. Do not remove, destroy, or cover this label. 7. Ne pas enlever, détruire ni couvrir cette étiquette.
Replace if it is missing, damaged, or worn (PN 110584 Rev C). La remplacer si elle est absente, endommagée ou usée (PN 110584 Rev C).
1-12 Hypertherm
03/10
Safety
Warning Labels 1. Cutting sparks can cause explosion

or fire.
This warning label is affixed to some power supplies. It is important
that the operator and maintenance technician understand the intent of 1.1 Do not cut near flammables.
these warning symbols as described. The numbered text corresponds 1.2 Have a fire extinguisher nearby and
to the numbered boxes on the label. ready to use.
1.3 Do not use a drum or other closed
container as a cutting table.
2. Plasma arc can injure and burn; point
the nozzle away from yourself. Arc starts
instantly when triggered.
2.1 Turn off power before disassembling
torch.
2.2 Do not grip the workpiece near the
cutting path.
2.3 Wear complete body protection.
3. Hazardous voltage. Risk of electric
shock or burn.
3.1 Wear insulating gloves. Replace gloves
when wet or damaged.
3.2 Protect from shock by insulating yourself
from work and ground.
3.3 Disconnect power before servicing.
Do not touch live parts.
4. Plasma fumes can be hazardous.
4.1 Do not inhale fumes.
4.2 Use forced ventilation or local exhaust to
remove the fumes.
4.3 Do not operate in closed spaces.
Remove fumes with ventilation.
5. Arc rays can burn eyes and injure skin.
5.1 Wear correct and appropriate protective
equipment to protect head, eyes, ears,
hands, and body. Button shirt collar.
Protect ears from noise. Use welding
helmet with the correct shade of filter.
6. Become trained. Only qualified
personnel should operate this
equipment. Use torches specified in the
manual. Keep non-qualified personnel
and children away.
7. Do not remove, destroy, or cover this
label. Replace if it is missing, damaged,
or worn.
Hypertherm 1-13
03/10
Safety
1-14 Hypertherm
03/10
Section 1a
SÉCURITÉ
Sommaire de cette section:

Identifier les consignes de sécurité..................................................................................................................................................... 1a-2
Suivre les instructions de sécurité........................................................................................................................................................ 1a-2
Risques électriques................................................................................................................................................................................. 1a-2
Les chocs électriques peuvent être fatals.......................................................................................................................................... 1a-3
Le coupage peut provoquer un incendie ou une explosion........................................................................................................... 1a-4
Les vapeurs toxiques peuvent provoquer des blessures ou la mort............................................................................................ 1a-5
Sécurité des bouteilles de gaz comprimé.......................................................................................................................................... 1a-6
Mise à la masse et à la terre.................................................................................................................................................................. 1a-6
L’électricité statique peut endommager les cartes de circuits imprimés.................................................................................... 1a-6
Les bouteilles de gaz comprimé peuvent exploser en cas de dommages................................................................................. 1a-6
L’arc plasma peut provoquer des blessures ou des brûlures.........................................................................................................1a-7
Les rayons de l’arc peuvent brûler les yeux et la peau.....................................................................................................................1a-7
Le bruit peut provoquer des problèmes auditifs............................................................................................................................... 1a-8
Un arc plasma peut endommager les tuyaux gelés......................................................................................................................... 1a-8
Pacemakers et prothèses auditives..................................................................................................................................................... 1a-8
Information sur le dépoussièrage......................................................................................................................................................... 1a-9
Radiation au laser.................................................................................................................................................................................. 1a-10
Symboles et marquage.........................................................................................................................................................................1a-11
Étiquettes de sécurtité..........................................................................................................................................................................1a-12
Hypertherm 1a-1
03/10
Sécurité
Identifier les DANGER AVERTISSEMENT ATTENTION

consignes de sécurité Hypertherm adopte les lignes directrices de l’American
National Standards Institute relativement aux termes
Les symboles indiqués dans cette section sont utilisés
et aux symboles de la signalisation de sécurité. Les
pour identifier les risques éventuels. Si vous trouvez un
signaux DANGER ou AVERTISSEMENT sont utilisés
symbole de sécurité, que ce soit dans ce manuel ou sur
avec un symbole de sécurité. DANGER correspond aux
l’équipement, soyez conscient des risques de blessures
risques les plus sérieux.
et suivez les instructions correspondantes afin d’éviter
ces risques. • Les étiquettes de sécurité DANGER et
AVERTISSEMENT sont placées sur l’équipement
pour situer certains dangers spécifiques.
Suivre les instructions
de sécurité • Les messages de sécurité DANGER précèdent
les directives correspondantes dans le manuel
le présent manuel et sur les étiquettes de sécurité se qui, si elles ne sont pas suivies scrupuleusement,
trouvant sur l’équipement. entraînent des blessures graves, voire mortelles.
• Les étiquettes de sécurité sur l’équipement doivent • Les messages d’AVERTISSEMENT précèdent les
rester lisibles. Remplacer immédiatement les instructions d’utilisation présentées dans ce manuel
étiquettes manquantes ou abîmées. qui, si elles ne sont pas suivies scrupuleusement,
• Il est important d’apprendre à faire fonctionner peuvent entraîner des blessures graves, voire
l’équipement et à utiliser correctement les mortelles.
commandes. Ne laisser personne utiliser l’équipement
• Les messages de sécurité ATTENTION précèdent
sans connaître son fonctionnement.
les directives associées dans le manuel qui, si elles
• Garder l’équipement en bon état. Des modifications ne sont pas suivies scrupuleusement, peuvent
non autorisées sur l’équipement peuvent entraîner entraîner des blessures mineures ou endommager
des problèmes de sécurité et raccourcir la durée de l’équipement.
vie utile de l’équipement.
Risques électriques
• Seul le personnel formé et autorisé peut ouvrir cet • Vérifier que le boîtier est bien fermé et que la mise
équipement. à la terre est bien effectuée avant de faire fonctionner
l’équipement après l’avoir déplacé, ouvert ou après
• Si l’équipement est branché en permanence, mettez-le
avoir effectué un entretien.
hors tension, puis coupez l’alimentation avant d’ouvrir
le boîtier. • Toujours suivre ces instructions concernant le
débranchement de la source de courant avant
• Si l’équipement est mis sous tension à l’aide d’un
d’inspecter ou de remplacer des consommables
cordon, débranchez-le avant d’ouvrir le boîtier.
de la torche.
• Dans un cas autre, des raccords ou des capots
d’obturateurs verrouillables doivent être fournis.
• Attendre ensuite 5 minutes après la coupure de
l’alimentation électrique avant l’ouverture du capot
pour que l’énergie stockée se décharge.
• Si l’équipement doit être sous tension lorsque le capot
est ouvert pour l’entretien, le coup d’arc peut se produire.
Respecter TOUTES les exigences locales (NFPA
70E aux États-Unis) relatives aux pratiques de travail
sécuritaires et à l’équipement de protection individuelle
lors de l’entretien de l’équipement électrique.
1a-2 Hypertherm
03/10
Sécurité
Les chocs électriques peuvent être fatals
Le contact avec les pièces électriques sous tension • Installer et mettre à la terre l’équipement selon les
peut entraîner une électrocution ou de brûlures graves, instructions du présent manuel et conformément
voire la mort. aux codes locaux et nationaux.
• L’utilisation d’un système plasma complète un circuit • Inspecter fréquemment le cordon de puissance
électrique entre la torche et la pièce à couper. d’entrée pour vérifier qu’il n’est pas endommagé
La pièce ainsi que tout autre élément la touchant ni fendu. Remplacer immédiatement un cordon
font partie du circuit électrique. d’alimentation endommagé. Un câble dénudé
• Ne jamais toucher le corps de la torche, la pièce peut causer la mort.
à couper ou l’eau de la table à eau lorsque • Inspecter et remplacer les câbles de la torche qui
le système plasma fonctionne. sont usés ou endommagés.
• Ne pas saisir la pièce à couper, ni les débris lors
Prévention des chocs électriques du coupage. Laisser la pièce à couper en place ou sur
Tous les systèmes plasma Hypertherm la table de travail et le câble de retour connecté lors
fonctionnent à haute tension pour le coupage du coupage.
(souvent de 200 à 400 V c.c.). Prendre les • Avant de vérifier, de nettoyer ou de remplacer
précautions suivantes lors de l’utilisation les pièces de la torche, couper l’alimentation
du système : ou débrancher la source de courant.
• Porter des bottes et des gants isolants et garder • Ne jamais contourner ou court-circuiter les verrous
le corps et les vêtements au sec. de sécurité.
• Ne pas se tenir, s’asseoir ou se coucher sur une • Avant d’enlever le capot du système ou de la source
surface mouillée, ni la toucher pendant l’utilisation de courant, couper la puissance d’entrée
du système plasma. électrique. Attendre ensuite 5 minutes pour que
• S’isoler de la surface de travail et du sol en utilisant les condensateurs se déchargent.
des tapis isolants ou des couvertures assez grandes • Ne jamais faire fonctionner le système plasma sans
pour éviter tout contact physique avec le matériel que les capots de la source de courant ne soient
de travail ou le sol. S’il s’avère nécessaire de travailler en place. Les raccords exposés de la source
dans ou près d’un endroit humide, procéder avec de courant sont extrêmement dangereux.
extrême prudence. • Lors de l’installation des connexions, attacher tout
• Installer un sectionneur avec fusibles appropriés, d’abord la prise de terre appropriée.
à proximité de la source de courant. Ce sectionneur • Chaque système plasma Hypertherm est conçu pour
permet à l’opérateur d’éteindre rapidement la source être utilisé uniquement avec des torches Hypertherm
de courant en cas d’urgence. spécifiques. Ne pas utiliser des torches inappropriées
• En cas d’utilisation d’une table à eau, s’assurer qui pourraient surchauffer et présenter des risques
que cette dernière est correctement mise à la terre. pour la sécurité.
Hypertherm 1a-3
03/10
Sécurité
Le coupage peut provoquer un incendie

ou une explosion
Prévention des incendies AVERTISSEMENT

• Avant de commencer, vérifier que la zone Risque d’explosion
de coupage ne présente aucun danger. Conserver Argon-hydrogène et méthane
un extincteur à proximité.
L’hydrogène et le méthane sont des gaz inflammables
• Éloigner toute matière inflammable à une distance
et potentiellement explosifs. Conserver à l’écart
d’au moins 10 m du poste de coupage.
de toute flamme les bouteilles et tuyaux contenant
• Tremper le métal chaud ou le laisser refroidir avant des mélanges à base d’hydrogène ou de méthane.
de le manipuler ou avant de le mettre en contact Maintenir toute flamme et étincelle à l’écart de la torche
avec des matériaux combustibles. lors de l’utilisation d’un plasma d’argon-hydrogène
• Ne jamais couper des récipients pouvant contenir ou de méthane.
des matières inflammables avant de les avoir vidés
et nettoyés correctement. AVERTISSEMENT
• Aérer toute atmosphère potentiellement inflammable Risque d’explosion
avant de commencer le coupage. Sous l’eau lors du coupage
• Lors de l’utilisation d’oxygène comme gaz plasma, avec gaz combustibles
un système de ventilation par extraction est • Ne pas couper l’aluminium sous l’eau ou lorsque
nécessaire. celle-ci touche la partie inférieure de la pièce
d’aluminium.
Prévention des explosions
• Le coupage de l’aluminium sous l’eau, ou l’eau qui
• Ne pas utiliser le système plasma en présence touche la partie inférieure de la pièce d’aluminium
possible de poussière ou de vapeurs. peut rassembler les conditions propices à une
• Ne pas couper de bouteilles, de tuyaux ou autres explosion causant une détonation lors du coupage
récipients fermés et pressurisés. plasma.
• Ne pas couper de récipients qui ont servi à contenir
des matières combustibles.
AVERTISSEMENT
Détonation de l’hydrogène
lors du coupage de l’aluminium
• Ne pas couper la pièce sous l’eau avec des gaz
combustibles contenant de l’hydrogène.
• Cela peut entraîner une explosion suivie d’une
détonation lors du coupage plasma.
1a-4 Hypertherm
03/10
Sécurité
Les vapeurs toxiques peuvent provoquer

des blessures ou la mort
L’arc plasma constitue la source de chaleur utilisée • Dimensions, volume d’air, ventilation et filtration
pour le coupage. Par conséquent, bien que l’arc plasma de la zone de travail.
n’ait pas été reconnu comme une source de vapeurs • Équipement de protection individuelle.
toxiques, le matériau coupé peut être une source de
vapeurs ou de gaz toxiques qui épuisent l’oxygène. • Nombre de systèmes de soudage et de coupage
en fonctionnement.
Les vapeurs produites varient selon le métal coupé. • Autres procédés du site qui peuvent produire
Les métaux qui peuvent dégager des vapeurs toxiques des vapeurs.
comprennent, entre autres, l’acier inoxydable, l’acier
au carbone, le zinc (galvanisé) et le cuivre. Si les lieux de travail doivent être conformes aux
réglementations nationales ou locales, seuls les
Dans certains cas, le métal peut être revêtu d’une contrôles ou les essais effectués au site peuvent
substance susceptible de dégager des vapeurs déterminer si celui-ci se situe au-dessus ou
toxiques. Les revêtements toxiques comprennent entre au-dessous des niveaux admissibles.
autres, le plomb (dans certaines peintures), le cadmium
Pour réduire le risque d’exposition aux vapeurs :
(dans certaines peintures et enduits) et le béryllium.
• Éliminer tout revêtement et solvant du métal avant
Les gaz produits par le coupage plasma varient selon le coupage.
le matériau à couper et la méthode de coupage, mais • Utiliser la ventilation par extraction locale pour éliminer
ils peuvent comprendre l’ozone, les oxydes d’azote, les vapeurs de l’air.
le chrome hexavalent, l’hydrogène et autres substances
• Ne pas inhaler les vapeurs. Porter un respirateur
présentes dans le matériau coupé ou en émanent.
à adduction d’air lors du coupage des métaux revêtus
d’éléments toxiques ou qui en contiennent ou sont
Certaines précautions s’imposent pour réduire au
susceptibles d’en contenir.
minimum l’exposition aux vapeurs produites par tout
processus industriel. Selon la composition chimique et la • S’assurer que les personnes qui utilisent un
concentration des vapeurs (ainsi que d’autres facteurs équipement de soudage ou de coupage ainsi que
comme la ventilation), celles-ci risquent de causer une les dispositifs de respiration par adduction d’air sont
maladie physique, comme des déficiences de naissance qualifiées et formées pour utiliser adéquatement cet
ou le cancer. équipement.
• Ne jamais couper les contenants dans lesquels il peut
Il incombe au propriétaire du matériel et du site y avoir des matériaux toxiques. En premier lieu, vider
de vérifier la qualité de l’air dans le secteur où le matériel et nettoyer correctement le contenant.
est utilisé et de s’assurer que la qualité de l’air sur les
• Contrôler ou éprouver la qualité de l’air du site au
lieux de travail répond aux normes et réglementations
besoin.
locales et nationales.
• Consulter un expert local pour mettre en œuvre
Le niveau de qualité de l’air dans tout lieu de travail un plan du site afin d’assurer la qualité de l’air.
dépend des variables propres au site comme :
• Type de table (humide, sèche, sous l’eau).
• Composition du matériau, fini de la surface
et composition des revêtements.
• Volume de matériau enlevé.
• Durée du coupage ou du gougeage.
Hypertherm 1a-5
03/10
Sécurité
Mise à la masse et à la terre
Câble de retour Bien fixer le câble de retour • S’il est nécessaire de brancher le cordon d’alimentation
(ou de masse) à la pièce à couper ou à la table de travail à la source de courant lors de l’installation du système,
de façon à assurer un bon contact métal à métal. vérifier que le fil de terre est correctement branché.
Ne pas fixer le câble de retour à la partie de la pièce • Placer tout d’abord le fil de terre du cordon
qui doit se détacher. d’alimentation sur le plot de mise à la terre, puis placer
les autres fils de terre par-dessus. Bien serrer l’écrou
Table de travail Raccorder la table de travail de retenue.
à la terre, conformément aux codes de sécurité locaux
ou nationaux appropriés. • Vérifier que toutes les connexions sont bien serrées
pour éviter une surchauffe.
Puissance d’entrée
• S’assurer que le fil de terre du cordon d’alimentation
est connecté à la terre dans le coffret du sectionneur.
L’électricité statique peut endommager

les cartes de circuits imprimés
Les précautions qui s’imposent doivent être respectées lors de la manipulation des circuits imprimés :
• Les cartes de circuits imprimés doivent être rangées dans des contenants antistatiques.
• L’utilisateur doit porter un bracelet antistatique lors de la manipulation des cartes de circuits imprimés.
Sécurité des bouteilles Les bouteilles

de gaz comprimé de gaz comprimé
• Ne jamais lubrifier les robinets des bouteilles peuvent exploser
ou les régulateurs avec de l’huile ou de la graisse. en cas de dommages
• Utiliser uniquement les bouteilles, régulateurs, tuyaux Les bouteilles de gaz contiennent du gaz à haute pression.
et accessoires appropriés et conçus pour chaque Si une bouteille est endommagée, elle peut exploser.
application spécifique.
• Manipuler et utiliser les bouteilles de gaz comprimé
• Entretenir l’équipement et les pièces d’équipement conformément aux codes locaux ou nationaux.
à gaz comprimé afin de les garder en bon état.
• Ne jamais utiliser une bouteille qui n’est pas placée
• Étiqueter et coder avec des couleurs tous les à la verticale et bien assujettie.
tuyaux de gaz afin d’identifier le type de gaz contenu
dans chaque tuyau. Consulter les codes locaux • Le capuchon de protection doit être placé sur le robinet
ou nationaux en vigueur. sauf si la bouteille est en cours d’utilisation ou connectée
pour utilisation.
• Éviter à tout prix le contact électrique entre l’arc plasma

et une bouteille.
• Ne jamais exposer des bouteilles à une chaleur excessive,

aux étincelles, aux scories ou aux flammes nues.
• Ne jamais utiliser des marteaux, des clés ou d’autres

outils pour débloquer le robinet des bouteilles.
1a-6 Hypertherm
03/10
Sécurité
L’arc plasma peut provoquer des blessures

ou des brûlures
Torches à allumage instantané L’arc plasma coupe facilement les gants et la peau.
L’arc plasma s’allume immédiatement après que • Rester éloigné de l’extrémité de la torche.
la torche est activée. • Ne pas tenir de métal près de la trajectoire de coupe.
• Ne jamais pointer la torche vers soi ou d’autres personnes.
Les rayons de l’arc peuvent brûler

les yeux et la peau
Protection des yeux Les rayons de l’arc plasma produisent de puissants rayons visibles et invisibles (ultraviolets
et infrarouges) qui peuvent brûler les yeux et la peau.
• Utiliser des lunettes de sécurité conformément aux codes locaux ou nationaux en vigueur.
• Porter des lunettes de protection (des lunettes ou masque muni d’écrans latéraux et un masque de soudure)
avec des verres teintés appropriés pour protéger les yeux des rayons ultraviolets et infrarouges de l’arc.
Protection de la peau Porter des vêtements de sécurité pour se protéger contre les brûlures que peuvent causer
les rayons ultraviolets, les étincelles et le métal brûlant :
• Gants à crispin, chaussures et casque de sécurité.
• Vêtements ignifuges couvrant toutes les parties exposées du corps.
• Pantalon sans revers pour éviter que des étincelles ou des scories puissent s’y loger.
• Avant le coupage, retirer de ses poches tout objet combustible comme les briquets au butane ou les allumettes.
Zone de coupage Préparer la zone de coupage afin de réduire la réverbération et la transmission de la lumière
ultraviolette :
• Peindre les murs et autres surfaces d’une couleur sombre pour réduire la réflexion de la lumière.
• Utiliser des écrans et autres dispositifs de protection afin de protéger les autres personnes de la lumière
et de la réverbération.
• Prévenir les autres personnes de ne pas regarder l’arc. Utiliser des affiches ou des panneaux.
Indice de protection
Indice de protection
Courant de l’arc suggéré pour OSHA 29CFR Europe
minimum
(A) assurer le confort 1910.133(a)(5) EN168:2002
(ANSI Z49.1:2005)
(ANSI Z49.1:2005)
Moins de 40 A 5 5 8 9
41 à 60 A 6 6 8 9
61 à 80 A 8 8 8 9
81 à 125 A 8 9 8 9
126 à 150 A 8 9 8 10
151 à 175 A 8 9 8 11
176 à 250 A 8 9 8 12
251 à 300 A 8 9 8 13
301 à 400 A 9 12 9 13
401 à 800 A 10 14 10
Hypertherm 1a-7
03/10
Sécurité
Pacemakers et prothèses auditives
Les champs magnétiques produits par les courants • Faire passer le faisceau de torche le plus près
à haute tension peuvent affecter le fonctionnement possible du câble de retour.
des prothèses auditives et des pacemakers.
• Ne pas s’enrouler le faisceau de torche ou le câble
Les personnes portant ce type d’appareil doivent de retour autour du corps.
consulter un médecin avant de s’approcher d’un lieu
• Se tenir le plus loin possible de la source de courant.
où s’effectue le coupage ou le gougeage d’arc plasma.
Pour réduire les risques associés aux champs
magnétiques :
• Garder loin de soi et du même côté du corps le câble
de retour et le faisceau de torche.
Le bruit peut provoquer des problèmes auditifs
Le coupage avec l’arc plasma peut dépasser les niveaux de l’opérateur, délimiter les zones bruyantes à l’aide
de bruits acceptables conformément aux codes locaux d’une paroi et/ou instaurer des mesures préventives
relatifs à de nombreuses applications. Une exposition visant à réduire la réverbération sur le lieu de travail
prolongée à un bruit excessif peut provoquer des en installant des dispositifs antibruits.
problèmes auditifs. Toujours porter un dispositif de
Utiliser des protecteurs d’oreille si le bruit est toujours
protection antibruit adéquat lors du coupage ou du
dérangeant ou si des problèmes auditifs peuvent
gougeage, sauf si les mesures de niveau de bruits prises
survenir après l’installation des dispositifs de sécurité
sur le site d’installation certifient que les prothèses
intégrés et l’instauration des mesures préventives.
auditives ne sont pas nécessaires, telles que spécifiées
Si des protecteurs d’oreilles s’avèrent être nécessaires,
par les codes internationaux, régionaux et locaux.
porter uniquement des articles de protection
Les bruits peuvent être considérablement réduits en personnelle approuvés, tels que des oreillères ou des
ajoutant de simples dispositifs de sécurité intégrés bouchons d’oreille avec un coefficient de réduction de
aux tables de coupe, telles que des barrières ou des bruits approprié pour la situation sur le lieu de travail.
rideaux placés entre l’arc plasma et le poste de travail; Prévenir les personnes aux alentours des risques
et/ou en éloignant le poste de travail de l’arc plasma. encourus en cas d’exposition au bruit. En outre,
Mettre sur pied des mesures administratives sur le site la protection des oreilles sert également de munition
de travail afin de limiter l’accès et la durée d’exposition contre les projections chaudes.
Un arc plasma peut endommager les tuyaux gelés

Tenter de dégeler les tuyaux gelés avec une torche plasma peut les endommager ou les faire éclater.
1a-8 Hypertherm
03/10
Sécurité
Information sur le dépoussièrage

À certains endroits, la poussière peut représenter Note 1 – L’interprétation d’Hypertherm de ces nouvelles
un risque d’explosion potentiel. exigences est que, sauf évaluation particulière du site,
pour déterminer que toute la poussière produite n’est
La norme NFPA 68 de la National Fire Protection
pas combustible, l’édition 2007 de la NFPA 68 exige
Association des É.-U. (édition 2007) « Explosion
l’utilisation d’évents d’explosion conçus pour l’indice Kst
Protection by Deflagration Venting » établit les
dans le pire des cas (voir annexe F) qui pourrait provenir
exigences relatives à la conception, à l’emplacement,
de la poussière de sorte que l’on puisse concevoir la
à l’installation, à l’entretien et à l’utilisation de dispositifs
dimension et le type d’évent d’explosion. La NFPA 68
et de systèmes pour évacuer à l’air libre les gaz de
ne stipule pas particulièrement le procédé de coupage
combustion et les pressions après une déflagration.
plasma ou d’autres procédés de coupage thermique,
Communiquer avec le fabricant ou avec l’installateur
mais elle prescrit ces nouveaux règlements à tous les
de tout système de dépoussiérage afin de connaître
systèmes de dépoussiérage.
les exigences applicables avant d’installer un tel système
neuf ou d’apporter des modifications importantes aux Note 2 – Les utilisateurs des manuels d’Hypertherm
procédés ou aux matériaux utilisés par un système doivent consulter tous les règlements et lois fédéraux
de dépoussiérage existant. et locaux applicables et s’y conformer. Hypertherm n’a
pas l’intention, en publiant un manuel d’Hypertherm, de
Consultez l’autorité compétente locale pour déterminer
demander des mesures qui ne sont pas conformes aux
si une édition de la NFPA 68 a été adoptée en référence
règlements et normes applicables et ce manuel ne peut
dans vos codes du bâtiment locaux.
jamais être interprété dans ce sens.
Voir le document NFPA 68 pour obtenir des définitions
et des explications des termes réglementaires tels que
« déflagration, autorité compétente, adopté en référence,
indice Kst, indice de déflagration » et autres termes.
Hypertherm 1a-9
03/10
Sécurité
Radiation au laser
L’exposition à une sortie laser peut provoquer des problèmes visuels graves. Éviter un contact
direct avec les yeux.
Pour votre aisance et votre sécurité, l’une des étiquettes de radiation au laser suivantes a été installée sur les
produits Hypertherm près de la sortie du faisceau laser du boîtier. Ont également été fournies la sortie maximale
(mV), la longueur d’onde émise (nM) et au besoin, la durée d’impulsion.
Autres consignes de sécurité relatives au laser :

• Consulter un expert local pour les réglementations • Toute modification du laser ou du produit peut
locales sur le laser. Une formation sur la sécurité accroître le risque de radiation au laser.
relative au laser peut être nécessaire. • L’utilisation des réglages ou le suivi des procédures
• Ne pas autoriser le personnel non formé à faire autres que celles spécifiées dans ce manuel peut
fonctionner le laser. Il peut s’avérer dangereux pour entraîner un risque de radiation au laser.
ce personnel. • Ne pas faire fonctionner l’appareil en présence
• Ne jamais regarder l’intérieur ou le faisceau du laser. d’explosifs tels que des liquides et des gaz
• Positionner le laser selon les instructions afin d’éviter inflammables ou la poussière.
un éventuel contact avec les yeux. • Utiliser uniquement les pièces et accessoires laser
• Ne pas utiliser le laser sur des pièces à couper recommandés ou fournis par le fabricant pour votre
réflectives. modèle.
• Ne pas utiliser des outils optiques pour visualiser • Les travaux de réparation et d’entretien DOIVENT
le faisceau du laser. être effectués par un personnel qualifié.
• Ne pas démonter ou retirer le laser ou son capot. • Ne pas retirer ou détruire l’étiquette de sécurité
du laser.
1a-10 Hypertherm
03/10
Sécurité
Symboles et marquage
Votre produit Hypertherm peut comporter une ou plusieurs des marques suivantes sur sa plaque signalétique
ou à proximité. En raison des différends et des conflits relatifs aux règlements nationaux, toutes les marques ne sont
pas appliquées à chaque version d’un produit.
Symbole de marque S
Le symbole de marque S indique que la source de courant et la torche conviennent pour les travaux
effectués dans les milieux à risque accru de choc électrique selon l’IEC 60974-1.
Marque CSA
Les produits Hypertherm portant la marque CSA sont conformes aux réglementations des États-Unis
et du Canada pour la sécurité des produits. Les produits ont été évalués, testés et certifiés par
CSA-International. Le produit peut autrement porter la marque d’autres laboratoires d’essais reconnus
à l’échelle nationale (NRTL) agréés à la fois aux États-Unis et au Canada, par exemple : Underwriters
Laboratories, Incorporated (UL) ou TÜV.
Marque CE
e marquage CE signifie : déclaration de conformité du fabricant aux directives et normes européennes
L
applicables. Seules les versions des produits Hypertherm portant la marque CE située sur ou à proximité
de la plaque signalétique ont été testées pour conformité à la directive européenne « basse tension »
et la directive européenne « compatibilité électromagnétique » (CEM). Les filtres CEM devant être
en conformité avec la directive européenne CEM sont intégrés dans les produits portant la marque CE.
Marque GOST-R
Les versions CE des produits Hypertherm qui portent la marque de conformité GOST-R répondent aux
exigences de sécurité du produit et de CEM en vue de l’exportation à la Fédération russe.
Marque c-Tick
es versions CE des produits Hypertherm portant la marque c-Tick sont conformes aux règlements CEM
L
prescrits pour la vente en Australie et en Nouvelle-Zélande.
Marque CCC
La marque de certification obligatoire en Chine (CCC) indique que le produit a été mis à l’essai et déclaré
conforme aux règlements de sécurité du produit prescrits pour la vente en Chine.
Hypertherm 1a-11
03/10
Sécurité
Étiquettes de sécurtité
Cette étiquette est affichée sur certaines sources de courant. Il est important que l’opérateur et le technicien d’entretien
comprennent la signification des symboles de sécurité.

1a-12 Hypertherm
03/10
Sécurité
Étiquette de sécurité 1. Les étincelles de coupage peuvent

provoquer une explosion ou un incendie.
Cette étiquette est affichée sur certaines sources de courant. Il est
important que l’opérateur et le technicien d’entretien comprennent 1.1 Ne pas couper près des matières
la signification des symboles de sécurité. Les numéros de la liste inflammables.
correspondent aux numéros des images. 1.2 Un extincteur doit se trouver sur les lieux
et être prêt à être utilisé.
1.3 Ne pas utiliser un fût ou un autre
contenant fermé comme table de coupe.
2. L’arc plasma peut blesser et brûler;
ne jamais pointer la buse vers soi.
L’arc s’amorce instantanément quand
on appuie sur la gâchette.
2.1 Couper l’alimentation avant de démonter
la torche.
2.2 Ne pas saisir la pièce à couper près
de la trajectoire de coupage.
2.3 Se protéger entièrement le corps.
3. Tension dangereuse. Risque de choc
électrique ou de brûlure.
3.1 Porter des gants isolants. Remplacer les
gants s’ils sont humides ou endommagés.
3.2 Se protéger contre les chocs en s’isolant
de la pièce et de la terre.
3.3 Couper l’alimentation avant de procéder
à l’entretien. Ne pas toucher les pièces
sous tension.
4. Les fumées du plasma peuvent être
dangereuses.
4.1 Ne pas inhaler les fumées.
4.2 Utiliser une ventilation forcée ou par
extraction locale pour éliminer les fumées.
4.3 Ne pas utiliser dans des espaces clos.
Éliminer les fumées avec la ventilation.
5. Les rayons d’arc peuvent brûler les yeux
et blesser la peau.
5.1 Porter un bon équipement de protection
pour se protéger la tête, les yeux, les
oreilles, les mains et le corps. Boutonner
le col de la chemise. Protéger les oreilles
contre le bruit. Utiliser le masque de
soudage avec le filtre ayant le bon indice
de protection.
6. Suivre une formation. Seul le personnel
qualifié doit faire fonctionner cet
équipement. Utiliser les torches prescrites
dans le manuel. Tenir le personnel non
qualifié et les enfants à l’écart.
7. Ne pas enlever, détruire ou couvrir
cette étiquette. La remplacer si elle
est manquante, endommagée ou usée.
Hypertherm 1a-13
03/10
Sécurité
1a-14 Hypertherm
03/10
Sección 1b
SEGURIDAD
En esta sección:
Reconocimiento de información de seguridad................................................................................................................................. 1b-2
Cumplimiento de instrucciones de seguridad.................................................................................................................................. 1b-2
Riesgos de electrocución...................................................................................................................................................................... 1b-2
Las descargas eléctricas pueden matar............................................................................................................................................. 1b-3
Los cortes pueden producir incendios o explosiones..................................................................................................................... 1b-4
Los vapores tóxicos pueden producir lesiones o la muerte........................................................................................................... 1b-5
Seguridad de equipos de gas comprimido....................................................................................................................................... 1b-6
Seguridad de toma a tierra.................................................................................................................................................................... 1b-6
La electricidad estática puede dañar las placas de circuitos........................................................................................................ 1b-6
Los cilindros de gas pueden explotar si están dañados................................................................................................................ 1b-6
El arco de plasma puede producir lesiones y quemaduras........................................................................................................... 1b-7
Los rayos del arco pueden quemar los ojos y la piel....................................................................................................................... 1b-7
Los ruidos pueden dañar la audición.................................................................................................................................................. 1b-8
Funcionamiento de marcapasos y audífonos.................................................................................................................................... 1b-8
El arco de plasma puede dañar las tuberías congeladas............................................................................................................... 1b-8
Información acerca de la recolección de polvo seco...................................................................................................................... 1b-9
Radiación láser....................................................................................................................................................................................... 1b-10
Símbolos y marcas................................................................................................................................................................................1b-11
Etiquetas de advertencia......................................................................................................................................................................1b-12
Hypertherm 1b-1
03/10
Seguridad
Reconocimiento PELIGRO ADVERTENCIA PRECAUCIÓN

Hypertherm utiliza las pautas del American National
de información Standards Institute en relación con los símbolos y las
de seguridad palabras de aviso de seguridad. Junto a los símbolos de
Los símbolos incluidos en esta sección se usan para seguridad, aparecen palabras de aviso como PELIGRO
identificar posibles peligros. Cuando vea un símbolo o ADVERTENCIA. La palabra PELIGRO identifica a los
de seguridad en este manual o en la máquina, debe riesgos más graves.
tomar conciencia del riesgo de lesiones personales
y seguir las instrucciones relacionadas para evitar ese • Las etiquetas de seguridad de PELIGRO
riesgo. y ADVERTENCIA están colocadas cerca de los riesgos
específicos que presenta la máquina.
Cumplimiento • Los mensajes de seguridad de PELIGRO aparecen en

de instrucciones este manual antes de las instrucciones relacionadas a
procesos que pueden producir lesiones o la muerte si
de seguridad no se siguen correctamente.
Lea cuidadosamente todos los mensajes de seguridad
de este manual y todas las etiquetas de seguridad de • Los mensajes de seguridad de ADVERTENCIA
la máquina. aparecen en este manual antes de las instrucciones
• Mantenga las etiquetas de seguridad de la máquina relacionadas a procesos que pueden producir lesiones
en buen estado. Reponga de inmediato las etiquetas o la muerte si no se siguen correctamente.
dañadas o faltantes.
• Los mensajes de seguridad de PRECAUCIÓN
• Aprenda a operar la máquina y usar los controles de aparecen en este manual antes de las instrucciones
manera adecuada. No permita que nadie la opere sin relacionadas a procesos que pueden producir lesiones
las instrucciones correspondientes. menores o daños en los equipos si no se siguen
• Asegúrese de que la máquina esté en buenas condiciones correctamente.
operativas. Las modificaciones no autorizadas pueden
afectar la seguridad y la vida útil de la máquina.
Riesgos de electrocución
• Sólo el personal capacitado y autorizado puede abrir • Si no se puede cortar el suministro de energía del
este equipo. equipo mientras se abre el armazón para realizar
reparaciones, es posible que se produzcan peligros
• Si el equipo está conectado en forma permanente,
de explosión de arco eléctrico. Siga TODOS los
apáguelo e implemente un cierre “con llave y etiqueta”
requisitos locales (NFPA 70E en los EE. UU.) en
de la energía antes de abrir el armazón.
relación con las practicas de trabajo seguro y con el
• Si el suministro de energía se realiza a través de un equipo de protección personal al realizar reparaciones
cable, desenchufe la unidad antes de abrir el armazón. en equipos energizados.
• Otras personas deberán suministrar las cubiertas para • El armazón debe permanecer cerrado y se debe
enchufes bloqueables y los elementos de desconexión verificar que la continuidad a tierra física al armazón
bloqueables. sea la adecuada antes de operar el equipo y luego
de moverlo, abrirlo o realizarle reparaciones.
• Espere 5 minutos luego de cortar la energía y antes
de ingresar en el armazón, a fin de permitir que • Siempre siga estas instrucciones para desconectar
la energía almacenada se descargue. la energía antes de inspeccionar o cambiar las piezas
consumibles de la antorcha.
1b-2 Hypertherm
03/10
Seguridad
Las descargas eléctricas pueden matar
El contacto con piezas eléctricas con corriente puede • Instale y ponga a tierra el equipo respetando el manual
causar una descarga mortal o quemaduras graves. de instrucciones y los códigos nacionales y locales.
• Cuando el sistema de plasma está en funcionamiento, • Inspeccione con frecuencia el cable de potencia
se completa un circuito eléctrico entre la antorcha y la de alimentación para detectar daños o rajaduras
pieza a cortar. La pieza a cortar y cualquier objeto que en la cubierta. Reemplace los cables dañados
la esté tocando pasan a formar parte de este circuito. de inmediato. Los cables pelados pueden ser
• Nunca toque el cuerpo de antorcha, la pieza a cortar mortales.
ni el agua de la mesa de agua cuando el sistema • Inspeccione las mangueras de la antorcha y reemplace
de plasma esté en funcionamiento. las que estén dañadas.
• No levante la pieza a cortar ni los residuos de corte
Prevención de descargas eléctricas
durante la tarea. Deje la pieza a cortar en su lugar
Todos los sistemas de plasma Hypertherm o en la mesa de trabajo con el cable de trabajo
usan voltajes altos en el proceso de corte colocado durante el proceso de corte.
(suelen ser de 200 a 400 VCD). Tome las • Antes de controlar, limpiar o reemplazar piezas de
siguientes precauciones al operar el sistema: la antorcha, desconecte la alimentación principal
• Use botas y guantes aislados, y mantenga su cuerpo o desenchufe la fuente de energía.
y su vestimenta secos. • Nunca anule ni puentee los bloqueos de seguridad.
• Asegúrese de que ninguna parte de su cuerpo esté • Antes de quitarle la cubierta a una fuente de energía
en contacto con una superficie mojada mientras usa o recinto del sistema, desconecte la potencia
el sistema de plasma. de alimentación eléctrica. Espere 5 minutos antes
• Aíslese de la pieza de trabajo y la tierra con una de desconectar la alimentación principal, para permitir
alfombra o cubierta aislante de tamaño suficiente la descarga de los condensadores.
para prevenir cualquier contacto físico con la pieza • Nunca opere el sistema de plasma sin las cubiertas
de trabajo o la tierra. Tenga mucha precaución si de la fuente de energía en su lugar. Si las conexiones
el lugar de trabajo o los alrededores están húmedos. de la fuente de energía están expuestas, presentan
• Instale un interruptor de desconexión con fusibles un alto riesgo de electrocución.
de tamaño apropiado cerca de la fuente de energía. • Al hacer las conexiones de entrada, una primero
Este interruptor permitirá al operador cortar la fuente el conductor de puesta a tierra correspondiente.
de energía rápidamente ante una emergencia.
• Cada sistema de plasma Hypertherm está diseñado
• Al usar una mesa de agua, asegúrese de que esté para usarse únicamente con antorchas Hypertherm
bien puesta a tierra. específicas. No utilice otras antorchas, ya que
podrían sobrecalentarse y presentar un riesgo para
la seguridad.
Hypertherm 1b-3
03/10
Seguridad
Los cortes pueden producir incendios

o explosiones
Prevención de incendios ADVERTENCIA

• Compruebe la seguridad del lugar antes de realizar Peligro de explosión
cortes. Tenga disponible un extintor de incendios Argón-hidrógeno y metano
cerca del lugar. El hidrógeno y el metano son gases inflamables que
• Mantenga todas las sustancias inflamables a 10 m presentan un riesgo de explosión. Mantenga las llamas
de distancia del área de corte. alejadas de los cilindros y las mangueras con metano
• Temple o deje enfriar el metal caliente antes de o mezclas de hidrógeno. Evite que las llamas y las
manipularlo o que entre en contacto con materiales chispas se acerquen a la antorcha cuando use plasma
combustibles. de metano o argón-hidrógeno.
• Nunca corte envases que contengan materiales
potencialmente inflamables; primero deben vaciarse
y limpiarse bien.
• Ventile las atmósferas que puedan ser inflamables ADVERTENCIA
antes de realizar cortes. Peligro de explosión
Cortes bajo el agua con
• Al cortar con oxígeno como gas plasma, es obligatorio
gases combustibles
el uso de un sistema de ventilación de escape.
• No corte aluminio bajo el agua o cuando el agua esté
Prevención de explosiones en contacto con la parte inferior del aluminio.
• No use el sistema de plasma si puede haber polvo • Cortar aluminio bajo el agua o cuando el agua esté
o vapores explosivos. en contacto con la parte inferior del aluminio puede
• No corte cilindros presurizados, tuberías ni envases provocar una situación explosiva que podría detonarse
cerrados. durante las operaciones de corte por plasma.
• No corte envases que tenían materiales combustibles.
ADVERTENCIA
Explosión de hidrógeno
al cortar aluminio
• No realice cortes bajo el agua con gases
combustibles que contengan hidrógeno.
• Realizar cortes bajo el agua con gases combustibles
que contienen hidrógeno puede provocar una situación
explosiva que podría detonarse durante operaciones
de corte por plasma.
1b-4 Hypertherm
03/10
Seguridad
Los vapores tóxicos pueden producir

lesiones o la muerte
El arco de plasma es la fuente de calor usada para el • Tamaño, volumen de aire, ventilación y filtración
corte. Por lo tanto, aunque el arco de plasma mismo no del área de trabajo.
sea fuente de vapores tóxicos, el material que se corta • Equipos de protección personal.
puede producir estos vapores o gases que agotan
el oxígeno. • Cantidad de sistemas de soldadura y corte en
funcionamiento.
Los vapores producidos varían según el metal que se • Otros procesos del lugar que pueden producir
corte. Algunos de los metales que pueden producir vapores.
vapores tóxicos son, entre otros, el acero inoxidable,
el acero al carbono, el zinc (galvanizado) y el cobre. Si el lugar de trabajo debe cumplir con reglamentaciones
nacionales o locales, sólo los controles o pruebas
En algunos casos, el metal puede estar recubierto por realizados en el lugar pueden determinar si los niveles
una sustancia que podría producir vapores tóxicos. se encuentran dentro de lo permitido.
Los revestimientos tóxicos incluyen, entre otros, el plomo
Para reducir el riesgo de exposición a vapores:
(de algunas pinturas), el cadmio (de algunas pinturas
y tapaporos) y el berilio. • Quite todos los revestimientos y solventes del metal
antes de cortar.
Los gases producidos por el corte por plasma varían • Use la ventilación de escape local para eliminar los
según el material y el método de corte, pero pueden vapores del aire.
incluir ozono, óxidos de nitrógeno, cromo hexavalente,
• No inhale los vapores. Use un respirador con suministro
hidrógeno y otras sustancias contenidas o liberadas
de aire al cortar metales que contienen o pueden
por el material de corte.
contener elementos tóxicos, o están recubiertos con
estos elementos.
Se deben tomar precauciones para minimizar la
exposición a los vapores producidos en cualquier • Asegúrese de que las personas que usen equipos
proceso industrial. Según la composición química de soldadura o corte, y respiradores con suministro
y la concentración de los vapores (junto con otros de aire estén calificadas y capacitadas en el uso
factores, como la ventilación), puede haber riesgo adecuado de estos equipos.
de contraer enfermedades físicas, como defectos • Nunca corte envases que contengan materiales
congénitos o cáncer. potencialmente tóxicos. Vacíe y limpie bien el envase
antes de cortarlo.
El propietario del equipo y las instalaciones debe
• Realice controles o pruebas de la calidad del aire del
analizar la calidad del aire del lugar donde se usa
lugar, según sea necesario.
el equipo, para asegurarse de que cumpla con todas
las normas y reglamentaciones locales y nacionales. • Consulte a un experto local sobre la implementación
de un plan para asegurarse de que la calidad del aire
La calidad del aire de cualquier lugar de trabajo sea segura.
depende de variables específicas del lugar, como:
• Diseño de la mesa (con agua, en seco, bajo el agua).
• Composición del material, acabado de la superficie
y composición de los revestimientos.
• Volumen de material descartado.
• Duración del corte o ranurado.
Hypertherm 1b-5
03/10
Seguridad
Seguridad de toma a tierra
Cable de trabajo Sujete el cable de trabajo firmemente • Si la instalación del sistema de plasma implica
a la pieza a cortar o la mesa de trabajo, estableciendo un la conexión del cable de alimentación a la fuente
buen contacto metal con metal. No lo conecte a la pieza de energía, asegúrese de conectar adecuadamente
que se caerá cuando se termine el corte. el conductor de puesta a tierra del cable de
alimentación.
Mesa de trabajo Ponga a tierra la mesa de trabajo, • Coloque el conductor de puesta a tierra del cable
en cumplimiento con los códigos eléctricos locales de alimentación en el borne antes que los demás;
y nacionales. los otros conductores de puesta a tierra deben ir
encima del conductor del cable de alimentación.
Potencia de alimentación (entrada) Ajuste bien la tuerca de retención.
• Asegúrese de conectar el conductor de puesta • Ajuste todas las conexiones eléctricas para evitar
a tierra del cable de alimentación con la puesta el calentamiento excesivo.
a tierra de la caja de desconexión.
La electricidad estática puede dañar las placas

de circuitos
Tome las precauciones necesarias para manipular placas de circuito impreso:
• Guarde las placas de PC en recipientes antiestáticos.
• Use una cinta de muñeca puesta a tierra para manipular las placas de PC.
Seguridad de equipos Los cilindros de gas

de gas comprimido pueden explotar si
• Nunca lubrique los reguladores o las válvulas están dañados
de cilindros con aceite o grasa. Los cilindros de gas tienen gas bajo alta presión. Si se
dañan, pueden explotar.
• Use únicamente los cilindros de gas, los reguladores,
las mangueras y los accesorios diseñados • Los cilindros de gas comprimido deben manipularse
específicamente para esa aplicación. y usarse respetando los códigos nacionales y locales.
• Mantenga todos los equipos de gas comprimido • Use únicamente cilindros que estén en posición
y las piezas relacionadas en buen estado. vertical y bien sujetos en su lugar.
• Etiquete e identifique con colores todas las • Mantenga la tapa protectora colocada en la válvula,
mangueras de gas, para saber el tipo de gas que a menos que el cilindro esté conectado o en uso.
transporta cada manguera. Consulte los códigos
nacionales y locales correspondientes. • Nunca permita que haya contacto eléctrico entre
el arco de plasma y un cilindro.
• Nunca exponga los cilindros al calor excesivo,

las chispas, la escoria ni la llama directa.
• Nunca use un martillo, llave ni otra herramienta para

abrir una válvula de cilindro atascada.
1b-6 Hypertherm
03/10
Seguridad
El arco de plasma puede producir lesiones

y quemaduras
Antorchas de encendido inmediato El arco de plasma puede cortar los guantes y la piel
El arco de plasma se enciende de inmediato al activar rápidamente.
el interruptor de la antorcha. • Evite el contacto con la punta de la antorcha.
• No ponga piezas de metal cerca de la ruta de corte.
• Nunca apunte la antorcha en dirección a usted
o a otras personas.
Los rayos del arco pueden quemar

los ojos y la piel
Protección ocular El arco de plasma produce rayos visibles e invisibles (ultravioletas e infrarrojos) que pueden
quemar los ojos y la piel.
• Use la protección ocular que exigen los códigos nacionales y locales.
• Las lentes de la protección ocular (anteojos o gafas de seguridad con protección lateral, y careta de soldador)
deben contar con el sombreado adecuado para proteger los ojos de los rayos ultravioletas e infrarrojos del arco.
Protección cutánea Use vestimenta de protección para evitar las quemaduras producidas por la luz ultravioleta,
las chispas y el metal caliente.
• Guantes de seguridad, calzado de seguridad y casco.
• Vestimenta ignífuga para cubrir todas las áreas expuestas.
• Pantalones sin dobladillo, para evitar el ingreso de chispas y escoria.
• Antes del corte, sáquese de los bolsillos todo material combustible, como los encendedores con butano o los fósforos.
Área de corte Prepare el área de corte para reducir el reflejo y la emisión de luz ultravioleta:
• Pinte las paredes y otras superficies de colores oscuros, para reducir el reflejo.
• Use pantallas o barreras protectoras para resguardar a los demás del centelleo y el resplandor.
• Advierta a las demás personas que no deben mirar el arco. Coloque carteles o anuncios.
Número mínimo Número de sombra
Corriente
de sombra de sugerido para OSHA 29CFR Europa
del arco
protección confort 1910.133(a)(5) EN168:2002
(amperios)
(ANSI Z49.1:2005) (ANSI Z49.1:2005)
Inferior a 40 A 5 5 8 9
41 a 60 A 6 6 8 9
61 a 80 A 8 8 8 9
81 a 125 A 8 9 8 9
126 a 150 A 8 9 8 10
151 a 175 A 8 9 8 11
176 a 250 A 8 9 8 12
251 a 300 A 8 9 8 13
301 a 400 A 9 12 9 13
401 a 800 A 10 14 10
Hypertherm 1b-7
03/10
Seguridad
Funcionamiento de marcapasos y audífonos
El funcionamiento de marcapasos y audífonos puede • Haga pasar las mangueras de la antorcha lo más
verse afectado por los campos magnéticos de las altas cerca posible del cable de trabajo.
corrientes.
• No se enrosque ni apoye los conductos de antorcha
Las personas que usan marcapasos o audífonos deben ni el cable de trabajo en el cuerpo.
consultar a un médico antes de acercarse a una operación
• Manténgase lo más alejado de la fuente de energía
de corte o ranurado por arco de plasma.
como sea posible.
Para reducir el riesgo que presentan los campos
magnéticos:
• Mantenga el cable de trabajo y los conductos
de antorcha a un costado, alejados del cuerpo.
Los ruidos pueden dañar la audición
Realizar cortes con un arco de plasma puede superar administrativos en el lugar de trabajo para restringir
los niveles de ruido aceptables, según se definen el acceso, limitar el tiempo de exposición del operador,
en los códigos locales en muchas aplicaciones. La cubrir áreas de trabajo ruidosas o tomar las medidas
exposición prolongada a ruidos excesivos puede dañar necesarias para reducir la reverberación en áreas de
la audición. Siempre use una protección apropiada para trabajo al colocar mecanismos de absorción de ruidos.
los oídos al realizar cortes o ranurados, a menos que
Se debe utilizar una protección auditiva si el ruido es
se haya verificado que, en función de las mediciones
perjudicial o si existe el riesgo de que se produzcan
de los niveles de presión de sonido tomadas en el sitio
daños a la audición una vez implementados todos los
instalado, no sea necesario utilizar protección auditiva
demás controles administrativos y de ingeniería. Si es
personal, de acuerdo con los códigos internacionales,
necesario utilizar una protección auditiva, utilice sólo los
regionales y locales correspondientes.
dispositivos de protección personal aprobados, como
Se puede obtener una reducción significativa de protectores para las orejas o tapones para los oídos
los ruidos mediante la incorporación de controles con una calificación de reducción de ruidos adecuada
de ingeniería simples a las mesas de corte, como para la situación. Advierta a las demás personas que
barreras o cortinas ubicadas entre el arco de trabajan en el área sobre los posibles riesgos que
plasma y la estación de trabajo; además, se puede presentan los ruidos. Además, la protección para los
ubicar la estación de trabajo en un lugar alejado oídos puede evitar que salpicaduras calientes ingresen
del arco de plasma. Se deben implementar controles en la oreja.
El arco de plasma puede dañar las tuberías

congeladas
Las tuberías pueden dañarse o reventar si se intenta descongelarlas con una antorcha de plasma.
1b-8 Hypertherm
03/10
Seguridad
Información acerca de la recolección de polvo seco

En algunos sitios, el polvo seco puede presentar un Nota 1 – La interpretación por parte de Hypertherm de
posible riesgo de explosión. estos nuevos requisitos implica que, a menos que se
haya realizado una evaluación específica del lugar para
La edición 2007 de la norma 68 NFPA de la U.S. National
determinar que el polvo generado no es combustible,
Fire Protection Association, “Explosion Protection by
la edición 2007 de NFPA 68 requiere el uso de
Deflagration Venting” (Protección contra explosiones
ventilaciones de explosión diseñadas para el peor valor
mediante ventilación en caso de deflagración)
Kst (consulte el anexo F) que se podría generar a causa
proporciona los requisitos para el diseño, la ubicación,
del polvo, de manera que se puedan diseñar el tipo y el
la instalación, el mantenimiento y el uso de dispositivos
tamaño de ventilación de explosión. La norma NFPA 68
y sistemas para ventilar presiones y gases de combustión
no identifica específicamente que el corte por plasma
después de un evento de deflagración. Consulte al
ni otros procesos de corte térmico requieran sistemas
fabricante o instalador de sistemas de recolección de
de ventilación en caso de deflagración; sin embargo,
polvo seco acerca de los requisitos aplicables antes
sí aplica estos nuevos requisitos a todos los sistemas
de instalar un nuevo sistema de recolección de polvo
de recolección de polvo seco.
seco o de realizar cambios significativos en los materiales
o procesos utilizados con un sistema de recolección Nota 2 – Los usuarios de los manuales de Hypertherm
de polvo seco existente. deben consultar y cumplir todas las regulaciones
y leyes federales, estatales y locales correspondientes.
Consulte la “Autoridad con jurisdicción” (AHJ, Authority
Mediante la publicación de sus manuales, Hypertherm
Having Jurisdiction) para determinar si la edición de la
no pretende instar la implementación de acciones
norma 68 de la NFPA se ha “adoptado por referencia”
que no cumplen los estándares y las regulaciones
en los códigos de construcción locales.
aplicables; asimismo, no se debe interpretar que este
Consulte la norma NFPA68 para conocer las manual persigue dicho fin.
definiciones y explicaciones de los términos aprobados
como deflagración, AHJ, adoptado por referencia, valor
Kst, índice de deflagración y otros términos.
Hypertherm 1b-9
03/10
Seguridad
Radiación láser
La exposición a la salida del láser puede provocar graves daños oculares. Evite la exposición
ocular directa.
Para su conveniencia y seguridad, en todos los productos Hypertherm que usan un láser, se ha aplicado una
de las siguientes etiquetas de radiación láser en el producto, cerca de lugar donde el haz láser sale del bastidor.
También se proporcionan los valores de salida máxima (mV), la longitud de onda emitida (nM) y, si corresponde,
la duración de pulso.
Instrucciones de seguridad adicionales sobre

la utilización de productos con láser:
• Consulte a un experto para conocer las regulaciones • Las modificaciones realizadas al láser o al producto
locales sobre la utilización de láser. Es posible que pueden aumentar el riesgo de que se produzca
se exija una capacitación de seguridad para el uso radiación láser.
de láser. • El uso de ajustes o la implementación de
• No permita que el personal no capacitado opere procedimientos que no sean aquellos especificados
el láser. El láser puede ser peligroso si es utilizado en este manual pueden provocar una exposición
por personal no capacitado. peligrosa a la radiación láser.
• No mire el haz o la apertura del láser en ningún • No opere el producto en atmósferas explosivas, como
momento. en presencia de polvo, gases o líquidos inflamables.
• Ubique el láser como se indica, a fin de evitar • Sólo utilice los accesorios y las piezas del láser que
contacto ocular no deseado. el fabricante suministra o recomienda para su modelo.
• No utilice el láser en piezas a cortar reflectantes. • Las reparaciones y el mantenimiento SE DEBEN
• No utilice herramientas ópticas para visualizar llevar a cabo por personal calificado.
o reflectar el haz del láser. • No extraiga ni mutile la etiqueta de seguridad
• No desarme ni extraiga el láser ni la cubierta del láser.
de apertura.
1b-10 Hypertherm
03/10
Seguridad
Símbolos y marcas
Su producto Hypertherm puede contener alguna de las siguientes marcas en la placa de datos o cerca de ella. Debido
a las diferencias y los conflictos con las regulaciones nacionales, no todas las marcas se aplican a todas las versiones
de un producto.
Marca símbolo S
La marca símbolo S indica que la fuente de energía y la antorcha son aptas para operaciones llevadas a cabo
en entornos en los que existe un alto peligro de descargas eléctricas, de acuerdo con la norma IEC 60974-1.
Marca CSA
Los productos de Hypertherm que tienen la marca CSA cumplen con los reglamentos de seguridad de los
productos de los Estados Unidos y Canadá. Estos productos han sido evaluados, probados y certificados
por CSA-International. De manera alternativa, es posible que el producto tenga una marca colocada por otro
Laboratorio de pruebas reconocido a nivel nacional (NRTL, por sus siglas en inglés) autorizado en los Estados
Unidos y en Canadá, por ejemplo, Underwriters Laboratories, Incorporated (UL) o TÜV.
Marca CE
La marca CE indica la declaración de cumplimiento del fabricante con las normas y las directivas europeas
aplicables. Sólo se considerarán probadas para cumplimiento con las Directivas europeas de baja tensión
y con las Directivas europeas de compatibilidad electromagnética (EMC) aquellas versiones de los productos
Hypertherm que tengan la marca CE colocada sobre la placa de datos o cerca de ésta. Aquellos filtros de
EMC que deban cumplir con las Directivas europeas de EMC se han incorporado a las versiones de los
productos con la marca CE.
Marca GOST-R
Las versiones CE de los productos de Hypertherm que incluyen una marca de conformidad GOST-R cumplen
los requisitos de compatibilidad electromagnética (EMC) y de seguridad del producto para exportación
a la Federación Rusa.
Marca c-Tick
Las versiones CE de los productos de Hypertherm que incluyen una marca c-Tick cumplen las regulaciones de
EMC para la venta del producto en Australia y Nueva Zelanda.
Marca CCC
La marca China Compulsory Certification (CCC) indica que se ha evaluado el producto y que este cumple
las regulaciones de seguridad .del producto requeridas para su venta en China.
Hypertherm 1b-11
03/10
Seguridad
Etiquetas de advertencia
Esta etiqueta de advertencia se coloca en ciertas fuentes de energía. Es importante que el operador y el técnico
de mantenimiento entiendan las ideas que transmiten estos símbolos de advertencia.

1b-12 Hypertherm
03/10
Seguridad
Etiquetas de advertencia 1. Las chispas de corte pueden producir

explosiones o incendios.
Esta etiqueta de advertencia se coloca en ciertas fuentes de energía.
1.1 No corte cerca de sustancias inflamables.
Es importante que el operador y el técnico de mantenimiento
entiendan las ideas que transmiten estos símbolos de advertencia. 1.2 Tenga disponible un extintor de incendios
Los textos numerados corresponden a los cuadros numerados cerca del lugar y listo para usar.
de la etiqueta. 1.3 No use tambores ni otros envases
cerrados como mesa de corte.
2. El arco de plasma puede producir
lesiones y quemaduras; mantenga
la boquilla alejada del cuerpo. El arco
arranca instantáneamente al apretar
el gatillo.
2.1 Corte la fuente de energía antes
de desarmar la antorcha.
2.2 No agarre la pieza a cortar cerca
de la ruta de corte.
2.3 Use protección corporal completa.
3. Voltaje peligroso. Riesgo de descargas
o quemaduras eléctricas.
3.1 Use guantes aislantes. Reemplácelos
cuando estén húmedos o dañados.
3.2 Protéjase de las descargas aislándose
de la pieza de trabajo y la tierra.
3.3 Desconecte la corriente antes de realizar
reparaciones. No toque las piezas con
corriente.
4. Los vapores de plasma pueden ser
peligrosos.
4.1 No inhale los vapores.
4.2 Use ventilación forzada o la ventilación
de escape local para eliminar los vapores.
4.3 No opere el sistema en espacios
cerrados. Elimine los vapores con
ventilación.
5. Los rayos del arco pueden quemar
los ojos y lesionar la piel.
5.1 Use el equipo de protección correcto
y adecuado para proteger la cabeza,
los ojos, los oídos, las manos y el cuerpo.
Abróchese el cuello de la camisa.
Protéjase los oídos del ruido. Use una
careta de soldador con el sombreado
o filtro adecuado.
6. Capacítese. Sólo personal calificado
debe operar este equipo. Use las
antorchas especificadas en el manual.
Mantenga al personal no calificado
y a los niños alejados del área de trabajo.
7. No quite, destruya, ni cubra esta etiqueta.
Reemplácela si falta o si está dañada
o gastada.
Hypertherm 1b-13
03/10
Seguridad
1b-14 Hypertherm
03/10
Section 2
Specifications
In this section:
General...............................................................................................................................................................................................2-3
Power supply.....................................................................................................................................................................................2-3
Cooler.................................................................................................................................................................................................2-3
Ignition console.................................................................................................................................................................................2-3
Torch...................................................................................................................................................................................................2-3
Specifications..............................................................................................................................................................................................2-4
System gas requirements...............................................................................................................................................................2-4
Power supply.....................................................................................................................................................................................2-5
Cooler – 078531...........................................................................................................................................................................2-6
Ignition console – 078172.............................................................................................................................................................2-7
Selection console – 078533.........................................................................................................................................................2-9
Metering console – 078535....................................................................................................................................................... 2-10
Torch – 228354............................................................................................................................................................................ 2-11
IEC symbols.............................................................................................................................................................................................. 2-12
HPR400XD Auto Gas – 806160 Revision 3 2-1

Specifications
2-2 HPR400XD Auto Gas – 806160 Revision 3

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 400-amp, 200-VDC constant-current supply. It contains the circuitry to ignite a torch. The power
supply has a serial interface to provide communication with a CNC controller.
Cooler
The cooler contains a heat exchanger and pump that reduces the temperature of the coolant that flows to the torch. It
also contains flow and temperature sensors that ensure the cooling system is working properly.
Ignition console
The ignition console uses a spark-gap assembly. The ignition console converts 120 VAC control voltage from the power
supply into high-frequency and high-voltage pulses (9-10 kV) to break over the torch electrode-nozzle gap. The high-
voltage, high-frequency signal is coupled to the cathode lead and pilot arc lead.
Selection console
The selection console manages the selection and mixing of the plasma gases. It contains motor valves, solenoid valves
and pressure transducers. It also contains a control board, an AC relay board and a power distribution board. The
selection console has an LED lamp that illuminates when power is supplied to the system.
Metering console
The metering console controls the flow rate of the gases to the torch in real time. It also controls the gas portion of
the LongLife® process. The metering console contains proportional control valves, a PC control board and a power
distribution board.
Torch
The dross-free cutting capacity of the torch is 40 mm (1.5 in) for HyDefinition cutting. The production pierce capacity is
50 mm (2 in) for mild steel, 45 mm (1.75 in) for stainless steel, and 40 mm (1.5 in) for aluminum. The maximum cutting
capability (edge start) is 80 mm (3 in) for mild steel, stainless steel, and aluminum.

Specifications
Specifications
System gas requirements
Gas quality and pressure requirements
Gas type Quality Pressure +/- 10% Flow rate

O2 oxygen 99.5% pure 793 kPa / 8 bar 4250 l/h 150 scfh
Clean, dry, oil-free 115 psi
N2 nitrogen 99.99% pure 793 kPa / 8 bar 11610 l/h 410 scfh
Air * Clean, dry, oil-free per 793 kPa / 8 bar 11330 l/h 400 scfh
ISO 8573-1 Class 1.4.2 115 psi
H35 99.995% pure 793 kPa / 8 bar 4250 l/h 150 scfh
argon-hydrogen (H35 = 65% Argon, 35% Hydrogen) 115 psi
F5 99.98% pure 793 kPa / 8 bar 4250 l/h 150 scfh
nitrogen-hydrogen (F5 = 95% Nitrogen, 5% Hydrogen) 115 psi
Ar argon 99.99% pure 793 kPa / 8 bar 4250 l/h 150 scfh
* ISO standard 8573-1 Class 1.4.2 requirements are:

• Particulates – no more than 100 particles per cubic meter of air at a size of 0.1 to 0.5 microns in the largest
dimension and 1 particle per cubic meter of air at a size of 0.5 to 5.0 microns in the largest
dimension.
• Water – the pressure dewpoint of the humidity must be less than or equal to 3° C (37.4° F).
• Oil – the concentration of oil can be no more than 0.1 mg per cubic meter of air.
Mild steel Stainless steel Aluminum
Gas types Plasma gas Shield gas Plasma gas Shield gas Plasma gas Shield gas
Cutting 30 to 50 A O2 O2 N2 & F5 N2 Air Air
Cutting 80 A O2 Air F5 N2 – –
Cutting 130 A O2 Air N2 & H35 N2 H35 & Air N2 & Air
Cutting 200 A O2 Air N2 & H35 N2 N2 & H35 N2
Cutting 260 A O2 Air N2 & H35 N2 N2 & H35 N2 & Air
Cutting 400 A O2 Air N2 & H35 N2 & Air N2 & H35 N2 & Air

Specifications
Power supply
General
Maximum OCV (U0) 360 VDC
Maximum output current (I2) 400 Amps
Output voltage (U2) 50 – 200 VDC
Duty cycle rating (X) 100% @ 80 kw, 40° C (104° F)
Power supplies will operate between -10° C and +40° C
Ambient temperature/Duty cycle
(+14° and 104° F)
Power factor (cosϕ) 0.98 @ 400 ADC output
Cooling Forced air (Class F)
Insulation Class H
Power supply
part numbers AC Voltage Frequency Amperage Power kVA
Phase Regulatory (+/- 10%)
Without With (U1) (Hz) (I1) approval (U1 x I1 x 1.73)
Hypernet Hypernet
078523 078570 200/208 3 50/60 262/252 CSA 90.6
078524 078571 220 3 50/60 238 CSA 90.6
078525 078572 240 3 60 219 CSA 90.6
078526 078573 380* 3 50/60 138 CCC 90.6
078527 078574 400 3 50/60 131 CE/GOST-R 90.6
078528 078575 440 3 50/60 120 CSA 90.6
078529 078576 480 3 60 110 CSA 90.6
078530 078577 600 3 60 88 CSA 90.6
* The 380 volt CCC regulatory approval only applies to 50 Hz operation
229 mm
9.00”
1270 mm
50.00”
851 kg
1877 lb
Approximate weight 1175 mm

of the heaviest unit 46.25”
870 mm
34.25”

Specifications
Cooler – 078531
• The cooling system can contain up to 34.5 liters (9 gallons) of coolant.
• Maximum cable length from the cooler to the power supply is 4.57 meters (15 ft).
• Maximum hose length from the cooler to the ignition console is 76.2 meters (250 ft).
• Allow 1 m (3 ft) of space on all sides of the cooler for ventilation and service.
76 mm To the filter on
3.00” the rear of the
cooler
75 kg
165 lb
895 mm
895 mm 35.25”
35.25”
Weight with no
coolant
457 mm
622 mm 18.00”
24.50”

Specifications
Ignition console – 078172

• The ignition console can be mounted remotely on the cutting table’s bridge. See Installation section for details.
• Maximum cable length from the ignition console to the torch lifter station is 15 m (50 ft). Allow room to remove
the top for servicing.
• The ignition console may be mounted horizontally or vertically.
283 mm
11.125”
219 mm
8.625”
194 mm 9.1 kg
7.625” 20 lb
216 mm
8.5”
152 mm
6”

Specifications
Mounted on table
Horizontal mounting
Vertical mounting

Specifications
Selection console – 078533

• Maximum cable length from the power supply to the selection console is 75 m (250 ft).
• Maximum cable length from the selection console to the metering console is 20 m (65 ft).
• Mount the selection console on top of the power supply or near the CNC on the cutting table. Allow room to
open the top for servicing.
285.75 mm 355.6 mm
11.25” 14.00”
311.15 mm
12.25”
13.6 kg
30 lb
314.5 mm
12.38”
38.1 mm
1.5”
0
0 76.2 mm 254.0 mm
3.0” 10.0”

Specifications
Metering console – 078535

• Maximum cable length from the metering console to the torch lifter station is 1.8 m (6 ft).
• Mount the metering console to the torch carriage on larger tables. On smaller tables it can be mounted to a
bracket just above the bridge.
• The vent hole on the console must be kept clear at all times.
155.58 mm 285.75 mm
6.125” 11.25”
263.53 mm
10.375”
Vent hole. Do not block.
153.9 mm
6.1”
122.2 mm
4.8”
76.2 mm
3.0”
6.4 kg
14 lb
33.3 mm
1.3”
0 54.9 mm 248.9 mm 282.5 mm

2.2” 9.8” 11.1”

Specifications
Torch – 228354
• The outside diameter of the torch mounting sleeve is 50.8 mm (2.0 in).
• The minimum bend radius for the torch leads is 152.4 mm (6.0 in).
1.8 m
6’
49 mm
194 mm 1.91”
7.62”
104 mm
4.10”
51 mm 51 mm 57 mm
2.00” 2” 2.25”
95 mm
3.74”
43 °
346 mm
13.63”
1.9 kg
4.2 lb

Specifications
IEC symbols
The following symbols may appear on the power supply data plate, control labels, switches, LEDs, and LCD screen.
Direct current (DC) l Power is ON
Alternating current (AC) O Power is OFF
1~ f 1
f2
An inverter-based power
Plasma torch cutting source, either 1-phase or
3-phase
Plate metal cutting Volt/amp curve, “drooping”

characteristic
Expanded metal cutting

AC
Power is ON (LED)
Gouging System fault (LED)
AC input power connection Inlet gas pressure fault (LCD)
The terminal for the

Missing or loose consumables
external protective
(LCD)
(earth) conductor
Power supply is out of

temperature range (LCD)

Section 3
Installation
In this section:
Upon receipt................................................................................................................................................................................................3-3
Claims............................................................................................................................................................................................................3-3
Noise levels..................................................................................................................................................................................................3-3
Placement of system components..........................................................................................................................................................3-3
Torque specifications......................................................................................................................................................................3-3
System components........................................................................................................................................................................3-5
Cables and hoses............................................................................................................................................................................3-5
Supply gas hoses.............................................................................................................................................................................3-5
Customer-supplied power cable..................................................................................................................................................3-5
Recommended grounding and shielding practices............................................................................................................................3-6
Introduction..................................................................................................................................................................................................3-6
Types of grounding..........................................................................................................................................................................3-6
Steps to take.....................................................................................................................................................................................3-7
Grounding diagram....................................................................................................................................................................... 3-10
Placement of the power supply............................................................................................................................................................ 3-11
Lifting the power supply............................................................................................................................................................... 3-12
Install the ignition console...................................................................................................................................................................... 3-14
Placement of the cooler......................................................................................................................................................................... 3-16
Install the metering console................................................................................................................................................................... 3-17
Placement of the selection console..................................................................................................................................................... 3-18
Power supply to ignition console leads.............................................................................................................................................. 3-20
Pilot arc lead................................................................................................................................................................................... 3-20
Negative lead.................................................................................................................................................................................. 3-20
Ignition console power cable...................................................................................................................................................... 3-22
Coolant hoses........................................................................................................................................................................................... 3-23
Power supply to cooler cables............................................................................................................................................................. 3-24
Control cable.................................................................................................................................................................................. 3-24
Power cable.................................................................................................................................................................................... 3-24
Power supply to selection console cables......................................................................................................................................... 3-26
Control cable.................................................................................................................................................................................. 3-26

Installation
Power cable.................................................................................................................................................................................... 3-26

Selection console to metering console connections...................................................................................................................... 3-28
Cable and gas hose assembly................................................................................................................................................... 3-28
Power supply to CNC interface cable................................................................................................................................................ 3-30
Optional multi-system CNC interface cable........................................................................................................................... 3-30
Notes to CNC interface cable run list...................................................................................................................................... 3-31
Examples of output circuits......................................................................................................................................................... 3-32
Examples of input circuits............................................................................................................................................................ 3-33
Remote ON/OFF switch (provided by customer)............................................................................................................................ 3-34
Torch lead assembly............................................................................................................................................................................... 3-35
Work lead.................................................................................................................................................................................................. 3-36
Connect the torch to the torch lead assembly....................................................................................................................... 3-37
Connect the torch to the quick-disconnect............................................................................................................................ 3-41
Torch mounting and alignment............................................................................................................................................................. 3-42
Mounting the torch........................................................................................................................................................................ 3-42
Torch alignment............................................................................................................................................................................. 3-42
Torch lifter requirement.......................................................................................................................................................................... 3-43
HyperNet.................................................................................................................................................................................................... 3-43
Power requirements................................................................................................................................................................................ 3-44
General............................................................................................................................................................................................ 3-44
Line disconnect switch................................................................................................................................................................ 3-45
Main power cable.......................................................................................................................................................................... 3-45
Connect the power.................................................................................................................................................................................. 3-46
Torch coolant requirements................................................................................................................................................................... 3-47
Premixed coolant for standard operating temperatures....................................................................................................... 3-47
Custom Coolant mix for cold operating temperatures.......................................................................................................... 3-48
Custom Coolant mix for hot operating temperatures............................................................................................................ 3-49
Water purity requirements..................................................................................................................................................................... 3-49
Fill the cooler with coolant..................................................................................................................................................................... 3-50
Gas requirements.................................................................................................................................................................................... 3-51
Setting the supply regulators...................................................................................................................................................... 3-51
Gas regulators.......................................................................................................................................................................................... 3-52
Supply gas plumbing.............................................................................................................................................................................. 3-53
Connect the supply gases.......................................................................................................................................................... 3-54
Supply gas hoses.................................................................................................................................................................................... 3-55

Installation
Upon receipt
• Verify that all system components on your order have been received. Contact your supplier if any items
are missing.
• Inspect the system components for any physical damage that may have occurred during shipping. If there is
evidence of damage, refer to Claims. All communications regarding claims must include the model number and
serial number located on the rear of the power supply.
Claims
Claims for damage during shipment – If your unit was damaged during shipment, you must file a claim with the
carrier. Hypertherm will furnish you with a copy of the bill of lading upon request. If you need additional assistance, call
Customer Service listed in the front of this manual, or your authorized Hypertherm distributor.
Claims for defective or missing merchandise – If any of the merchandise is defective or missing, contact your
supplier. If you need additional assistance, call Customer Service listed in the front of this manual, or your authorized
Hypertherm distributor.
Installation requirements
All installation and service of the electrical and plumbing systems must conform to national and local
electrical and plumbing codes. This work should be performed only by qualified, licensed personnel.
Direct any technical questions to the nearest Hypertherm Technical Service Department listed in the front of this manual,
or your authorized Hypertherm distributor.
Noise levels
Acceptable noise levels as defined by national and local codes may be exceeded by this plasma system. Always
wear proper ear protection when cutting or gouging. Any noise measurements taken are dependant on the specific
environment in which the system is used. See also Noise can damage hearing in the Safety section of this manual.
Specific information by product can be found in the Hypertherm downloads library at:
https://www.hypertherm.com/Xnet/library/DocumentLibrary.jsp
Select the product you are looking for from the Product Type drop down menu, choose “Regulatory” from the Category
drop down menu, and choose “Acoustical Noise Data Sheets” from the Sub Category drop down menu. Hit Submit.
Placement of system components

• Place all system components in position prior to making electrical, gas, and interface connections. Use the
diagram in this section for component-placement guidelines.
• Ground all system components to earth. See Recommended grounding and shielding practices in this section
for details.
• To prevent leaks in the system, tighten all gas and water connections as shown below:
Torque specifications
Gas or water hose
size kgf-cm lbf-in lbf-ft
Up to 10 mm (3/8 in) 8.6-9.8 75-85 6.25-7
12 mm (1/2 in) 41.5-55 360-480 30-40

2WRENCHES

Installation
Installation requirements
18 A B
5
6 1
C D
3
4
9
12
13
17
8 17
7 E 16
15 F
15
14
10 11

Installation
System components
A Power supply
B Ignition console
C Cooler
D Metering console
E Selection console
F Torch
Cables and hoses

1 Pilot arc lead
2 Negative lead
3 Ignition console power cable
4 Coolant hoses
5 Cooler control cable

6 Cooler power cable
7 Selection console control cable
8 Selection console power cable
9 Selection console to metering console hose and lead assembly
10 CNC interface cable
11 Optional CNC interface cable for systems with multiple power supplies
12 Torch lead assembly
13 Work lead
Supply gas hoses

14 Oxygen
15 Nitrogen or argon

16 Air
17 Argon-hydrogen (H35) or nitrogen-hydrogen (F5)
Customer-supplied power cable

18 Main power cable

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.
Introduction
This document describes the grounding and shielding necessary to protect a plasma cutting system installation against
radio frequency interference (RFI) and electromagnetic interference (EMI) noise. It addresses the three grounding
systems described below. There is a diagram on page 3-4 for reference.
Note: These procedures and practices are not known to succeed in every case to eliminate RFI/EMI noise
issues. The practices listed here have been used on many installations with excellent results, and we
recommend that these practices be a routine part of the installation process. The actual methods
used to implement these practices may vary from system to system, but should remain as consistent
as possible across the product line.
Types of grounding
A. The safety (PE) or service ground. This is the grounding system that applies to the incoming line voltage. It prevents
a shock hazard to any personnel from any of the equipment, or the work table. It includes the service ground coming
into the plasma power supply and other systems such as the CNC controller and the motor drivers, as well as the
supplemental ground rod connected to the work table. In the plasma circuits, the ground is carried from the plasma
power supply chassis to the chassis of each separate console through the interconnecting cables.
B. The DC power or cutting current ground. This is the grounding system that completes the path of the cutting current
from the torch back to the power supply. It requires that the positive lead from the power supply be firmly connected
to the work table ground bus with a properly sized cable. It also requires that the slats, on which the workpiece rests,
make good contact with the table and the workpiece.
C. RFI and EMI grounding and shielding. This is the grounding system that limits the amount of electrical “noise”
emitted by the plasma and motor drive systems. It also limits the amount of noise that is received by the CNC and
other control and measurement circuits. This grounding/shielding process is the main target of this document.
11-08

Installation
Steps to take
1. Unless noted, use only 6 AWG (16 mm2) welding cable (Hypertherm part no. 047040) for the EMI ground cables
shown on the diagram.
2. The cutting table is used for the common, or star, EMI ground point and should have threaded studs welded to the
table with a copper bus bar mounted on them. A separate bus bar should be mounted on the gantry as close to
each drive motor as possible. If there are drive motors at each end of the gantry, run a separate EMI ground cable
from the far drive motor to the gantry bus bar. The gantry bus bar should have a separate, heavy EMI ground cable
(4 AWG (21,2 mm2) part no. 047031) to the table bus bar. The EMI ground cables for the torch lifter and the RHF
console must each run separately to the table ground bus.
3. A ground rod that meets all applicable local and national electrical codes must be installed within 6 m (20 ft)
of the table. This is a PE ground and should be connected to the ground bus on the cutting table with 6 AWG
(16 mm2) green/yellow grounding cable (Hypertherm part number 047121) or equivalent. All PE grounds are shown
on the diagram in green.
4. For the most effective shielding, use the Hypertherm CNC interface cables for I/O signals, serial communication
signals, power supply-to-power supply multi-drop connections, and interconnections between all parts of the
Hypertherm system.
5. All hardware used in the ground system must be brass or copper. The only exception is that the studs welded to the
table for mounting the ground bus can be steel. Under no circumstances should aluminum or steel hardware be used.
6. AC power, PE, and service grounds must be connected to all equipment according to local and national codes.
7. * The positive, negative, and pilot arc leads should be bundled together for as long a distance as possible.
The torch lead, work lead, and the pilot arc (nozzle) leads may only be run parallel to other wires or cables if they
are separated by at least 150 mm (6 in). If possible, run power and signal cables in separate cable tracks.
8. * The ignition console should be mounted as close as possible to the torch, and must have a separate ground cable
to the bus bar on the cutting table.
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.
10. The metal braided shield on the torch leads must be connected firmly to the ignition console and to the torch.
It must be electrically insulated from any metal and from any contact with the floor or building. The leads can be
run in a plastic cable tray (track) or covered with a plastic or leather sheath.
11. The torch holder and the torch breakaway mechanism – the part mounted to the lifter, not the part mounted on
the torch – must be connected to the stationary part of the lifter with copper braid at least 12.7 mm (1/2 in) wide.
A separate cable must run from the lifter to the bus bar on the gantry. The valve assembly should also have a
separate ground connection to the gantry bus bar.
* Applies to systems that use a remote high frequency (RHF) console
11-08

Installation
12. If the gantry runs on rails that are not welded to the table, then the rails need to be connected with a ground cable
from each end of both rails to the table. These need not go to the common (star) point, but could take the shortest
path to the table.
13. If the OEM is installing a voltage divider to process arc voltage for use in the control system, the voltage divider
board should be mounted as close as possible to the point where the arc voltage is sampled. One acceptable
location is inside the plasma power supply. If the Hypertherm voltage divider board is used, the output signal is
isolated from all other circuits. The processed signal should be run in twisted, shielded cable (Belden type 1800F
or equivalent). The cable used must have a braided shield, not a foil shield. The shield should be connected to the
chassis of the power supply and left unconnected at the other end.
14. All other signals (analog, digital, serial, encoder) should run in twisted pairs inside a shielded cable. Connectors on
these cables should have a metal housing and the shield, not the drain, should be connected to the metal housing
of the connectors at each end of the cable. Never run the shield or the drain through the connector on any of the
pins.
Power
supply Remote
Ground rod lead (+) high frequency
(RHF) console
Gantry
CNC enclosure
Torch holder
Power supply
chassis
Example of a good cutting table ground bus. The picture above shows the connection from the
gantry ground bus, the connection from the ground rod, the power supply positive lead, the RHF
console*, the CNC enclosure, the torch holder, and the power supply chassis.

Installation
Cable to ground
bus on the Component
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. A single heavy cable then goes from the gantry ground bus to the
ground bus bolted to the table.

**
3-10
Command RHF Metering Gas/Selection CNC
THC console console console console
Bus bar
Installation
Gantry
Command
THC
**
Bus bar Cooler
Ground rod
Cutting table
Positive DC
Plasma
power supply
Grounding diagram (some systems will not include all the components shown)
** The lifter assembly and the RHF console each
require a separate path to the cutting table
AC earth/service ground Chassis and RFI ground ground bus bar.
HPR400XD Auto Gas – 806160 Revision 3

Installation
A Placement of the power supply
DANGER
Electric Shock Can Kill
Remove all electrical connections to the power supply before moving or positioning. Transporting the
unit can cause personal injury and equipment damage.
The power supply can be moved by forklift but the forks must be long enough to extend the entire length of the base.
Take care when lifting so that the underside of the power supply is not damaged. The forks must also be centered front
to back and side to side to prevent tipping while moving. Fork lift speeds should be kept to a minimum, especially when
making a turn or going around a corner.
• Place the power supply in an area that is free of excessive moisture, has proper ventilation and is relatively clean.
Allow 1 m (3 ft) of space on all sides of the power supply for ventilation and service.
• Cooling air is drawn in through the front panel and is exhausted through the rear of the unit by a cooling
fan. Do not place any filter device over the air intake locations, which reduces cooling efficiency and VOIDS
THE WARRANTY.
• Do not place the power supply on an incline greater than 10° to prevent it from toppling.
HPR400XD power supplies with serial number HPR400-000560 or later can be upgraded to a HPR800XD
primary or secondary power supply.

Installation
Lifting the power supply
DANGER
The HPR400XD power supply weighs approximately 746 kg (1645 lbs). 1 or 2 person manual pushing
or lifting could cause injury. Use appropriate lifting aids and techniques when moving a power
supply
A strap kit (228336) for lifting the HPR400XD is available from Hypertherm. The strap kit should only be used to lift the
HPR400 as outlined herein. Before using the strap kit, the customer understands and assumes exclusive responsibility
for supplying personnel trained and qualified to operate forklifts, cranes, hoists and other lifting devices to lift or move
the power supply. All movement of the power supply must be done in compliance with applicable local laws and
regulations. All handling equipment must be evaluated for each application and inspected and tested before each use.
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. The customer agrees to observe and
ensure compliance with the following:
• The straps and other handling equipment must comply with applicable local standards, laws and regulations.
• The rated capacity, design factor, and efficiency rating of the lifting system, including the straps sold by
Hypertherm, may be affected by wear, misuse, overloading, corrosion, deformation, intentional alteration, age, and
other use conditions. An inspection of the straps by qualified personnel should be conducted before each use.
Worn or damaged straps may not be used, nor may they be altered or modified in any way.
• All 4 loops at the ends of the straps must be securely and properly attached to the lifting mechanism.
• The power supply is a nonsymmetrical load; ensure that an analysis by a qualified person is performed properly to
balance the load to prevent tipping and overloading of any one strap.
• All enclosure panels must be securely fastened before lifting the power supply.
• The lifting mechanism must be rated for the appropriate weight and be suitable for the strap size.
• Each strap should pass through all 4 holes in the base of the power supply and should not be twisted,
constricted, bunched or pinched.
Correct path for lifting straps
• Straps shall not be shortened or lengthened by knotting, twisting, choker hitching, or other means.
• The power supply should be lifted slowly, not more than 203 mm (8 in.) above the floor, to insure that the weight
is evenly distributed.
• The power supply should be moved slowly to prevent sudden acceleration and deceleration when moving.
• Access to the area should be restricted when moving or lifting to prevent injury of personnel if the power supply
shifts or tips.

Installation
• Personnel should never be allowed to place themselves or any part of the body under the equipment, or between
the equipment and walls or other solid objects.
• Store straps in a proper manner such that they are not subjected to mechanical, chemical, or ultraviolet damage,
or to extreme temperatures.
In the United States, OSHA regulates slings in 29 CFR 1910.184. This regulation covers general requirements, basic
definitions, safe operating practices, inspections of the various types of slings. Read the OSHA regulations and OSHA
sling guidelines carefully before moving the power supply, and observe all requirements and recommendations for safe
handling in 29 CFR 1910.184 and other applicable sections. If there is any question respecting the interpretation or
application of these or other OSHA regulations, you should consult appropriate legal counsel.
Hypertherm slings are not for sale In Europe, where locally purchased slings are required to have “CE Marking.” In
the UK the interpretation of the European Directives translated into the following UK Statutory Instruments (SI): SI
2306 PUWER, The Provision and Use of Work Equipment Regulations and SI 2307 LOLER, Lifting Operations Lifting
Equipment Regulations. Reference to the European Directives may not be construed to mean that the strap kit may be
used in other countries or jurisdictions.
The body responsible for the workplace where the equipment is to be installed needs to ensure all applicable local
regulations are followed, and Hypertherm assumes no responsibility or liability therefore. The customer assumes
exclusive responsibility for ensuring that all local laws and regulations are followed, including those applicable to the use
of equipment and work place conditions.

Installation
B Install the ignition console

• Mount the ignition console in a vertical or horizontal position.
• Allow room to remove the top for servicing
32 mm 184 mm
1.25 in 7.25 in
216 mm
8.50 in
32 mm
1.25 in
248 mm
9.75 in
279 mm
11.00 in
7 mm
0.28 in
(4 places)
Ignition console grounding

Installation
Horizontal RHF mounting
Vertical RHF mounting

Installation
C Placement of the cooler

• Place the cooler in an area that is free of excessive moisture, has proper ventilation, and is relatively clean. Allow
1 m (3 ft) of space on all sides of the power supply for ventilation and service.
• Cooling air is drawn in through the front panel and is exhausted through the rear of the unit by a cooling fan. Do
not place any filter device over the air intake locations, which reduces cooling efficiency and VOIDS
THE WARRANTY.
• Do not place the cooler on an incline greater than 10° to prevent it from toppling.

Installation
D Install the metering console

• Mount the metering console near the torch lifter station. The maximum length of the gas hoses between the
metering console and the torch is 1.8 m (6 ft).
Metering console grounding
Vent hole:
Do not block
153.9 mm
6.1 in
122.2 mm
4.8 in
7 mm
0.28 in
(4 places)
76.2 mm
3.0 in
33.3 mm
1.3 in
0 54.9 mm 248.9 mm 282.5 mm

2.2 in 9.8 in 11.1 in

Installation
E Placement of the selection console

• Mount the selection 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 selection console is 75 m (250 ft). The maximum length of cables and hoses between the selection
console and the metering console assembly is 20 m (65 ft).
Preferred selection
console orientation
Selection console grounding
314.5 mm
12.38 in
7 mm
0.28 in
(4 places)
38.1 mm
1.5 in
0
0 76.2 mm 254.0 mm
3.0 in 10.0 in

Installation
This page is blank intentionally

Installation
Power supply to ignition console leads
1 Pilot arc lead
Ignition console I/O board
Part no. Length Part no. Length

123820 3 m (10 ft) 123735 25 m (82 ft)
123821 4.5 m (15 ft) 123668 35 m (115 ft)
123666 7.5 m (25 ft) 123669 45 m (150 ft)
123822 10 m (35 ft) 123824 60 m (200 ft)
123667 15 m (50 ft) 123825 75 m (250 ft)
123823 20 m (65 ft)
2 Negative lead
Ignition console Power supply

123418 3 m (10 ft) 123996 25 m (82 ft)
023382 4.5 m (15 ft) 123997 35 m (115 ft)
023078 7.5 m (25 ft) 023081 45 m (150 ft)
123994 10 m (35 ft) 023188 60 m (200 ft)
023079 15 m (50 ft) 023815 75 m (250 ft)
123995 20 m (65 ft)
Pilot arc lead
Negative lead

Installation
1
Pilot arc lead
2
Negative lead
Work lead
1
Pilot arc lead
2
Negative lead
2

Installation
3 Ignition console power cable
Female end to ignition console
Part no. Length Part no. Length Cable signal list – power supply to ignition console
123419 3 m (10 ft) 123425 22.5 m (75 ft)
Power supply end Ignition console end
123834 4.5 m (15 ft) 123736 25 m (82 ft)
Pin No. Description Pin No.
123420 6 m (20 ft) 123426 30 m (100 ft)
123670 7.5 m (25 ft) 123672 35 m (115 ft) 1 120 VAC-Hot 1
123422 9 m (30 ft) 123938 37.5 m (125 ft) 2 120 VAC-Return 2
123835 10 m (35 ft) 123673 45 m (150 ft)
3 Ground 3
123423 12 m (40 ft) 123837 60 m (200 ft)
123671 15 m (50 ft) 123838 75 m (250 ft) 4 Not used 4
123836 20 m (65 ft)
3
3

Installation
4 Coolant hoses Caution: Never use teflon

tape on any joint
preparation.
Red
Green

128499 1.5 m (5 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 45 m (150 ft)
128173 10 m (35 ft) 028637 60 m (200 ft)
028442 15 m (50 ft) 128985 75 m (250 ft)
Green
Red

Installation
Power supply to cooler cables
5 Control cable
Female end to cooler
Part no. Length

123844 1.5 m (5 ft)
123784 3 m (10 ft)
123839 4.5 m (15 ft)
Cable signal list – power supply to cooler (9-pin DSUB connectors)

Power supply end Cooler end
Pin No. Wire color Input/Output Description Pin No. Input/Output Function
2 Black Input/Output CAN L 2 Input/Output CAN communication
3 Black Input CAN ground 3 Output Power ground
7 Red Input/Output CAN H 7 Input/Output CAN communication
9 Red Input Not used 9 Output Not used
6 Power cable
Female end to cooler
Part no. Length

123979 1.5 m (5 ft)
123980 3 m (10 ft)
123981 4.5 m (15 ft)
Cable signal list – power supply to cooler

Power supply end Cooler end
Pin No. Wire color Description Pin No. Function
8 Black 120 VAC-Hot 8 Coolant solenoid (V1)
13 White 120 VAC-Return 13 Coolant solenoid (V1)
4 Shield 4 Ground
12 Black 240 VAC-Hot 12 Cooler fan
16 Yellow 240 VAC-Return 16 Cooler fan
7 Shield 7 Ground
11 Black 240 VAC-Hot 11 Pump motor
15 Blue 240 VAC-Return 15 Pump motor
6 Shield 6 Ground

Installation
See note below
5
6
Note: The inductor on the pump motor drive board makes a noise during operation that has been
described as a “hum”, “sing”, and “click”. This is normal and can be disregarded.

Installation
Power supply to selection console cables
7 Control cable

123784* 3 m (10 ft) 123841 20 m (65 ft)
123839 4.5 m (15 ft) 123737 25 m (82 ft)
123963 6 m (20 ft) 123738 35 m (115 ft)
123691 7.5 m (25 ft) 123739 45 m (150 ft)
123840 10 m (35 ft) 123842 60 m (200 ft)
123711 15 m (50 ft) 123843 75 m (250 ft)
Cable signal list – power supply to selection console

Power supply end Gas console end
Pin No. Input/Output Description Pin No. Input/Output Function
1 Not used 1 Not used
2 Input/Output CAN L 2 Input/Output CAN serial communication
7 Input/Output CAN H 7 Input/Output CAN serial communication
3 CAN ground 3 CAN ground reference
8 Power cable
Cable signal list – power supply to selection console

Power supply end Gas console end
Pin No. Description Pin No.
1 120 VAC-Hot 1
123785* 3 m (10 ft) 123848 20 m (65 ft)
123846 4.5 m (15 ft) 123740 25 m (82 ft) 2 120 VAC-Return 2
123964 6 m (20 ft) 123676 35 m (115 ft) 3 Ground 3

123674 7.5 m (25 ft) 123677 45 m (150 ft) 4 Not used 4
123847 10 m (35 ft) 123849 60 m (200 ft)
5 Not used 5
123675 15 m (50 ft) 123850 75 m (250 ft)
6 24 VAC-Hot 6
7 24 VAC-Return 7
* Cable numbers 123784 and 123785 are for use with systems that have the gas console mounted on the power supply

Installation

Installation
Selection console to metering console connections
9 Cable and gas hose assembly Part no. Length

128992 3 m (10 ft)
128993 4.5 m (15 ft)
228338 6 m (20 ft)
128952 7.5 m (25 ft)
128994 10 m (35 ft)
128930 15 m (50 ft)
128995 20 m (65 ft)
Power cable signal list – 9-pin connectors

Metering console end Selection console end
1 Input 120 VAC power 1 Output AC in, return
2 Input 120 VAC power 2 Output AC in, hot
3 Input Chassis ground 3 Output Chassis ground
Female end to metering console Male end to selection console
Typical female DSUB connector
Communication cable signal list – 9-pin DSUB connectors

Metering console end Selection console end
2 Input/Output CAN L 2 Input/Output CAN communication
3 Input CAN ground 3 Output Power ground
7 Input/Output CAN H 7 Input/Output CAN communication
9 Input Not used 9 Output Not used

Installation
Caution: Never use teflon

tape on any joint
preparation.

Installation
10 Power supply to CNC interface cable

Part no. Length Part no. Length Part no. Length
123210 3 m (10 ft) 123216 13.5 m (45 ft) 123742 35 m (115 ft)
123211 4.5 m (15 ft) 123023 15 m (50 ft) 123219 37.5 m (125 ft)
To J 300
123212 6 m (20 ft) 123494 16.5 m (55 ft) 123220 45 m (150 ft)
123022 7.5 m (25 ft) 123851 20 m (65 ft) 123852 60 m (200 ft)
123213 9 m (30 ft) 123217 22.5 m (75 ft) 123853 75 m (250 ft)
123214 10 m (35 ft) 123741 25 m (82 ft)
123215 12 m (40 ft) 123218 30 m (100 ft)
11 Optional multi-system CNC interface cable (see schematics for installation information)
Power supply
end CNC end
Wire Input/ Input/
color Pin no. Output Signal name Function Output Notes
Black 1 Input Rx – RS-422 serial receiver Output
Red 20 Input Rx + RS-422 serial receiver Output
Black 2 Output Tx – RS-422 serial transmitter Input
Green 21 Output Tx + RS-422 serial transmitter Input
Black 3 RS-422 ground RS-422 serial ground
Blue 22 None Not used
Black 4 Output Motion 1 E (–) Notifies the CNC that an arc transfer has occurred and to begin Input
2&3
Yellow 23 Output Motion 1 C (+) machine motion once the CNC’s pierce delay has timed out Input
Black 5 Output Error E (–) Input
Notifies the CNC that an error has occurred 2
Brown 24 Output Error C (+) Input
Black 6 Output Rampdown error E (–) Input
Notifies the CNC that a rampdown error has occurred 2
Orange 25 Output Rampdown error C (+)
Red 7 Output Not ready E (–) Input
Notifies the CNC that the plasma system is not ready to fire an arc 2
White 26 Output Not ready C (+)
Red 8 Output Motion 2 E (–) Notifies the CNC that an arc transfer has occurred and to begin Input
2&3
Green 27 Output Motion 2 C (+) machine motion once the CNC’s pierce delay has timed out Input
2&3
Blue 28 Output Motion 3 C (+) machine motion once the CNC’s pierce delay has timed out Input
2&3
Yellow 29 Output Motion 4 C (+) machine motion once the CNC’s pierce delay has timed out Input
Red 11 None Not used
Brown 30 None Not used
The CNC Notifies the plasma system that a corner is approaching
Red 12 Input Corner (–) Output
and to reduce cut current (Cut current is CNC selectable or 1
Orange 31 Input Corner (+) Output
defaults to 50% of cut current)
Green 13 Input Pierce (–) The CNC Notifies the plasma system to maintain the shield preflow Output
1
White 32 Input Pierce (+) until the CNC releases the signal
Green 14 Input Hold (–) Not required without CommandTHC. CommandTHC requires a Output
1
Blue 33 Input Hold (+) signal to preflow gases during IHS
Green 15 Input Start (–) Output
The CNC initiates the plasma arc 1
Yellow 34 Input Start (+) Output
Green 16 None Not used
Brown 35 None Not used
Green 17 None Not used
Orange 36 Power ground Ground
White 18 Power ground Ground
4
Black 37 CNC +24 VDC Available 24 VDC (200 milliamps maximum) see notes
19 CNC +24 VDC Not connected

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
Note 2. Outputs are optically isolated, open collector, transistors. The maximum rating is 24 VDC at 10 mA.
Note 3. Machine motion is selectable and is used for configurations with multiple plasma systems.
Note 4.* CNC +24 VDC provides 24 VDC at 200 mA maximum. A jumper is required on J304 to use 24 V power.
Caution: The CNC cable must be constructed using cable with 360 degree shielding and
metal housing connectors at each end. The shielding must be terminated to the
metal housings at each end to ensure proper grounding and to provide the best
shielding.
* See example 1 on page 3-33

Installation
Examples of output circuits

1. Logic interface, active-high 5 VDC-24 VDC
HPR
C
+ CNC/PLC
-
10K
E
(optional)
High-impedance (≤10 mA)
2. Logic interface, active-low

5 VDC-24 VDC
10K
(optional)
HPR CNC/PLC
C
+
-
E High-impedance (≤10 mA)
3. Relay interface
CNC +24 V
+24 VDC CNC +24 V
Install a °t
Jumper
J304 HPR
108056 C
+ CNC/PLC
-
E High-current
contact closure
inputs (AC or DC)
External relay
24 VDC low-power coil
≤10 mA or ≥2400 ohms
All relay coils require a freewheeling diode
Power across the relay coil
ground
4. Do not use this configuration. Warranty will be void.

HPR Any voltage
C
VO
+ WA I
RR DS
-
AN
TY
E

Installation
Examples of input circuits
Note: The external relay’s life may be improved by adding a

metallized-polyester capacitor (0.022µF 100 V or higher)
in parallel with the relay contacts.
1. Relay interface
+24 VDC (See note 4 on page 3-31)
Output from
HPR
CNC/PLC
External relay
(AC or DC)
Power
ground
2. Optocoupler interface
+24 VDC
CNC/PLC
HPR
Transistor-output
optocoupler
Power
ground
3. Amplified-output interface
CNC/PLC +24 VDC

12V-24 VDC
HPR
Power
Active-high drive ground Power
ground

Installation
Remote ON/OFF switch (provided by customer)
DANGER
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. Remove wire 1 and wire 3 as shown. These wires do not need to be reconnected.
1 3
TB2 1 2 3
1 3
3. Connect switch to terminals 1 and 3 as shown.
1 3
TB2 1 2 3
Note: Use a switch, relay or solid-state relay that is compatible with 24 VAC @ 100 mA. It must be a maintained
contact switch, not a momentary contact switch.

Installation
12 Torch lead assembly Part no. Length

228291 2 m (6 ft)
228292 3 m (10 ft)
228293 4.5 m (15 ft)
228294 6 m (20 ft)
228295 7.5 m (25 ft)
228296 10 m (35 ft)
228297 15 m (50 ft)
Note: A 20 m (65 ft) torch

lead is not available for
HPR400XD systems
Blue
Black Plasma-gas vent hose
(white)
Caution: The length of the hoses Caution: Locate the exposed end
from the torch to the of the plasma-gas vent
metering console are hose away from sparks
10 caused by piercing
critical to cut quality
and consumable life. to avoid ignition and
possible damage to the
Do not alter the length
torch leads.
of the hoses.

Installation
13 Work lead
Work table Power supply

123418 3 m (10 ft) 123996 25 m (82 ft)
023382 4.5 m (15 ft) 123997 35 m (115 ft)
023078 7.5 m (25 ft) 023081 45 m (150 ft)
123994 10 m (35 ft) 023188 60 m (200 ft)
023079 15 m (50 ft) 023815 75 m (250 ft)
123995 20 m (65 ft)
Work lead
Work lead
Lower frame of work table (typical).

Installation
F Torch connections
Connect the torch to the torch lead assembly
1. Uncoil the first 2 meters (6.5 ft) of the leads on a flat surface.
2. Hold the torch assembly in place with the spanner wrench (104269) and remove the mounting sleeve from the torch
assembly.
3. Push back the braided cover and slide the sleeve over the leads. Align the torch with the hoses in the lead assembly.
The hoses must not be twisted. They are taped together to help prevent twisting.
Sleeve
Braided cover
4. Connect the coolant return hose (red).

Coolant return hose

tape on any joint
preparation.
2WRENCHES

Installation
5. Connect the pilot arc lead (yellow). Insert the connector into the torch receptacle and turn it by hand until it is tight.
6. Connect the optional ohmic contact wire.
6a. Route the ohmic contact wire through the opening in the braided cover and the torch sleeve.
Sleeve
Braided cover
6b. Insert the connector into the torch receptacle and turn it by hand until it is tight.
Ohmic contact wire part numbers (Not part of the HPR400XD system. Shown for reference only)
Part no. Length

123983 3 m (10 ft)
123984 6 m (20 ft)
123985 7.5 m (25 ft)
123986 9 m (30 ft)
123987 12 m (40 ft)
123988 15 m (50 ft)
123989 23 m (75 ft)
123990 30 m (100 ft)
123991 45 m (150 ft)

Installation
7. Connect the plasma-gas vent hose (white).
Note: The connectors in steps

7–10 are push-to-connect
fittings.
To make a connection, push

the hose fitting into the
appropriate connector until it
stops, 13 mm (0.5 in.).
connector-collar
8. Connect the coolant supply hose (green).

To disconnect a fitting, push
the connector-collar toward
the torch, and pull the hose
away from the torch.
9. Connect the plasma gas hose (black).
10. Connect the shield gas hose (blue).

Installation
11. Slide the torch sleeve over the connections and screw it onto the torch assembly.
12. Slide the braided cover up to the torch sleeve. Make sure that the plasma, shield and vent hoses are routed through
the hole in the braided cover. Loosen the hose clamp on the braided cover, slide the braided cover and clamp over
the sleeve and tighten the clamp.

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

220706 220705
Installation note
Align the torch body to the torch leads and secure by
screwing completely together. Be certain that there is no
space between the torch body and the o-ring on the torch
leads. See also Torch connections earlier in this section for
torch lead connections to ignition console.

Installation
Torch mounting and alignment
Mounting the torch
Installation
1. Install the torch (with torch leads
attached) in the torch mounting bracket.
Upper torch sleeve
2. Position the torch below the mounting
bracket, so that the bracket is around the
lower portion of the torch sleeve but not
Lower torch sleeve Torch mounting touching the torch quick-disconnect.
bracket
(customer supplied) 3. Tighten the securing screws.
Note: The bracket should be as low on the

Quick-disconnect torch sleeve as possible to minimize
receptacle vibration at the tip of the torch.
Torch alignment
To align the torch at right angles to the workpiece, use a square. See figure above.

Installation
Torch lifter requirement

The system requires a high-quality, motorized torch lifter with sufficient travel to cover all cutting thickness requirements.
The lifter must provide 203 mm (8 in) of vertical travel. The unit should have the capability of maintaining a constant
speed of up to 5080 mm/min (200 ipm) with positive braking. A unit which drifts through the stop point is not
acceptable.
HyperNet
HyperNet is only used to connect certain Hypertherm components to each other. An HPRXD system can be connected
to the ArcGlide® torch height control, and an EDGE® Pro or MicroEDGE® Pro CNC using an ethernet hub and cable.
The HyperNet PCB provides communication between components and is the source for the arc voltage needed for the
torch height control. See the ArcGlide instruction manual (806450), the EDGE Pro instruction manual (806360) or the
MicroEDGE Pro CNC instruction manual (807290) for more information.
Location of the Hypernet board

Installation
Power requirements
General
All switches, slow-blow fuses and power cables are customer-supplied and must be chosen as outlined by applicable
national and local electrical codes. Installation must be performed by a licensed electrician. Use a separate, primary, line
disconnect switch for the power supply. Recommendations on fuse and circuit breaker sizing are listed below, however
actual sizes required will vary based on individual site electrical line conditions (including but not limited to: source
impedance, line impedance, and line voltage fluctuation), product inrush characteristics, and regulatory requirements.
The main feed protection device (circuit breaker or fuse) must be sized to handle all branch-feed loads for both inrush
and steady-state current. The power supply must be wired into one of the branch-feed circuits. The power supply has a
steady-state current listed in the table below.
Use a motor-start circuit breaker or equivalent if time delay high inrush fuses are not permitted by local and national
codes. Time delay fuses and circuit breakers must be capable of withstanding inrush current that is up to 30 times the
rated input current (FLA) for 0.01 seconds and up to 12 times the rated input current (FLA) for 0.1 seconds.
Recommended
Rated time delay, Recommended cable size for 15 m
input current (FLA) high inrush (50 ft) maximum length
Input voltage Phase @ 80 kW output fuse size Rated for 90°C (194°F)
200/208 VAC 3 262/252 amps 325 amps 235 mm2 (350 MCM)
220 VAC 3 238 amps 300 amps 201.1 mm2 (300 MCM)
240 VAC 3 219 amps 275 amps 167.5 mm2 (250 MCM)
380 VAC 3 138 amps 175 amps 67.5 mm2 (2/0 AWG)
400 VAC 3 131 amps 175 amps 67.5 mm2 (2/0 AWG)
440 VAC 3 120 amps 150 amps 53.5 mm2 (1 AWG)
Note: Cable AWG recommendations taken from table 310-16 of the National Electric Code handbook (USA).

Installation
Line disconnect switch

The line disconnect switch serves as the supply-voltage disconnecting (isolating) device. Install
this switch near the power supply for easy access by the operator.
Installation must be performed by a licensed electrician and according to applicable national

and local codes.
The switch should: SWITCH BOX
• Isolate the electrical equipment and disconnect all live conductors from the supply
voltage when in the “OFF” position
• Have one “OFF” and one “ON” position clearly marked with “O” (OFF) and “l” (ON)
• Have an external operating handle capable of being locked in the “OFF” position
• Contain a power-operated mechanism that serves as an emergency stop
• Have slow-blow fuses installed for the proper breaking capacity (see table above).
18 Main power cable

Wire sizes vary based on the distance of the receptacle from the main box. The wire sizes listed in the table above were
taken from the National Electric Code 1990 handbook, table 310.16 (USA). Use a 4-conductor Type SO input power
cable with a conductor temperature rating of 90° C (194° F). Installation must be performed by a licensed electrician.

Installation
Connect the power
DANGER
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 and local safety procedures.
1. Insert the power cable through the strain relief at the rear of the power supply.
2. Connect the ground lead (PE) to the GROUND terminal ( ) of TB1 as shown below.
3. Connect the power leads to the terminals of TB1 as shown below.
4. Verify that the line disconnect switch is in the OFF position and remains in the OFF position for the remainder of the
installation of the system.
5. Connect the power cord leads to the line disconnect switch following national and local electrical codes.
North American wire colors European wire colors
U = Black U = Black
V = White V = Blue
W = Red W = Brown
(PE) Earth ground = Green/Yellow (PE) Earth ground = Green/Yellow
Line
disconnect
switch
U V W
TB1
Ground
W Power
V cable
U

Installation
torch coolant requirements

The system is shipped without any coolant in the tank. Before filling the coolant system, determine what coolant mix is
correct for your operating conditions.
Observe the warning and cautions below. Refer to the Material Safety Data Sheets appendix for data on safety,
handling and storage of propylene glycol and benzotriazole.
DANgER
coolANt cAN bE IRRItAtINg to SkIN AND EyES AND
HARmFUl oR FAtAl IF SwAllowED
Propylene glycol and benzotriazole are irritating to skin and eyes, and harmful or fatal if
swallowed. Upon contact, flush skin or eyes with water. If swallowed, seek immediate medical
attention.
caution: Never use automotive anti-freeze in place of propylene glycol. Antifreeze

contains corrosion inhibitors that will damage the torch coolant system.
Always use purified water in the coolant mixture in order to prevent damage
to the pump and corrosion in the torch coolant system.
Premixed coolant for standard operating temperatures

Use Hypertherm premixed coolant (028872) when operating in a temperature range of -12° C to 40° C
(10° F to 104° F). Refer to the custom coolant mix recommendations, if temperatures during operation are ever outside
of this range.
Hypertherm premixed coolant consists of 69.8% water, 30% propylene glycol, and 0.2% benzotriazole.
10/16/08

Installation
custom coolant mix for cold operating temperatures (below -12° c / 10° F)
caution: For operating temperatures colder than the temperature stated above,
the percentage of propylene glycol must be increased. Failure to do so
could result in a cracked torch head, hoses or other damage to the torch
coolant system due to freezing.
Use the chart below to determine what percentage of propylene glycol to use in the mixture.
Mix 100% glycol (028873) with the premixed Hypertherm coolant (028872) to increase the percentage of glycol. The
100% glycol solution can also be mixed with purified water (see next page for water purity requirements) to achieve the
required protection from freezing.
Note: Maximum percentage of glycol should never exceed 50%.
°c °F
4 40
-1 30
-7 20 Hypertherm pre-mix (028872)
-12 10
-18 0
temperature
-23 -10
-29 -20
Maximum glycol percentage
-34 -30
-40 -40
-46 -50
-51 -60
-57 -70
0 10 20 30 40 50 60
% of Propylene glycol
Freezing Point of Propylene glycol Solution
10/16/08

Installation
custom coolant mix for hot operating 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° C (32° F). For operations in very warm temperatures treated water will provide the best cooling properties.
Treated water refers to a mixture of purified water, that meets the specifications below, and 1 part benzotriazole (BZT)
to 300 parts of water. BZT (128020) acts as a corrosion inhibitor for the copper based coolant system contained in the
plasma system.
water purity requirements

It is critical to maintain a low level of calcium carbonate in the coolant to avoid reduced performance of the torch or
cooling system.
Always use water that meets the minimum and maximum specifications in the table below when using a custom coolant
mix.
Water that does not meet the minimum purity specifications below can cause excessive deposits on the nozzle that will
alter the water flow and produce an unstable arc.
Water that does not meet the maximum purity specifications below can also cause problems. Deionized water that is too
pure will cause leaching problems with the coolant system plumbing.
Use water purified by any method (deionization, reverse osmosis, sand filters, water softeners, etc.) as long as the water
purity meets the specifications in the table below. Contact a water specialist for advice in choosing a water filtration
system.
water purity measurement method
Conductivity Resistivity
μS/cm mΩ-cm Dissolved solids Grains per gallon
water purity at 25° C (77° F) at 25° C (77° F) (ppm of NaCl) (gpg of CaCO2)
Pure water (for reference only) 0.055 18.3 0 0
Maximum purity 0.5 2 0.206 0.010
Minimum purity 18 0.054 8.5 0.43
Maximum potable water

1000 0.001 495 25
(for reference only)
10/16/08

Installation
Fill the cooler with coolant

The cooling system’s capacity is 15.5 to 34.5 liters (4 to 9 gallons) of coolant, depending on the length of the torch
leads and coolant hoses.
Caution: sing the wrong coolant can cause damage to the system. Refer to Torch
U
Coolant Requirements in this section for more information.
Do not over fill the coolant tank.
1. Remove the filler cap and add coolant until the level in the sight glass
reaches full.
ON the power supply using the remote ON/OFF switch or the CNC.
2. Turn Sight glass
The coolant level in the tank will drop as the coolant circulates through the
system, and an error code (060 or 093) may occur.
3. Turn OFF the power.
4. Add coolant to the cooler until the level in the sight glass reaches full, and
turn ON the power.
5. Repeat this process as many times as necessary, until the pump can be run
continuously. This will allow coolant to completely fill the coolant loop and
purge any air from the system.
6. Replace the filler cap.

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 selection console. See gas regulators in this section for recommendations.
See the Specification section for gas and flow specifications. See Supply gas hoses at the end of this section for
recommendations.
Caution: Gas supply pressures not within the specifications in Section 2 can cause
poor cut quality, poor consumable life and operational problems.
If the purity level of the gas is too low or if there are leaks in the supply
hoses or connections,
• Cut speeds can decrease

• Cut quality can deteriorate
• Cutting thickness capability can decrease
• Parts life can shorten
Setting the supply regulators

1. Turn OFF the power to the system. Set all gas
regulator pressures to 8 bar (115 psi).
2. Turn ON the power to the system using the remote

ON/OFF switch or the CNC.
3. Set to Test Preflow.
4. While gas is flowing adjust the supply regulator for the

shield gas to 8 bar (115 psi).
5. Turn OFF Test Preflow.
6. Set system to Test Cutflow.
7. While gas is flowing adjust the supply regulator for the

plasma gas to 8 bar (115 psi).
8. Turn OFF Test Cutflow.

Installation
Gas regulators
Low-quality gas regulators do not provide consistent supply pressures and can result in poor cut quality and system
operation problems. Use a high-quality, 1-stage, gas regulator to maintain consistent gas supply pressure, if using liquid
cryogenic or bulk storage. Use a high-quality, 2-stage, gas regulator to maintain consistent gas supply pressure from
high pressure gas cylinders.
The high-quality gas regulators listed below are available from Hypertherm and meet U.S. Compressed Gas Association
(CGA) specifications. In other countries, select gas regulators that conform to national and local codes.
2-stage regulator Single stage regulator
Part
Number Description Qty.
128544 Kit: Oxygen, 2-stage * 1
128545 Kit: Inert Gas, 2-stage 1
128546 Kit: Hydrogen (H5, H35 and methane) 2-stage 1
128547 Kit: Air, 2-stage 1
128548 Kit: 1-stage (for use with cryogenic liquid nitrogen or oxygen) 1
022037 Oxygen, 2-stage 1
022038 Inert gas, 2-stage 1
022039 Hydrogen/methane, 2-stage 3
022040 Air, 2-stage 1
022041 Line regulator, 1-stage 1
* Kits include appropriate fittings

Installation
Supply gas plumbing

Rigid copper plumbing or suitable flexible hose may be used for all gas supplies. Do not use steel or aluminum pipe.
After installation, pressurize the entire system and check for leaks.
Recommended hose diameters are 9.5 mm (3/8 in) for lengths < 23 m (75 ft) and 12.5 mm (1/2 in) for
lengths > 23 m (75 ft).
For flexible-hose systems, use a hose designed for inert gas to carry air, nitrogen or argon-hydrogen. See the last page
of this section for hose part numbers.
Caution: Never use teflon tape on any joint preparation.
Caution: When connecting the selection console to the supply gases, make sure that
all hoses, hose connections and fittings are acceptable for use with oxygen
and argon-hydrogen. Installation must be made in accordance with national
and local codes.
Note: When cutting with oxygen as the plasma gas, air must also be connected to the selection console to
achieve the proper mixtures in the preflow and cutflow modes.
WARNING
CUTTING WITH OXYGEN CAN CAUSE FIRE OR EXPLOSION
Cutting with oxygen as the plasma gas can cause a potential fire hazard due to the oxygen-enriched
atmosphere that it creates. As a precaution, Hypertherm recommends that an exhaust ventilation
system be installed when cutting with oxygen.
Flashback arrestors are required (unless not available for specific gases or required pressures)
to prevent fire from propagating back to supply gas.

Installation
Connect the supply gases

Connect the supply gases to the selection console. Torch leads must be purged between gas changes.
Fitting Size
N2 / Ar 5/8 – 18, RH, internal (inert gas) “B”
Air 9/16 – 18, JIC, No. 6
H35 / F5 / H5 9/16 – 18, LH, (fuel gas) “B”
O2 9/16 – 18, RH, (oxygen) “B”
Caution: Replacing the fittings on the selection console may cause the internal valves
to malfunction, because particulates can migrate into the valves.

Installation
Supply gas hoses

14 Oxygen hose
tape on any joint
preparation.

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 60 m (200 ft)
024155 15 m (50 ft) 024762 75 m (250 ft)
024761 20 m (65 ft)
15 Nitrogen or argon hose

024210 3 m (10 ft) 024739 25 m (82 ft)
024203 4.5 m (15 ft) 024451 35 m (115 ft)
024134 7.5 m (25 ft) 024120 45 m (150 ft)
024211 10 m (35 ft) 024124 60 m (200 ft)
024112 15 m (50 ft) 024764 75 m (250 ft)
024763 20 m (65 ft)
16 Air hose

024671 3 m (10 ft) 024740 25 m (82 ft)
024658 4.5 m (15 ft) 024744 35 m (115 ft)
024659 7.5 m (25 ft) 024678 45 m (150 ft)
024765 10 m (35 ft) 024680 60 m (200 ft)
024660 15 m (50 ft) 024767 75 m (250 ft)
024766 20 m (65 ft)
17 Argon-hydrogen (H35) or nitrogen-hydrogen (F5)

024768 3 m (10 ft) 024741 25 m (82 ft)
024655 4.5 m (15 ft) 024742 35 m (115 ft)
024384 7.5 m (25 ft) 024743 45 m (150 ft)
024769 10 m (35 ft) 024771 60 m (200 ft)
024656 15 m (50 ft) 024772 75 m (250 ft)
024770 20 m (65 ft)

Installation

Section 4
Operation
In this section:
Daily start-up................................................................................................................................................................................................4-3
Check torch.......................................................................................................................................................................................4-3
Power indicators.........................................................................................................................................................................................4-4
General...............................................................................................................................................................................................4-4
Power supply.....................................................................................................................................................................................4-4
CNC controller requirements...................................................................................................................................................................4-5
CNC screen examples...............................................................................................................................................................................4-6
Main (control) screen.......................................................................................................................................................................4-6
Diagnostic screen............................................................................................................................................................................4-7
Test screen........................................................................................................................................................................................4-8
Cut chart screen...............................................................................................................................................................................4-9
Consumable selection............................................................................................................................................................................ 4-10
Standard cutting (0°).................................................................................................................................................................... 4-10
Bevel cutting (0° to 45°).............................................................................................................................................................. 4-10
Marking............................................................................................................................................................................................ 4-10
Consumables for mirror-image cutting..................................................................................................................................... 4-10
SilverPlus electrodes.................................................................................................................................................................... 4-10
Mild steel......................................................................................................................................................................................... 4-11
Stainless steel................................................................................................................................................................................ 4-12
Aluminum......................................................................................................................................................................................... 4-13
Mild steel bevel cutting................................................................................................................................................................ 4-14
Mild steel, thick piercing, bevel cutting.................................................................................................................................... 4-14
Stainless steel bevel cutting....................................................................................................................................................... 4-15
Install and Inspect consumables.......................................................................................................................................................... 4-16
Torch maintenance.................................................................................................................................................................................. 4-19
Routine maintenance.................................................................................................................................................................... 4-19
Quick-disconnect maintenance................................................................................................................................................. 4-19
Maintenance kit.............................................................................................................................................................................. 4-19
Replace torch water tube....................................................................................................................................................................... 4-20
Common cutting faults........................................................................................................................................................................... 4-21

Operation
How to optimize cut quality................................................................................................................................................................... 4-22

Tips for table and torch................................................................................................................................................................ 4-22
Plasma set-up tips........................................................................................................................................................................ 4-22
Maximize the life of consumable parts...................................................................................................................................... 4-22
Additional Factors of cut quality................................................................................................................................................. 4-23
Additional improvements............................................................................................................................................................. 4-25
Cut charts.................................................................................................................................................................................................. 4-26
Bevel cut charts............................................................................................................................................................................. 4-26
Bevel cutting definitions......................................................................................................................................................................... 4-27
Estimated kerf-width compensation.................................................................................................................................................... 4-28

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
DANGER
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.
1. Turn main disconnect switch to the power supply OFF.
2. Remove the consumables from the torch and check for worn or damaged parts. Always place the consumables
on a clean, dry, oil-free surface after removing. Dirty consumables can cause the torch to malfunction.
• Refer to Install and inspect consumables later in this section for details and for parts inspection tables.
• Refer to the Cut charts to choose the correct consumables for your cutting needs.
3. Replace consumable parts. Refer to Install and inspect consumables later in this section for details.
4. Ensure that the torch is perpendicular to the workpiece.
Shield cap Shield Nozzle retaining cap Nozzle Swirl ring Electrode Current ring Torch

Operation
Power indicators
General
Power for the system is controlled by the CNC. The power supply, selection console and metering console each have
an LED lamp that illuminates when power is supplied to the component.
Power supply
Green indicator
Selection console
Green indicator
Metering console

Operation
CNC controller requirements

Note: See appendix B, CNC interface protocol, for more detailed information.
Base required elements

The following elements should be able to be displayed and adjusted on the CNC for setup and basic system
information. The plasma system needs this group for basic setup and operation capability.
1. Remote ON/OFF
2. Ability to display and adjust the basic plasma process set-points (command ID No. 95)
a. Current set point
b. Plasma preflow
c. Plasma cutflow
d. Shield preflow
e. Shield cutflow
f. Plasma gas type
g. Shield gas type
h. Gas mixing set-points
3. Display basic system information
a. System error code
b. Gas and PS firmware version
4. Manual pump control
Required real time elements

The following elements should be able to be displayed in real time while cutting. This is necessary for troubleshooting
and diagnostic purposes.
5. Display line voltage
6. Display chopper current
7. Display work lead current
8. Display system status code
9. Display chopper temperature
10. Display transformer temperature
11. Display coolant temperature
12. Display coolant flow
13. Display pressure transducers
Required diagnostic elements

These elements provide additional diagnostic capability to the system for troubleshooting gas-delivery problems. The
CNC should be capable of executing these commands and displaying the relevant information for the respective test
according to the serial protocol guidelines.
14. Test preflow gases
15. Test cutflow gases
16. Inlet leak test
17. System leak test
18. System flow test

Operation
CNC screen examples

The screens shown are for reference. The screens you work with may be different, but should include the functions
listed on the previous page.
Main (control) screen

Operation
Diagnostic screen

Operation
Test screen

Operation
Cut chart screen

Operation
Consumable selection
Standard cutting (0°)
Most of the consumables on the following pages are designed for standard (straight) cutting, when the torch is
perpendicular to the workpiece.
Bevel cutting (0° to 45°)

Consumables for 130 amp and 260 amp bevel cutting are specifically designed for bevel cutting. 400 amp
consumables can be used for standard cutting and bevel cutting, but bevel-specific, 400 amp cut charts are provided
for convenience.
Marking
Any of the consumable sets can also be used for marking with argon or nitrogen. Marking parameters are shown at the
bottom of each cut chart. The quality of the marks will vary depending on the marking process, cut process, material
type, material thickness, and material surface finish. For best mark quality, use the argon marking process settings. For
all marking processes the depth of the mark can be increased by reducing the marking speed, or the depth can be
decreased by increasing the marking speed. Argon marking currents can be increased by up to 30% to increase the
depth of the mark. When marking with an argon process at 25 amps or greater, the process will start with air before
changing to argon, and a thicker, darker mark will be seen at the start of the mark. When using the argon marking
processes, mark and cut individual parts. Marking the entire nest prior to cutting may lead to reduced consumable life.
For better results intersperse cuts and marks. Poor quality marking or burn-through may occur with material less than
1.5 mm (0.06 in. or 16 gauge).
Consumables for mirror-image cutting

See the Parts List section in this manual for part numbers.
SilverPlus electrodes
SilverPlus electrodes provide increased life when the average cut duration is short (< 60 seconds), and cut quality is not
the most critical requirement. SilverPlus electrodes are available for 130 amp, 200 amp, and 260 amp mild steel O2 / Air
cutting. Part numbers can be found on the following page.

Operation
Mild steel
Nozzle Water
Shield cap Shield retaining cap Nozzle Swirl ring Electrode tube
30 A
220194 220754 220193 220180 220192
50 A
220555 220754 220554 220553 220552
220747 80 A
220189 220756 220188 220179 220187

220340
130 A
220183 220756 220182 220179 220181*
200 A
220761 220757 220354 220353 220352*
260 A
220764 220760 220439 220436 220435*

220637
400 A
220571
220636 220635 220632 220631 220629
* SilverPlus electrodes are available for these processes.
Mild steel, 130 amp, O2 / Air – 220665


Operation
Stainless steel
Nozzle Water
45 A
220202 220755 220201 220180 220308
80 A
220747 220338 220755 220337 220179 220339
130 A
220340
220198 220755 (H35) 220197 220179 220307
220756 (N2)
200 A
220762 220758 220343 220342 220307
260 A
220763 220758 220406 220405 220307

220637
400 A
220571
220707 220712 220708 220405 220709

Operation
Aluminum
Nozzle Water
45 A
220202 220756 220201 220180 220308
220747 130 A
220198 220755 (H35) 220197 220179 220307 (H35)

220756 (Air) 220181 (Air)
220340
200 A
220762 220759 220346 220342 220307
260 A
220763 220758 220406 220405 220307

220637
400 A
220571
220707 220712 220708 220405 220709

Operation
Mild steel bevel cutting
Nozzle Swirl Water

Shield cap Shield retaining cap Nozzle ring Electrode tube
80 A
220742 220845 220806 220179 220802

220700
130 A
220742 220740 220646 220179 220649
220637 260 A
220741 220740 220542 220436 220541

220571
400 A
220636 220635 220632 220631 220629
Mild steel, thick piercing, bevel cutting
260 A
220637 220897 220896 220898 220436 220899 220571

Operation
Stainless steel bevel cutting
Nozzle Swirl Water

130 A
220738 220739 220656 220179 220606
260 A
220571
220738 220739 220607 220405 220606
220637
400 A
220707 220712 220708 220405 220709

Operation
Install and Inspect consumables
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. The torch might be hot.
Install consumables
Check the consumable parts daily for wear before cutting. Before removing consumables, bring the torch to the edge of
the cutting table, with the torch lifter raised to its highest point to prevent the consumables from dropping into the water
of the water table.
Note: Do not overtighten parts! Only tighten until mating parts are seated.
Apply a thin film of silicone lubricant on each o-ring. Wipe the internal and external surfaces of the
The o-ring should look shiny, but there should not be torch with a clean cloth or paper towel.
any excess or built-up grease.
Tool: 104119
1. Install the 2. Install the 3. Install the 4. Install the 5. Install the 6. Install the
electrode swirl ring nozzle and nozzle shield shield cap
swirl ring retaining cap

Operation
Inspect consumables
Inspect Look for Action
Shield cap
Erosion, missing material Replace shield cap
Cracks Replace shield cap
Burned surface Replace shield cap
Shield General:
Erosion or missing material Replace shield
Molten material attached Replace shield
Blocked gas holes Replace shield
Center hole:
Must be round Replace the shield when the hole is no longer round
O-rings:
Damage Replace shield
Lubricant Apply a thin film of silicone lubricant if the o-rings
are dry
Nozzle retaining cap
General:
Damage to insulating ring Replace nozzle retaining cap
Poor cut quality Replace nozzle retaining cap

after replacing other
consumables
Insulating ring
Nozzle General:
Always replace the nozzle and Erosion or missing material Replace nozzle
electrode as a set.
Blocked gas holes Replace nozzle
Center hole:
Must be round Replace the nozzle when the hole is no longer round
Signs of arcing Replace nozzle
O-rings:
Damage Replace nozzle
are dry

Operation
Inspect Look for Action
Swirl ring General:

Chips or cracks Replace swirl ring
Blocked gas holes Replace swirl ring
Dirt or debris Clean and check for damage; replace when damaged
O-rings:
Damage Replace swirl ring
are dry
Electrode Center surface:

Always replace the nozzle and Emitter wear – a pit forms as In general, replace the electrode when the pit depth is
electrode as a set. the emitter wears. 1 mm (0.04 in.) or greater. For the 400 amp mild steel
electrode and all SilverPlus electrodes, replace the
Emitter
electrode when the pit depth is 1.5 mm (0.06 in.) or
greater.
O-rings:
Damage Replace electrode

are dry

Operation
Torch maintenance
Poor cut quality and premature failure may occur if the HPR torch is not maintained properly.
The torch is manufactured to very tight tolerances to maximize cut quality. The torch should not be subjected to hard
impacts that can cause critical features to become misaligned.
The torch should be stored in a clean location when not in use, to avoid contamination of critical surfaces and passages.
Routine maintenance
The following steps should be completed each time consumables are changed: External
o-rings (2)
1. Use a clean cloth to wipe off the torch inside and outside. A cotton swab can be
used to access hard-to-reach internal surfaces.
2. Use compressed air to blow away any remaining dirt and debris from internal
and external surfaces.
3. Apply a thin film of silicone lubricant on each external o-ring. The o-rings should
look shiny, but there should not be any excess or built-up grease.
4. If consumables will be reused, use a clean cloth to wipe them off, and use Front view of the torch
compressed air to blow them off before they are installed again. This is especially
critical for the nozzle retaining cap.
Quick-disconnect maintenance
The following steps should be completed every 5-10 times
consumables are changed:
1. Remove the torch from the quick-disconnect assembly.

2. Use compressed air to blow off all internal surfaces and O-rings (5)
the external threads.
3. Use compressed air to blow off all internal surfaces at the
rear of the torch.
External
4. Inspect each of the 5 o-rings at the rear of the torch for threads
nicks or cuts. Replace any damaged o-rings. If they are
not damaged, apply a thin film of silicone lubricant on each
o-ring. The o-rings should look shiny, but there should not
be any excess or built-up grease.
Rear view of the torch
Maintenance kit
Even with proper care, the o-rings at the rear of the torch will need to be replaced periodically. Hypertherm provides
a kit (128879) of replacement parts. Kits should be kept in stock and be used as part of your routine maintenance
schedule.

Operation
Torch connections
Plasma vent
Shield gas
Ohmic Pilot arc

contact
pin
Coolant return
Coolant return
Plasma gas
Coolant in Coolant in
Torch Torch quick-disconnect receptacle
Replace torch water tube
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. The torch might be hot.
Note: The water tube may seem loose when correctly inserted, but any side-to-side looseness will disappear
after the electrode is installed.
1. Turn OFF all power to the system.
2. Remove consumables from torch. See Install and inspect

consumables in this section.
3. Remove the old water tube.
4. Apply a thin film of silicone lubricant on the o-ring, and install a

new water tube. The o-ring should look shiny, but there should
not be any excess or built-up grease.
5. Replace consumables. See Install and inspect consumables in

this section.

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 5.
3. Torch-to-work distance is too high.
• The workpiece is not totally penetrated, and there is excessive sparking on top of the workpiece.
Causes can be:
1. Current is set too low (check Cut chart information).
2. Cut speed is too high (check Cut chart information).
3. Torch parts are worn (see Install and inspect consumables).
4. Metal being cut is too thick.
• Dross forms on the bottom of the cut. Causes can be:
1. Cutting speed is not correct (check Cut chart information).
2. Arc current is set too low (check Cut chart information).
3. Torch parts are worn (see Install and inspect consumables).
• Cut angle is not square. Causes can be:
1. Wrong direction of machine travel.

High-quality side is on the right with respect to the forward motion of the torch.
2. Torch-to-work distance is not correct (check Cut chart information).
3. Cutting speed is not correct (check Cut chart information).
4. Arc current is not correct (check Cut chart information).
5. Damaged consumable parts (see Install and inspect consumables).
• Short consumable life. Causes can be:
1. Arc current, arc voltage, travel speed, motion delay, gas flow rates, or initial torch height not set as specified
in the Cut charts.
2. Attempting to cut highly magnetic metal plate, such as armor plate with a high nickel content, will shorten
consumable life. Long consumable life is difficult to achieve when cutting plate that is magnetized or
becomes magnetized easily.
3. Beginning or ending the cut off the plate surface. To achieve consumable long life, all cuts must begin
and end on the plate surface.

Operation
Dross
Low-speed dross forms when the torch’s cutting speed is too slow and the arc shoots ahead. It forms as a heavy,
bubbly deposit at the bottom of the cut and can be removed easily. Increase the speed to reduce the dross.
High-speed dross forms when the cutting speed is too fast and the arc lags behind. It forms as a thin, linear bead of
solid metal attached very close to the cut. It is welded to the bottom of the cut and is difficult to remove. To reduce
high-speed dross:
• Decrease the cutting speed.

• Decrease arc voltage, to decrease the torch-to-work distance.
Notes: Dross is more likely to form on warm or hot metal than on cool metal. For example, the first cut
in a series of cuts will likely produce the least dross. As the workpiece heats up, more dross
may form on subsequent cuts.
Dross is more likely to form on mild steel than on stainless steel or aluminum.
Worn or damaged consumables may produce intermittent dross.
Straightness of the cut surface

A typical plasma cut surface is slightly concave.
The cut surface may become more concave, or convex. Correct torch height is required to keep the cut
surface acceptably close to straight.
A strongly concave cut surface occurs when the torch-to-work distance is too low. Increase the arc voltage
to increase the torch-to-work distance and straighten the cut surface.
A convex cut surface occurs when the torch-to-work distance is too great or the cutting current is too high.
First, reduce the arc voltage, then reduce the cutting current. If there is overlap between different cutting
currents for that thickness, try the consumables designed for the lower current.

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. Next, rotate the torch 90° in its
holder and repeat the process. If the angles are the same in both tests, the problem is in the
drive system.
If a cut-angle problem persists after “mechanical causes” have been eliminated (see Tips for table and torch, previous
page), check the torch-to-work distance, especially if cut angles are all positive or all negative.
• A positive cut angle results when more material is removed from the top of the cut than from the bottom.
• A negative cut angle results when more material is removed from the bottom of the cut.
Problem cause Solution

Negative cut angle The torch is too low. Increase arc voltage to raise the torch.
Square cut
Positive cut angle

\
The torch is too high. Decrease arc voltage to lower the torch.

Operation
How to optimize cut quality

The following tips and procedures will help produce square, straight, smooth and dross-free cuts.
tips for table and torch

• Use a square to align the torch at right angles to the workpiece.
• The torch may travel more smoothly if you clean, check and “tune” the rails and drive system on the cutting table.
Unsteady machine motion can cause a regular, wavy pattern on the cut surface.
• The torch must not touch the workpiece during cutting. Contact can damage the shield and nozzle, and affect
the cut surface.
Plasma set-up tips

Follow carefully each step in the Daily start-up procedure described earlier in this section.
Purge the gas lines before cutting.
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.
• The torch should never fire into the air.

– Starting the cut at the edge of the workpiece is acceptable, as long as the arc is not fired in the air.
– To start with a pierce, use a pierce height that is 1.5 to 2 times the torch-to-work distance. See Cut charts.
• Each cut should end with the arc still attached to the workpiece, to avoid arc blow-outs (ramp-down errors).
– When cutting drop parts (small parts that drop down after being cut from the workpiece), check that the arc
stays attached to the edge of the workpiece, for proper ramp-down.
• If arc blow-outs occur, try one or more of the following:

– Reduce the cutting speed during the final part of the cut.
– Stop the arc before the part is completely cut, to allow completion of the cut during the ramp-down.
– Program the path of the torch into the scrap area for ramp-down.
Note: Use a “chain cut” if possible, so the path of the torch can lead directly from one cut part into
the next, without stopping and starting the arc. However, do not allow the path to lead off the
workpiece and back on, and remember that a chain cut of long duration will cause electrode
wear.
Note: It may be difficult to achieve the full benefits of the LongLife process in some conditions.

Operation
additional improvements
Some of these improvements involve trade-offs, as described.
piercing
The pierce delay should allow sufficient time to penetrate the full thickness of the material, but not so long that it allows
the arc to “wander” while trying to find the edge of a large pierce hole. As consumables wear, this delay time may need
to be increased. Pierce delay times given in the cut charts are based on average delay times throughout the life of the
consumables.
Using the “pierce complete” signal during piercing maintains the shield-gas pressure at the higher preflow pressure,
which provides additional protection for the consumables (for example: 30 amp O2/O2 and 50 amp O2/O2 processes).
The pierce complete signal must be turned off for processes with shield gas preflow pressures that are lower than the
cutflow pressures (for example: 600 amp and 800 amp processes).
When piercing materials close to the maximum thickness for a specific process, there are several important factors to
consider:
• Allow a lead-in distance that is about the same as the thickness of the material being pierced. 50 mm (2 in)
material requires a 50 mm lead-in.
• To avoid damage to the shield from the build up of molten material created by the pierce, do not allow the torch
to descend to cut height until it has cleared the puddle of molten material.
• When pre-piercing with the 400 amp O2/air process, the arc should be on for a minimum of 4 seconds or the
electrode may experience rapid wear. This 4 seconds allows the current to properly ramp-up and ramp-down
which is required for the long life process. A small torch movement may be necessary if the peirce time is less
than 4 seconds to keep the arc transferred to the plate.
• Different material chemistries can have an adverse effect on the pierce capability of the system. In particular,
high-strength steel and steel with a high manganese or silicon content can reduce the maximum pierce
capability. Hypertherm calculates mild steel pierce parameters with certified A-36 plate.
• If the system has difficulty piercing a specific material or thickness, increasing the shield preflow pressure can
help in some cases.
Trade-off: This may reduce starting reliability.
• Using a “moving pierce” or “flying pierce” (starting torch motion immediately after transfer and during the pierce
process) can extend the piercing capability of the system in some cases. Because this can be a complex
process that can damage the torch, lifter, or other components, an edge start is recommended unless the
operator is experienced with this technique.
How to increase cutting speed

• Decrease the torch-to-work distance.
Trade-off: This will increase the negative cut angle.
Note: The torch must not touch the workpiece while piercing or cutting.

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.
Bevel cut charts

The bevel cut charts are slightly different from the standard cut charts. The torch-to-work distance is a range rather than
a single value, material thickness is given as an equivalent value, a column for minimum clearance has been added, and
there is no column for arc voltage.
Equivalent thicknesses and the arc voltages will vary depending on the angle of the cut. The angle for bevel cutting can
range from 0° to 45°.
See Bevel cutting definitions on the next page for more detailed information.

Operation
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°.
Nominal thickness The vertical thickness of the workpiece.
Equivalent thickness The length of the cut edge, or the distance the arc travels through the material while cutting.
Equivalent thickness is equal to the nominal thickness divided by the cosine of the bevel
angle. Equivalent thicknesses are listed in the cut chart.
Clearance The vertical distance from the lowest point of the torch to the surface of the workpiece.
Torch-to-work distance The linear distance from the center of the torch outlet to the workpiece surface along the
torch center-line. A range of torch-to-work distances are listed in the cut chart. The smallest
number is for a straight cut (bevel angle = 0°). The largest number is for a 45° bevel cut
with a clearance of 3 mm (0.120 in).
Arc voltage The arc voltage setting is dependent on the bevel angle and the setup of the cutting system.
The arc voltage setting on one system may be different from a second system even if the
workpiece is the same thickness. The arc voltages for bevel cutting are not supplied in the
bevel cut charts.
Torch
center-line
0°
Bevel angle
Torch-to-work
distance
Clearance
Nominal
thickness
Equivalent
thickness

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. N/A = data not available.
Metric
Thickness (mm)
Process 1.5 3 5 6 8 10 12 15 20 25 30 32 38 40 50 60 70 80
Mild steel
400A O2 / Air N/A N/A N/A N/A N/A N/A 3.40 3.50 3.68 3.76 4.06 N/A N/A 4.88 5.94 6.60 7.80 9.10
260A O2 / Air N/A N/A N/A 2.54 2.54 2.54 2.79 3.43 3.56 3.91 N/A 4.32 4.45 N/A 5.72 N/A N/A N/A
200A O2 / Air N/A N/A 1.93 1.98 2.09 2.20 2.26 2.61 2.95 3.16 N/A 4.19 4.87 N/A 5.45 N/A N/A N/A
130A O2 / Air N/A 1.64 1.77 1.81 1.92 2.04 2.11 2.22 2.65 3.43 N/A 4.26 4.59 N/A N/A N/A N/A N/A
80A O2 / Air N/A 1.37 1.53 1.73 1.79 1.91 2.00 2.11 2.72 N/A N/A N/A N/A N/A N/A N/A N/A N/A
50A O2 / O2 1.52 1.74 1.86 1.86 2.09 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A
30A O2 / O2 1.35 1.45 1.54 1.56 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A
Stainless steel
400A N2 / Air N/A N/A N/A N/A N/A N/A 3.00 2.90 2.80 3.10 3.30 N/A N/A 5.00 N/A N/A N/A N/A
400A H35 / N2 N/A N/A N/A N/A N/A N/A N/A N/A 5.10 5.30 5.45 N/A N/A 5.50 5.80 6.35 N/A N/A
400A
H35 and N2 / N2 N/A N/A N/A N/A N/A N/A 3.90 4.00 4.20 4.45 4.65 N/A N/A 5.15 5.65 5.90 6.35 6.95
260A
H35 and N2/ N2 N/A N/A N/A 2.34 3.02 3.71 3.80 3.82 4.32 4.34 N/A 4.58 4.77 N/A 5.63 N/A N/A N/A
260A N2 / Air N/A N/A N/A 2.31 2.39 2.46 2.54 2.76 3.08 3.30 N/A 3.64 4.43 N/A 4.16 N/A N/A N/A
260A H35 / N2 N/A N/A N/A N/A 3.84 3.83 3.81 3.81 4.06 4.32 N/A 4.53 4.70 N/A 7.46 N/A N/A N/A
200A N2 / N2 N/A N/A N/A N/A 2.10 2.16 2.29 2.47 2.92 N/A N/A N/A N/A N/A N/A N/A N/A N/A
200A H35 / N2 N/A N/A N/A N/A 3.66 3.68 3.81 3.68 3.94 N/A N/A N/A N/A N/A N/A N/A N/A N/A
200A
H35 and N2/ N2 N/A N/A N/A N/A 3.05 3.05 3.05 2.88 3.30 N/A N/A N/A N/A N/A N/A N/A N/A N/A
130A H35 / N2 N/A N/A N/A N/A 2.69 2.72 2.77 3.03 2.90 3.25 N/A N/A N/A N/A N/A N/A N/A N/A
130A N2 / N2 N/A N/A N/A 1.83 1.89 1.88 2.42 2.51 3.00 N/A N/A N/A N/A N/A N/A N/A N/A N/A
130A
H35 and N2/ N2 N/A N/A N/A 1.78 2.25 2.73 2.76 3.03 2.90 N/A N/A N/A N/A N/A N/A N/A N/A N/A
80A F5 / N2 N/A N/A 1.02 1.20 1.05 0.96 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A
45A F5 / N2 0.59 0.38 0.52 0.54 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A
45A N2 / N2 0.49 0.23 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

Operation
Metric
Thickness (mm)
Process 1.5 3 5 6 8 10 12 15 20 25 30 32 38 40 50 60 70 80
Aluminum
400A N2 / Air N/A N/A N/A N/A N/A N/A 3.50 3.60 3.70 3.90 4.00 N/A N/A 4.00 7.60 N/A N/A N/A
400A H35 / N2 N/A N/A N/A N/A N/A N/A N/A N/A 4.20 4.30 4.30 N/A N/A 4.45 5.40 7.05 8.00 8.15
400A
H35 and N2 / N2 N/A N/A N/A N/A N/A N/A 3.55 3.65 3.80 3.80 4.20 N/A N/A 4.45 4.55 6.15 6.85 7.10
260A N2 / Air N/A N/A N/A 2.49 2.73 2.97 3.05 2.91 3.05 3.30 N/A 2.87 3.99 N/A 5.66 N/A N/A N/A
260A H35 / N2 N/A N/A N/A 2.64 2.64 2.62 2.79 3.09 3.30 3.56 N/A 3.29 3.60 N/A 5.37 N/A N/A N/A
200A N2 / N2 N/A N/A N/A N/A 1.78 2.03 2.58 2.54 3.01 N/A N/A N/A N/A N/A N/A N/A N/A N/A
200A H35 / N2 N/A N/A N/A N/A 2.44 2.67 2.92 3.18 3.30 N/A N/A N/A N/A N/A N/A N/A N/A N/A
200A
H35 and N2/ N2 N/A N/A N/A N/A 2.79 2.92 3.05 3.30 3.81 N/A N/A N/A N/A N/A N/A N/A N/A N/A
130A H35 / N2 N/A N/A N/A N/A 2.70 2.72 2.77 2.36 2.90 1.72 N/A N/A N/A N/A N/A N/A N/A N/A
130A Air / Air N/A N/A N/A 2.09 2.09 2.10 2.19 1.91 1.87 2.23 N/A N/A N/A N/A N/A N/A N/A N/A
130A
H35 and N2/ N2 N/A N/A N/A 2.06 2.39 2.73 2.76 2.00 2.90 N/A N/A N/A N/A N/A N/A N/A N/A N/A
45A Air / Air 1.07 1.10 1.25 1.25 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

Operation
English
Thickness (in)
Process 0.060 0.135 1/4 5/16 3/8 1/2 5/8 3/4 1.0 1-1/4 1-1/2 1-3/4 2.0 2-1/4 2-1/2 3.0
Mild steel
400A O2 / Air N/A N/A N/A N/A N/A 0.135 0.140 0.145 0.148 0.164 0.183 0.215 0.237 0.250 0.275 0.340
260A O2 / Air N/A N/A 0.100 0.100 0.100 0.110 0.115 0.135 0.150 0.170 0.175 0.220 0.225 0.240 0.260 N/A
200A O2 / Air N/A N/A 0.078 0.082 0.086 0.089 0.108 0.116 0.125 0.164 0.192 N/A 0.216 N/A N/A N/A
130A O2 / Air N/A 0.066 0.071 0.076 0.080 0.083 0.089 0.104 0.135 0.167 0.181 N/A N/A N/A N/A N/A
80A O2 / Air N/A 0.054 0.068 0.070 0.075 0.080 0.084 0.102 N/A N/A N/A N/A N/A N/A N/A N/A
50A O2 / O2 0.060 0.063 0.073 0.082 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A
30A O2 / O2 0.053 0.057 0.067 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A
Stainless steel
400A N2 / Air N/A N/A N/A N/A N/A 0.118 0.116 0.112 0.122 0.132 0.198 0.235 N/A N/A N/A N/A
400A H35 / N2 N/A N/A N/A N/A N/A N/A N/A 0.200 0.210 0.215 0.218 0.220 0.230 0.245 0.255 N/A
400A
H35& N2 / N2 N/A N/A N/A N/A N/A 0.135 0.160 0.165 0.175 0.185 0.200 0.210 0.225 0.230 0.235 0.265
260A
H35 and N2/ N2 N/A N/A 0.092 0.119 0.145 0.151 0.151 0.170 0.171 0.180 0.188 0.197 0.225 N/A N/A N/A
260A N2 / Air N/A N/A 0.091 0.094 0.100 0.100 0.120 0.120 0.130 0.142 0.175 0.223 0.155 N/A N/A N/A
260A H35 / N2 N/A N/A N/A 0.150 0.151 0.165 0.170 0.177 0.182 0.184 0.185 0.202 0.307 N/A N/A N/A
200A N2 / N2 N/A N/A N/A 0.083 0.085 0.090 0.100 0.115 N/A N/A N/A N/A N/A N/A N/A N/A
200A H35 / N2 N/A N/A N/A 0.144 0.145 0.150 0.152 0.155 N/A N/A N/A N/A N/A N/A N/A N/A
200A
H35 and N2/ N2 N/A N/A N/A 0.120 0.120 0.120 0.111 0.130 N/A N/A N/A N/A N/A N/A N/A N/A
130A H35 / N2 N/A N/A N/A 0.115 0.121 0.123 0.124 0.125 0.129 N/A N/A N/A N/A N/A N/A N/A
130A N2 / N2 N/A N/A 0.072 0.074 0.083 0.095 0.100 0.118 N/A N/A N/A N/A N/A N/A N/A N/A
130A
H35 and N2/ N2 N/A N/A 0.070 0.089 0.107 0.109 0.123 0.114 N/A N/A N/A N/A N/A N/A N/A N/A
80A F5 / N2 N/A 0.032 0.047 0.050 0.052 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A
45A F5 / N2 0.023 0.015 0.021 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A
45A N2 / N2 0.019 0.009 0.006 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A
Aluminum
400A N2 / Air N/A N/A N/A N/A N/A 0.140 0.143 0.145 0.155 0.160 0.160 0.230 0.300 N/A N/A N/A
400A H35 / N2 N/A N/A N/A N/A N/A N/A N/A 0.164 0.170 0.170 0.170 0.190 0.215 0.250 0.310 0.318
400A
H35& N2 / N2 N/A N/A N/A N/A N/A 0.140 0.145 0.150 0.150 0.170 0.175 0.175 0.180 0.225 0.263 0.276
260A N2 / Air N/A N/A 0.098 0.107 0.120 0.120 0.120 0.120 0.130 0.145 0.158 0.193 0.227 N/A N/A N/A
260A H35 / N2 N/A N/A 0.104 0.104 0.105 0.110 0.126 0.130 0.140 0.141 0.142 0.222 0.210 N/A N/A N/A
200A N2 / N2 N/A N/A N/A 0.070 0.080 0.090 0.100 0.105 N/A N/A N/A N/A N/A N/A N/A N/A
200A H35 / N2 N/A N/A N/A 0.096 0.105 0.115 0.125 0.130 N/A N/A N/A N/A N/A N/A N/A N/A
200A
H35 and N2/ N2 N/A N/A N/A N/A 0.115 0.120 0.130 0.150 N/A N/A N/A N/A N/A N/A N/A N/A
130A H35 / N2 N/A N/A N/A 0.106 0.107 0.109 0.112 0.114 0.120 N/A N/A N/A N/A N/A N/A N/A
130A Air / Air N/A N/A 0.082 0.082 0.082 0.086 0.071 0.071 0.089 N/A N/A N/A N/A N/A N/A N/A
130A
H35 and N2/ N2 N/A N/A 0.081 0.094 0.107 0.109 0.067 0.114 N/A N/A N/A N/A N/A N/A N/A N/A
45A Air / Air 0.042 0.043 0.049 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

Operation
Mild steel Flow rates – lpm/scfh

O2 Air
O2 Plasma / O2 Shield Preflow 0/0 43 / 90
30 A Cutflow 25 / 52 0/0
Note: Air must be connected to use this process. It is used as the preflow gas.
220747 220194 220754 220193 220180 220192 220340

Metric
Select Set Set Material Arc Torch-to-Work Cutting Initial Pierce Pierce Delay
Gases Preflow Cutflow Thickness Voltage Distance Speed Height Time
Plasma Shield Plasma Shield Plasma Shield
mm Volts mm mm/m mm Factor % Seconds
gas gas gas gas gas gas
0.5 114 5355 0.1
0.8 115 4225 0.2
17 17 1 116 1.3 3615 2.3
1.2 117 2865 0.3
1.5 119 2210
O2 O2 78 94 180
2 120 1490
35 0.4
2.5 122 1325
7 3* 123 1.5 1160 2.7 0.5
75 4* 125 905 0.7
6* 128 665 1.0
English
in Volts in ipm in Factor % Seconds
0.018 215
114 0.1
0.024 200
0.030 115 170 0.2
17 17 0.05 0.09
0.036 116 155
0.048 117 110 0.3
O2 O2 78 94 0.060 119 85 180
0.075 120 60
35 0.4
0.105 122 50
7 0.135* 123 0.06 40 0.11 0.5
75 3/16* 30 0.7
128
1/4* 25 1.0
Marking
Torch-to-Work Marking Arc
Select Set Set Amperage
Distance Speed Voltage
Gases Preflow Cutflow
Amps mm in mm/m ipm Volts
N2 N2 10 10 10 10 15 2.5 0.10 6350 250 105
Ar Air 90 10 90 10 9 2.5 0.10 2540 100 80
* Pierce complete is recommended for these thicknesses.

Operation

O2 Air
O2 Plasma / O2 Shield Preflow 0/0 43 / 90
50 A Cutflow 25 / 52 0/0
Note: Air must be connected to use this process. It is used as the preflow gas.
220747 220555 220754 220554 220553 220552 220340

Metric
0.8 110 6500
1 111 1.0 5000 2.0
1.2 112 4150 0.0
1.5 114 3200
2 115 1.3 2700 2.6
2.5 117 2200 0.1
O2 O2 70 30 81 14 200
3 119 1800 0.2
4 121 1.5 1400 3.0 0.3
5 122 1200 0.4
6 126 950
7 128 2.0 780 4.0 0.5
8 130 630
English
0.030 270
110
0.036 0.04 210 0.08
0.048 112 160 0.0
0.060 114 125
0.075 115 0.05 110 0.10
O2 O2 70 30 81 14 200
0.105 118 80 0.1
0.135 120 60 0.2
0.06 0.12
3/16 121 50 0.3
1/4 125 35
0.08 0.16 0.5
5/16 130 25
Marking
N2 N2 10 10 10 10 15 2.5 0.10 6350 250 118
Ar Air 90 10 90 10 9 2.5 0.10 2540 100 77

Operation

O2 Air
O2 Plasma / Air Shield Preflow 0/0 76 / 161
80 A Cutflow 23 / 48 41 / 87
220747 220189 220756 220188 220179 220187 220340
Metric
mm Volts mm mm/m mm factor % seconds
2 112 9810
0.1
2.5 115 2.5 7980 3.8 150
3 117 6145
0.2
4 120 4300
23
5 121 3670
0.3
O2 Air 48 23 78 6 123 3045 4.0 200
8 125 2.0 2430 0.4
10 127 1810 0.5
12 130 1410 0.7
5.0
10 15 133 1030 250 0.8
20 135 2.5 545 6.3 0.9
English
in Volts in ipm in factor % seconds
0.075 112 400
0.1
0.105 115 0.10 290 0.15 150
0.135 117 180
0.2
23 3/16 120 155
1/4 123 110 0.3
O2 Air 48 23 78 0.16 200
5/16 125 96 0.4
0.08
3/8 127 75 0.5
1/2 130 50 0.7
0.20
10 5/8 133 37 250 0.8
3/4 135 0.10 25 0.25 0.9
Marking
N2 N2 10 10 10 10 15 2.5 0.10 6350 250 130
Ar Air 50 10 50 10 15 3.0 0.12 2540 100 78

Operation
Mild steel bevel cutting Flow rates – lpm/scfh

O2 Air
80 A Cutflow 23 / 48 47 / 100
220637 220742 220845 220806 220179 220802 220700
Metric
Equivalent
Select Set Set Minimum Torch-to-Work Cutting Initial Pierce Pierce Delay
Material
Gases Preflow Cutflow Clearance Distance Speed Height Time
Thickness
mm mm Range (mm) mm/m mm factor % seconds
2 9810
0.1
2.5 2.5 – 8.6 7980 3.8 150
3 6145
0.2
4 4300
39
5 3670
0.3
O2 Air 48 39 78 2.0 6 3045 4.0 200
8 2.0 – 8.6 2430 0.4
10 1810 0.5
12 1410 0.7
5.0
17 15 1030 250 0.8
20 2.5 – 8.6 545 6.3 0.9
English
Equivalent
Material
Thickness
in in Range (in) ipm in factor % seconds
0.075 400
0.1
0.105 0.1 – 0.34 290 0.15 150
0.135 180
0.2
39 3/16 155
1/4 110 0.3
O2 Air 48 39 78 0.08 0.16 200
5/16 96 0.4
0.08 – 0.34
3/8 75 0.5
1/2 50 0.7
0.20
17 5/8 37 250 0.8
3/4 0.1 – 0.34 25 0.25 0.9
Marking
N2 N2 10 10 10 10 15 2.5 0.10 6350 250 130
Ar Air 50 10 50 10 15 3.0 0.12 2540 100 78

Operation

O2 Air
O2 Plasma / Air Shield Preflow 0 / 0 102 / 215
130 A Cutflow 33 / 70 45 / 96
220747 220183 220756 220182 220179 220181 220340

Metric
3 124 2.5 6505 5.0 0.1
4 5550 0.2
28 126
5 2.8 4795 5.6
6 127 4035
32 0.3
8 129 3360 200
3.0 6.0
10 130 2680
O2 Air 32 84
12 132 3.3 2200 6.6 0.5
15 135 1665 0.7
22 3.8
20 138 1050 7.6 1.0
25 141 4.0 550 190 1.8
52
32 160 375
4.5 Edge start
38 167 255
English
0.135 124 0.10 240 0.20 0.1
28 3/16 126 190 0.2
0.11 0.22
1/4 127 150
32 5/16 129 132 0.3
0.12 0.24 200
3/8 130 110
O2 Air 32 84 1/2 132 0.13 80 0.26 0.5
5/8 135 60 0.7
22 0.15
3/4 138 45 0.30 1.0
1 141 0.16 20 190 1.8
52
1-1/4 160 15
0.18 Edge start
1-1/2 167 10
Marking
N2 N2 10 10 10 10 15 2.5 0.10 6350 250 130
Ar Air 50 10 50 10 15 3.0 0.12 2540 100 75

Operation
O2 Plasma / Air Shield O2 Air
Preflow 0/0 64 / 135
130 A Cutflow 33 / 70 45 / 96
220637 220742 220740 220646 220179 220649 220700

Note: Bevel angle range is 0° to 45°.
Metric
Equivalent
Material
Thickness
3 2.5 – 8.6 6505 5.0 0.1
4 5550 0.2
21
5 2.8 – 8.6 4795 5.6
6 4035
0.3
8 3360 200
23 3.0 – 8.6 6.0
10 2680
O2 Air 15 84 2.0
12 3.3 – 8.6 2200 6.6 0.5
15 1665 0.7
15 3.8 – 8.6
20 1050 7.6 1.0
25 4.0 – 8.6 550 190 1.8
32* 375 10.2 220 4.0
33 4.5 – 8.6
38 255 Edge start
English
Equivalent
Material
Thickness
0.135 0.10 – 0.34 240 0.20 0.1
21 3/16 190 0.2
0.11 – 0.34 0.22
1/4 150
5/16 132 0.3
0.12 – 0.34 0.24 200
23 3/8 110
O2 Air 15 84 0.08 1/2 0.13 – 0.34 80 0.26 0.5
5/8 60 0.7
15 0.15 – 0.34
3/4 45 0.30 1.0
1 0.16 – 0.34 20 190 1.8
1-1/4* 15 0.40 220 4.0
33 0.18 – 0.34
1-1/2 10 Edge start
Marking
N2 N2 10 10 10 10 15 2.5 0.10 6350 250 130
Ar Air 50 10 50 10 15 3.0 0.12 2540 100 75
* Suggestions for piercing 32 mm (1-1/4 in) mild steel: 1. Turn preflow on during IHS, 2. Use ohmic contact during IHS,
3. Use pierce complete when piercing.

Operation

O2 Air
200 A Cutflow 39 / 82 48 / 101
220637 220761 220757 220354 220353 220352 220340
Metric
5 123 5700
0.2
6 124 5250
8 125 3.3 4355 6.6
0.3
10 126 3460
12 128 3060 0.5
O2 Air 23 42 74 18 15 131 2275 200 0.6
4.1 8.2
20 133 1575 0.8
25 143 1165 1.0
32 145 750
5.1 10.2
38 152 510 Edge start
50 163 255
English
3/16 230
124 0.2
1/4 200
5/16 125 0.13 171 0.26
0.3
3/8 126 140
1/2 128 115 0.5
O2 Air 23 42 74 18 5/8 131 80 200 0.6
0.16 0.32
3/4 133 65 0.8
1 143 45 1.0
1-1/4 145 30
0.20 0.40
1-1/2 152 20 Edge start
2 163 10
Marking
N2 N2 10 10 10 10 15 2.5 0.10 6350 250 130
Ar Air 30 10 30 10 20 3.0 0.12 2540 100 63

Operation

O2 Air
260 A Cutflow 42 / 88 104 / 220
220637 220764 220760 220439 220436 220435 220340

Metric
6 6500
8 5470 0.3
76 46 150 2.8 8.5 300
10 4440
12 3850 0.4
15 155 3130 0.5
80 20 159 2170 0.6
3.6 9.0 250
22 166 1930 0.7
O2 Air 22 49 25 171 1685 0.8
28 170 1445 0.9
9.5 200
49 32 172 1135 1.0
38 174 895
84
44 185 4.8 580
58 193 290
64 202 195
English
1/4 245
5/16 215 0.3
76 46 150 0.11 0.33 300
3/8 180
1/2 145 0.4
5/8 155 115 0.5
80 3/4 159 90 0.6
0.14 0.35 250
7/8 166 75 0.7
O2 Air 22 49 1 171 65 0.8
1-1/8 170 55 0.9
0.38 200
49 1-1/4 172 45 1.0
1-1/2 174 35
84
1-3/4 185 0.19 22
2 188 15 Edge start
2-1/4 193 12
2-1/2 202 8
Marking
N2 N2 10 10 10 10 18 2.5 0.10 6350 250 135
Ar Air 30 20 30 20 24 3.0 0.12 2540 100 68

Operation
Mild steel bevel cutting (standard) Flow rates – lpm/scfh
O2 Plasma / Air Shield O2 Air
260 A Preflow 0 / 0 130 / 275
Cutflow 42 / 88 104 / 220
220637 220741 220740 220542 220436 220541 220571

Metric
Equivalent
Material
Thickness
6 6500
8 5470 0.3
76 46 2.8 – 7.6 8.5 300
10 4440
12 3850 0.4
15 3130 0.5
80 20 2170 0.6
3.6 – 7.6 9.0 250
22 1930 0.7
O2 Air 22 49 2.0 25 1685 0.8
28 1445 0.9
49 32 1135 9.5 200 1.0
38* 895 2.0
84
44 4.8 – 7.6 580
50 405
Edge start
58 290
64 195
English
Equivalent
Material
Thickness
1/4 245
5/16 215 0.3
76 46 0.11 – 0.30 0.33 300
3/8 180
1/2 145 0.4
5/8 115 0.5
80 3/4 90 0.6
0.14 – 0.30 0.35 250
7/8 75 0.7
O2 Air 22 49 0.08 1 65 0.8
1-1/8 55 0.9
49 1-1/4 45 0.38 200 1.0
1-1/2* 35 2.0
84
1-3/4 0.19 – 0.30 22
2 15
Edge start
2-1/4 12
2-1/2 8
Marking
N2 N2 10 10 10 10 18 2.5 0.10 6350 250 135
Ar Air 30 20 30 20 24 3.0 0.12 2540 100 68
* See the alternate, thick metal piercing, cut chart if you have a problem with excessive slag on the shield or problems with the torch misfiring.

Operation
Mild steel bevel cutting (alternate) Flow rates – lpm/scfh

thick metal piercing O2 Air
Preflow 0/0 85 / 180
O2 Plasma / Air Shield Cutflow 47 / 99 54 / 115
260 A
220637 220897 220896 220898 220436 220899 220571
Metric
Equivalent
Material
Thickness
25 3.6 – 7.6 1685 9.0 250 0.8
28 1445 1.0
32 1135 9.5 200 1.2
38* 895 3.0
O2 Air 22 20 74 19 2.0
44 4.8 – 7.6 580
50 405
Edge start
58 290
64 195
English
Equivalent
Material
Thickness
1 0.14 – 0.30 65 0.35 250 0.8
1-1/8 55 1.0
1-1/4 45 0.38 200 1.2
1-1/2* 35 3.0
O2 Air 22 20 74 19 0.08
1-3/4 0.19 – 0.30 22
2 15
Edge start
2-1/4 12
2-1/2 8
Marking
N2 N2 10 10 10 10 18 2.5 0.10 6350 250 122
Ar Air 30 10 30 10 24 3.0 0.12 2540 100 62
The consumables on this page are designed for thick metal piercing. They are only recommended for use if you have
a problem with excessive slag on the shield, or problems with the torch misfiring, when using the standard bevel
consumables.
Using the thick metal piercing process may result in a 20% decrease in the life of the consumables.
*S uggestions for piercing 38 mm (1-1/2 in) mild steel:
1. Turn preflow on during IHS
2. Use stall force during IHS
3. Use pierce complete when piercing

Operation

O2 Air
O2 Plasma / Air Shield
Preflow 0 / 0 190 / 400
400 A Cutflow 66 / 140 137 / 290
220637 220636 220635 220632 220631 220629 220571

Metric
12 139 4430 0.4
15 142 3.6 3950 7.2 0.5
20 146 2805 0.7
200
22 148 3.8 2540 7.6 0.8
25 150 4.0 2210 8.0 0.9
O2 Air 24 50 60 50 30 153 1790 9.2 1.1
4.6
40 158 1160 11.5 250 1.9
50 167 5.3 795 19.1 360 5.2
60 173 580
6.4
80 197 7.9 180
English
1/2 140 170 0.4
5/8 143 0.14 150 0.28 0.5
3/4 145 115 0.6
200
7/8 148 0.15 100 0.30 0.8
1 151 0.16 85 0.32 0.9
1-1/4 153 65 0.36 1.2
O2 Air 24 50 60 50
1-1/2 157 0.18 48 1.6
0.45 250
1-3/4 160 40 2.5
2 168 0.21 30 0.75 360 5.5
2-1/4 171 25
0.25
2-1/2 175 20 Edge start
3 193 0.31 10
Marking
N2 N2 10 10 10 10 22 2.5 0.10 1270 50 123
Ar Air 20 10 30 10 25 3.0 0.12 1270 50 55

Operation

O2 Air
400 A Cutflow 66 / 140 137 / 290
220637 220636 220635 220632 220631 220629 220571

Metric
Equivalent
Material
Thickness
mm mm Range (mm) mm/m mm Factor % Seconds
12 4430 0.4
15 3.6 – 9.4 3950 7.2 0.5
20 2805 0.7
200
22 3.8 – 9.4 2540 7.6 0.8
25 4.0 – 9.4 2210 8.0 0.9
O2 Air 24 50 60 50 2.0 30 1790 9.2 1.1
4.6 – 9.4
40 1160 11.5 250 1.9
50 5.3 – 9.4 795 19.1 360 5.2
60 580
6.4 – 9.4
70 380 Edge start
80 7.9 – 9.4 180
English
Equivalent
Material
Thickness
in in Range (in) ipm in Factor % Seconds
1/2 170 0.4
5/8 0.14 – 0.37 150 0.28 0.5
3/4 115 0.6
7/8 0.15 – 0.37 100 0.30 200 0.8
1 0.16 – 0.37 85 0.32 0.9
1-1/4 65 0.36 1.2
O2 Air 24 50 60 50 0.08 1-1/2 0.18 – 0.37 48 1.6
0.45 250
1-3/4 40 2.5
2 0.21 – 0.37 30 0.75 360 5.5
2-1/4 25
0.25 – 0.37
2-1/2 20 Edge start
3 0.31 – 0.37 10
Marking
N2 N2 10 10 10 10 22 2.5 0.10 1270 50 123
Ar Air 20 10 30 10 25 3.0 0.12 1270 50 55

Operation
Stainless steel Flow rates – lpm/scfh

N2
N2 Plasma / N2 Shield Preflow 24 / 51
45 A Cutflow 75 / 159
220747 220202 220755 220201 220180 220308 220340
Metric
0.8 6380 0.0
1 94 5880 0.1
1.2 5380
1.5 95 4630
N2 N2 35 5 62 49 2.5 3.8 150 0.2
2 97 3935
2.5 101 3270
3 2550
103 0.3
4 1580
English
0.036 240 0.0
94
0.048 210 0.1
0.060 95 180
N2 N2 35 5 62 49 0.10 0.15 150
0.075 97 160 0.2
0.105 101 120
0.135 103 75 0.3
Marking
N2 N2 10 10 10 10 15 2.5 0.10 6350 250 85
Ar N2 90 10 90 10 12 2.5 0.10 2540 100 65
Note: This process produces a darker cut edge than the 45 A, F5/N2 stainless steel process.

Operation

F5 N2
F5 Plasma / N2 Shield Preflow 0/0 43 / 91
45 A Cutflow 8 / 17 65 / 138
220747 220202 220755 220201 220180 220308 220340
Metric
0.8 6570
1 5740
99
1.2 4905
0.2
1.5 3890
49 2.5 150
F5 N2 35 18 62 2 101 3175 3.8
2.5 102 2510
3 103 2010
0.3
4 104 1435
11 6 110 2.0 845 190 0.5
English
0.036 240
0.048 99 190
0.060 150 0.2
49 0.10 150
0.075 100 130
F5 N2 35 18 62 0.15
0.105 102 90
0.135 104 65 0.3
3/16 108 45 0.4
11 0.08 190
1/4 110 30 0.5
Marking
N2 N2 10 10 10 10 15 2.5 0.10 6350 250 85
Ar N2 90 10 90 10 12 2.5 0.10 2540 100 65
Note: This process produces a shinier cut edge than the 45 A, N2/N2 stainless steel process.

Operation

F5 N2
F5 Plasma / N2 Shield Preflow 0/0 67 / 142
80 A Cutflow 31 / 65 87 / 185
220747 220338 220755 220337 220179 220339 220340
Metric
4 108 3.0 2180 4.5 0.2
5 110 2.7 1700 4.1
0.3
F5 N2 33 23 65 60 6 112 2.5 1225 3.8 150
8 116 895 0.4
3.0 4.5
10 120 560 0.5
English
0.135 108 0.12 105 0.18 0.2
3/16 110 0.11 60 0.17
0.3
F5 N2 33 23 65 60 1/4 112 0.10 45 0.15 150
5/16 116 35 0.4
0.12 0.18
3/8 120 25 0.5
Marking
N2 N2 10 10 10 10 15 2.5 0.10 6350 250 95
Ar N2 50 10 50 10 12 3.0 0.12 2540 100 60

Operation

N2
130 A Cutflow 79 / 168
220747 220198 220756 220197 220179 220307 220340
Metric
6 153 1960 0.3
8 155 3.0 1630 6.0 0.4
200
10 156 1300 0.5
N2 N2 19 51 75 23
12 162 3.5 900 7.0 0.8
15 167 3.8 670
Edge start
20 176 4.3 305
English
1/4 153 75 0.3
5/16 155 0.12 64 0.24 0.4
200
3/8 156 55 0.5
N2 N2 19 51 75 23
1/2 162 0.14 30 0.28 0.8
5/8 167 0.15 25
Edge start
3/4 176 0.17 15
Marking
N2 N2 10 10 10 10 18 2.5 0.10 6350 250 140
Ar N2 50 10 50 10 15 3.0 0.12 2540 100 75
Note: This process produces a rougher, darker cut edge with more dross, and the cut edges are closer to
perpendicular than the 130 A, H35/N2 process.

Operation

H35 N2
H35 Plasma / N2 Shield Preflow 0/0 76 / 160
130 A Cutflow 26 / 54 68 / 144
220747 220198 220755 220197 220179 220307 220340

Metric
Plasma Shield Plasma Shield Plasma
Shield mm Volts mm mm/m mm factor % seconds
gas gas gas gas gas
8 150 1140
49 0.3
10 154 980
37 12 158 820 7.7 170 0.5
H35 N2 19 32 75 4.5
15 162 580 0.8
24
20 165 360 1.3
16 25 172 260 Edge start
English
5/16 150 45
49 0.3
3/8 154 40
37 1/2 158 30 0.31 170 0.5
H35 N2 19 32 75 0.18
5/8 162 20 0.8
24
3/4 165 15 1.3
16 1 172 10 Edge start
Marking
N2 N2 10 10 10 10 18 2.5 0.10 6350 250 130
Ar N2 50 10 50 10 15 3.0 0.12 2540 100 75
Note: This process produces a smoother, shinier cut edge with less dross, and the cut edges are less
perpendicular than the 130 A, N2/N2 process.

Operation

H35 N2
H35 and N2 Plasma / N2 Shield Preflow 0/0 97 / 205
130 A Cutflow 13 / 28 71 / 150
220747 220198 220755 220197 220179 220307 220340
Metric
Pierce
Select Set Set Material Arc Torch-to-Work Cutting Initial Pierce
Delay
Gases Preflow Cutflow Thickness Voltage Distance Speed Height
Time
Plasma Shield Plasma Shield Plasma Shield Mix Mix
gas gas gas gas gas gas Gas 1 Gas 2
6 150 1835
38 8 152 3.0 1515 6.0 0.3
10 153 1195 200
H35 N2 19 51 75 32 18
12 160 3.5 875 7.0 0.5
27 15 168 3.8 670 7.6 0.8
20 176 4.3 305 7.7 180 1.3
English
Pierce
Delay
Time
1/4 150 70
38 5/16 152 0.12 60 0.24 0.3
3/8 153 50 200
H35 N2 19 51 75 32 18
1/2 160 0.14 30 0.28 0.5
27 5/8 168 0.15 25 0.30 0.8
3/4 176 0.17 15 0.31 180 1.3
Marking
N2 N2 10 10 10 10 18 2.5 0.10 6350 250 130
Ar N2 50 10 50 10 15 3.0 0.12 2540 100 75
Note: This process produces a smoother, shinier cut edge with less dross, and the cut edges are less
perpendicular than the 130 A, N2/N2 process. Edge color is more silver than the H35/N2 process.

Operation
Stainless steel bevel cutting Flow rates – lpm/scfh

N2
130 A Cutflow 125 / 260
220637 220738 220739 220656 220179 220606 220571
Metric
Equivalent
Material
Thickness
6 1960 0.3
8 3.0 – 10.0 1630 6.0 0.4
200
10 1300 0.5
N2 N2 19 51 75 63 2.0
12 3.5 – 10.0 900 7.0 0.8
15 3.8 – 10.0 670
Edge start
20 4.3 – 10.0 305
English
Equivalent
Material
Thickness
1/4 75 0.3
5/16 0.12 – 0.40 64 0.24 0.4
200
3/8 55 0.5
N2 N2 19 51 75 63 0.08
1/2 0.14 – 0.40 30 0.28 0.8
5/8 0.15 – 0.40 25
Edge start
3/4 0.17 – 0.40 15
Marking
N2 N2 10 10 10 10 18 2.5 0.10 6350 250 140
Ar N2 50 10 50 10 15 3.0 0.12 2540 100 75

Operation

H35 N2
130 A Cutflow 26 / 54 114 / 240
220637 220738 220739 220656 220179 220606 220571
Metric
Equivalent
Material
Thickness
8 1140
0.3
10 980
12 820 7.7 170 0.5
H35 N2 19 32 75 63 2.0 4.5 – 10.0
15 580 0.8
20 360 1.3
25 260 Edge start
English
Equivalent
Material
Thickness
5/16 45
0.3
3/8 40
1/2 30 0.31 170 0.5
H35 N2 19 32 75 63 0.08 0.18 – 0.40
5/8 20 0.8
3/4 15 1.3
1 10 Edge start
Marking
N2 N2 10 10 10 10 18 2.5 0.10 6350 250 130
Ar N2 50 10 50 10 15 3.0 0.12 2540 100 75

Operation

H35 N2
130 A Cutflow 13 / 28 120 / 250
220637 220738 220739 220656 220179 220606 220571
Metric
Equivalent Pierce
Select Set Set Minimum Torch-to-Work Cutting Initial Pierce
Material Delay
Gases Preflow Cutflow Clearance Thickness Distance Speed Height
Time
6 1835
8 3.0 – 10.0 1515 6.0 0.3
10 1195 200
H35 N2 19 51 75 80 32 18 2.0
12 3.5 – 10.0 875 7.0 0.5
15 3.8 – 10.0 670 7.6 0.8
20 3.0 – 10.0 305 7.7 180 1.3
English
Equivalent Pierce
Material Delay
Time
1/4 70
5/16 0.12 – 0.40 60 0.24 0.3
3/8 50 200
H35 N2 19 51 75 80 32 18 0.080
1/2 0.14 – 0.40 30 0.28 0.5
5/8 0.15 – 0.40 25 0.30 0.8
3/4 0.17 – 0.40 15 0.31 180 1.3
Marking
N2 N2 10 10 10 10 18 2.5 0.10 6350 250 130
Ar N2 50 10 50 10 15 3.0 0.12 2540 100 75

Operation

N2
200 A Cutflow 137 / 290
220637 220762 220758 220343 220342 220307 220340
Metric
8 159 3000 0.4
10 160 2700 0.5
N2 N2 17 42 84 42 12 161 3.8 2400 7.6 200 0.6
15 163 1800 0.8
20 167 1000 1.0
English
5/16 159 118 0.4
3/8 160 110 0.5
N2 N2 17 42 84 42 1/2 161 0.15 90 0.3 200 0.6
5/8 163 65 0.8
3/4 167 45 1.0
Marking
N2 N2 10 10 10 10 18 2.5 0.10 6350 250 140
Ar N2 30 10 30 10 20 3.0 0.12 2540 100 66

Operation

H35 N2
H35 Plasma / N2 Shield Preflow 0 / 0 116 / 245
200 A Cutflow 30 / 63 104 / 220
220637 220762 220758 220343 220342 220307 220340
Metric
8 1790 0.4
175 9.0 9.0
10 1620 0.5
H35 N2 17 43 88 52 12 170 1450 100 0.6
15 173 7.5 1200 7.5 0.7
20 177 820 0.8
English
5/16 70 0.4
175 0.35 0.35
3/8 65 0.5
H35 N2 17 43 88 52 1/2 170 55 100 0.6
5/8 173 0.30 45 0.30 0.7
3/4 177 35 0.8
Marking
N2 N2 10 10 10 10 18 2.5 0.10 6350 250 140
Ar N2 30 10 30 10 20 3.0 0.12 2540 100 66

Operation

H35 N2
H35 and N2 Plasma / N2 Shield Preflow 0 / 0 116 / 245
200 A Cutflow 11 / 24 118 / 250
220637 220762 220758 220343 220342 220307 220340
Metric
Pierce
Delay
Time
8 160 2000 0.4
10 161 4.0 1900 8.0 200 0.5
H35 N2 17 41 87 41 42 20 12 162 1800 0.6
15 167 4.6 1600 7.0 0.8
150
20 171 5.1 1000 7.5 1.0
English
Pierce
Delay
Time
5/16 160 79 0.4
3/8 161 0.16 75 0.320 200 0.5
H35 N2 17 41 87 41 42 20 1/2 162 70 0.6
5/8 167 0.18 60 0.270 0.8
150
3/4 171 0.20 45 0.300 1.0
Marking
N2 N2 10 10 10 10 18 2.5 0.10 6350 250 140
Ar N2 30 10 30 10 20 3.0 0.12 2540 100 66

Operation

N2 Air
N2 Plasma / Air Shield Preflow 127 / 270 0/0
260 A Cutflow 54 / 114 116 / 245
220637 220763 220758 220406 220405 220307 220340

Metric
6 160 6375
8 158 4910 0.3
10 157 3440
12 161 2960 0.4
7.5 200
15 163 2520 0.5
N2 Air 12 47 79 56 20 164 3.8 1590 0.6
25 168 1300 0.8
32 171 875 1.0
38 179 515
50 195 180
English
1/4 160 240
5/16 158 193 0.3
3/8 157 140
1/2 161 110 0.4
0.3 200
5/8 163 95 0.5
N2 Air 12 47 79 56 3/4 164 0.15 70 0.6
1 168 50 0.8
1-1/4 171 35 1.0
1-1/2 179 20
1-3/4 190 14 Edge start
2 200 6
Marking
N2 N2 10 10 10 10 18 2.5 0.10 6350 250 120
Ar N2 30 10 30 10 20 3.0 0.12 2540 100 63

Operation

H35 N2
260 A Cutflow 40 / 84 122 / 260
220637 220763 220758 220406 220405 220307 220340
Metric
8 2030
188 11.0 11.0 0.3
10 1870 100
12 173 9.0 1710 0.4
15 171 1465 0.5
20 175 1085 9.0 0.6
H35 N2 12 49 85 60 120
25 180 785 0.7
32 185 7.5 630 1.0
38 186 510
50 200 270
English
5/16 80
188 0.45 0.45 0.3
3/8 75 100
1/2 173 0.35 65 0.35 0.4
5/8 171 55 0.5
3/4 175 45 0.6
H35 N2 12 49 85 60 0.36 120
1 180 30 0.7
1-1/4 185 0.30 25 1.0
1-1/2 186 20
1-3/4 189 15 Edge start
2 200 10
Marking
N2 N2 10 10 10 10 18 2.5 0.10 6350 250 120
Ar N2 30 10 30 10 20 3.0 0.12 2540 100 63

Operation

H35 N2
260 A Cutflow 13 / 27 163 / 345
220637 220763 220758 220406 220405 220307 220340

Metric
Pierce
Delay
Time
6 170 3980
8 173 3085 0.3
10 175 2190
60 21
12 176 1790 0.5
8.0 200
15 177 1650 0.7
H35 N2 12 49 87 60 20 179 4.0 1320 0.8
25 182 920 1.0
32 186 755 1.2
40 26 38 189 510
50 202 270
English
Pierce
Delay
Time
1/4 170 150
5/16 173 121 0.3
3/8 175 90
60 21
1/2 176 0.5
65 0.32 200
5/8 177 0.7
H35 N2 12 49 87 60 3/4 179 0.16 55 0.8
1 182 35 1.0
1-1/4 186 30 1.2
40 26 1-1/2 189 20
1-3/4 187 15 Edge start
2 202 10
Marking
N2 N2 10 10 10 10 18 2.5 0.10 6350 250 120
Ar N2 30 10 30 10 20 3.0 0.12 2540 100 63

Operation

H35 N2
260 A Cutflow 40 / 84 122 / 260
220637 220738 220739 220607 220405 220606 220571

Notes: Bevel angle range is 0° to 45°.
Metric
Equivalent
Material
Thickness
8 2030
11.0 11.0 0.3
10 1870 100
12 9.0 – 10.0 1710 0.4
15 1465 0.5
20 1085 9.0 0.6
H35 N2 12 49 85 60 2.0 120
25 785 0.7
32 7.5 – 10.0 630 1.0
38 510
44 390 Edge start
50 270
English
Equivalent
Material
Thickness
5/16 80
0.45 – 0.40 0.45 0.3
3/8 75 100
1/2 0.35 – 0.40 65 0.35 0.4
5/8 55 0.5
3/4 45 0.6
H35 N2 12 49 85 60 0.08 0.36 120
1 30 0.7
1-1/4 0.30 – 0.40 25 1.0
1-1/2 20
1-3/4 15 Edge start
2 10
Marking
N2 N2 10 10 10 10 18 2.5 0.10 6350 250 120
Ar N2 30 10 30 10 20 3.0 0.12 2540 100 63

Operation

N2 Plasma / Air Shield N2 Air
Preflow 127 / 270 0 / 0
260 A Cutflow 54 / 114 116 / 245
220637 220738 220739 220607 220405 220606 220571

Metric
Equivalent
Material
Thickness
6 6375
8 4910 0.3
10 3440
12 2960 0.4
7.5 200
15 2520 0.5
N2 Air 12 47 79 56 2.0 20 3.8 – 10.0 1590 0.6
25 1300 0.8
32 875 1.0
38 515
44 365 Edge start
50 180
English
Equivalent
Material
Thickness
1/4 240
5/16 193 0.3
3/8 140
1/2 110 0.4
0.3 200
5/8 95 0.5
N2 Air 12 47 79 56 0.08 3/4 0.15 – 0.40 70 0.6
1 50 0.8
1-1/4 35 1.0
1-1/2 20
1-3/4 14 Edge start
2 6
Marking
N2 N2 10 10 10 10 18 2.5 0.10 6350 250 120
Ar N2 30 10 30 10 20 3.0 0.12 2540 100 63

Operation

H35 and N2 Plasma / N2 Shield H35 N2
Preflow 0 / 0 132 / 280
260 A Cutflow 13 / 27 163 / 345
220637 220738 220739 220607 220405 220606 220571

Metric
Equivalent Pierce
Material Delay
Time
6 3980
8 3085 0.3
10 2190
60 21
12 1790 0.5
8.0 200
15 1650 0.7
H35 N2 12 49 87 60 2.0 20 4.0 – 10.0 1320 0.8
25 920 1.0
32 755 1.2
40 26 38 510
44 390 Edge start
50 270
English
Equivalent Pierce
Material Delay
Time
1/4 150
5/16 121 0.3
3/8 90
60 21
1/2 0.5
65 0.32 200
5/8 0.7
H35 N2 12 49 87 60 0.08 3/4 0.16 – 0.40 55 0.8
1 35 1.0
1-1/4 30 1.2
40 26 1-1/2 20
1-3/4 15 Edge start
2 10
Marking
N2 N2 10 10 10 10 18 2.5 0.10 6350 250 120
Ar N2 30 10 30 10 20 3.0 0.12 2540 100 63

Operation

N2 Air
N2 Plasma / Air Shield Preflow 42 / 90 146 / 310
400 A Cutflow 86 / 182 102 / 217
220637 220707 220712 220708 220405 220709 220571
Metric
12 158 3300 0.3
3.8 9.9 260
15 159 2800 0.4
20 162 2340 0.5
4.6 13.8
N2 Air 30 50 85 31 25 164 1940 300 0.6
30 176 6.4 1450 19.2 0.8
40 177 570
4.6 Edge start
45 187 430
English
1/2 158 125 0.3
0.15 0.39 260
5/8 159 105 0.4
3/4 162 95 0.5
0.18 0.54
N2 Air 30 50 85 31 1 164 75 300 0.6
1-1/4 176 0.25 50 0.75 0.8
1-1/2 177 25
0.18 Edge start
1-3/4 187 17
Marking
N2 N2 10 10 10 10 22 2.5 0.10 1270 50 94
Ar N2 30 10 30 10 24 3.0 0.12 2540 100 50

Operation

H35 N2
400 A Cutflow 86 / 182 123 / 260
220637 220707 220712 220708 220405 220709 220571
Metric
20 180 1100 14.5 150 0.7
25 181 905 1.0
30 184 800 19.0 210 1.5
H35 N2 30 45 86 45 9.0
40 186 600 2.0
50 192 400
Edge start
60 198 280
English
3/4 180 45 0.53 150 0.7
1 181 35 1.0
1-1/4 184 30 0.75 210 1.5
1-1/2 186 25 2.0
H35 N2 30 45 86 45 0.35
1-3/4 189 20
2 192 15
Edge start
2-1/4 198 12
2-1/2 202 10
Marking
N2 N2 10 10 10 10 22 2.5 0.10 1270 50 94
Ar N2 30 10 30 10 24 3.0 0.12 2540 100 50

Operation

H35 N2
H35 and N2 Plasma / N2 Shield
Preflow 0 / 0 194 / 410
400 A Cutflow 36 / 77 194 / 410
220637 220707 220712 220708 220405 220709 220571

Metric
Pierce
Delay
Time
12 157 2750 0.4
15 159 2390 0.5
40 4.6 14
20 166 1810 0.7
25 172 1310 300 1.0
30 186 5.3 1080 16 2.0
H35 N2 30 45 88 45 60 40 720
187 19 3.0
45 635
60 50 190 520
6.4
60 192 410
Edge start
70 194 310
80 210 180
English
Pierce
Delay
Time
1/2 157 105 0.4
5/8 159 90 0.5
40 0.18 0.5
3/4 166 75 0.7
1 172 50 300 1.0
1-1/4 182 0.21 40 0.6 1.5
H35 N2 30 45 88 45 60 1-1/2 186 30 2.0
0.8
1-3/4 187 25 3.0
60 2 190 20
0.25
2-1/4 192 17
Edge start
2-1/2 194 15
3 202 10
Marking
N2 N2 10 10 10 10 22 2.5 0.10 1270 50 94
Ar N2 30 10 30 10 24 3.0 0.12 2540 100 50

Operation

N2 Air
N2 Plasma / Air Shield
Preflow 42 / 90 146 / 310
400 A Cutflow 86 / 182 102 / 217
220637 220707 220712 220708 220405 220709 220571
Metric
Equivalent
Material
Gases Preflow Cutflow Clearance Thickness Distance Speed Height Time

12 3300 0.3
3.8 – 11.6 9.9 260
15 2800 0.4
20 2340 0.5
4.6 – 11.6 13.8
N2 Air 30 50 85 31 2.0 25 1940 300 0.6
30 6.4 – 11.6 1450 19.2 0.8
40 570
4.6 – 11.6 Edge start
45 430
English
Equivalent
Material

1/2 125 0.3
0.15 – 0.46 0.39 260
5/8 105 0.4
3/4 95 0.5
0.18 – 0.46 0.54
N2 Air 30 50 85 31 0.08 1 75 300 0.6
1-1/4 0.25 – 0.46 50 0.75 0.8
1-1/2 25
0.18 – 0.46 Edge start
1-3/4 17
Marking
N2 N2 10 10 10 10 22 2.5 0.10 1270 50 94
Ar N2 30 10 30 10 24 3.0 0.12 2540 100 50

Operation

H35 N2
H35 Plasma / N2 Shield
Preflow 0 / 0 189 / 400
400 A Cutflow 86 / 182 123 / 260
220637 220707 220712 220708 220405 220709 220571
Metric
Equivalent
Material

20 1100 14.5 150 0.7
25 905 1.0
30 800 19.0 210 1.5
H35 N2 30 45 86 45 2.0 9.0 – 11.6
40 600 2.0
50 400
Edge start
60 280
English
Equivalent
Material

3/4 45 0.53 150 0.7
1 35 1.0
1-1/4 30 0.75 210 1.5
1-1/2 25 2.0
H35 N2 30 45 86 45 0.08 0.35 – 0.46
1-3/4 20
2 15
Edge start
2-1/4 12
2-1/2 10
Marking
N2 N2 10 10 10 10 22 2.5 0.10 1270 50 94
Ar N2 30 10 30 10 24 3.0 0.12 2540 100 50

Operation

Preflow 0 / 0 194 / 410
400 A Cutflow 36 / 77 194 / 410
220637 220707 220712 220708 220405 220709 220571

Metric
Equivalent Pierce
Material Delay
Gases Preflow Cutflow Clearance Distance Speed Height
Thickness Time
12 2750 0.4
15 2390 0.5
40 4.6 – 11.6 14
20 1810 0.7
300
25 1310 1.0
30 5.3 – 11.6 1080 16 2.0
H35 N2 30 45 88 45 60 2.0
40 720 19 3.0
50 520
60
60 6.4 – 11.6 410
Edge start
70 310
80 180
English
Equivalent Pierce
Material Delay
Gases Preflow Cutflow Clearance Distance Speed Height
Thickness Time
1/2 105 0.4
5/8 90 0.5
40 0.18 – 0.46 0.5
3/4 75 0.7
1 50 300 1.0
1-1/4 0.21 – 0.46 40 0.6 1.5
H35 N2 30 45 88 45 60 0.08 1-1/2 30 2.0
0.8
1-3/4 25 3.0
60 2 20
0.25 – 0.46
2-1/4 17
Edge start
2-1/2 15
3 10
Marking
N2 N2 10 10 10 10 22 2.5 0.10 1270 50 94
Ar N2 30 10 30 10 24 3.0 0.12 2540 100 50

Operation
Aluminum Flow rates – lpm/scfh

Air
Air Plasma / Air Shield Preflow 45 / 95
45 A Cutflow 78 / 165
220747 220202 220756 220201 220180 220308 220340
Metric
1.2 130 4750
1.5 115 4160
49 2 113 2.5 3865 3.8 0.2
Air Air 35 19 62 2.5 110 3675 150
3 107 2850
4 102 1.8 2660 2.7 0.3
33
6 117 3.0 1695 4.5 0.6
English
0.040 130 220
0.051 115 170
49 0.10 0.15 0.2
0.064 113 160
Air Air 35 19 62 0.102 110 140 150
0.125 102 0.07 110 0.11 0.3
33 3/16 114 90 0.4
0.12 0.18
1/4 117 60 0.6
Marking
N2 N2 10 10 10 10 15 2.5 0.10 6350 250 85
Ar Air 90 10 90 10 12 2.5 0.10 2540 100 75

Operation

Air
Air Plasma / Air Shield Preflow 73 / 154
130 A Cutflow 78 / 165
220747 220198 220756 220197 220179 220181 220340
Metric
6 153 2.8 2370 5.6 0.2
8 1920
154 0.3
10 3.0 1465 6.0
200
Air Air 19 31 75 23 12 156 1225 0.5
15 158 3.3 1050 6.6 0.8
20 162 3.5 725 7.0 1.3
25 172 4.0 525 Edge start
English
1/4 153 0.11 90 0.22 0.2
5/16 76
154 0.3
3/8 0.12 60 0.24
200
Air Air 19 31 75 23 1/2 156 45 0.5
5/8 158 0.13 40 0.26 0.8
3/4 162 0.14 30 0.28 1.3
1 172 0.16 20 Edge start
Marking
N2 N2 10 10 10 10 18 2.5 0.10 6350 250 120
Ar Air 50 10 50 10 15 3.0 0.12 2540 100 82
Note: This process produces a rougher cut edge that is less perpendicular than the 130 A, H35/N2 process.

Operation

H35 N2
130 A Cutflow 26 / 54 68 / 144
220747 220198 220755 220197 220179 220307 220340
Metric
8 1775
49 158 5.0 6.5 130 0.3
10 1615
37 12 1455 0.5
H35 N2 19 32 75 156
15 1305 7.7 170 0.8
24 4.5
20 157 940 1.3
16 25 176 540 Edge start
English
5/16 70
49 158 0.20 0.26 130 0.3
3/8 65
37 1/2 55 0.5
H35 N2 19 32 75 156
5/8 50 0.31 170 0.8
24 0.18
3/4 157 40 1.3
16 1 176 20 Edge start
Marking
N2 N2 10 10 10 10 18 2.5 0.10 6350 250 130
Ar N2 50 10 50 10 15 3.0 0.12 2540 100 75

Operation

H35 N2
130 A Cutflow 13 / 28 71 / 150
220747 220198 220755 220197 220179 220307 220340
Metric
Pierce
Delay
Time
6 156 2215
8 157 3.5 1915 7.0 0.3
10 158 1615
H35 N2 19 51 75 27 32 18 200
12 159 1455 0.5
15 160 3.0 1215 6.0 0.8
20 163 815 1.3
English
Pierce
Delay
Time
1/4 156 85
5/16 157 0.14 75 0.28 0.3
3/8 158 65
H35 N2 19 51 75 27 32 18 200
1/2 159 55 0.5
5/8 160 0.12 45 0.24 0.8
3/4 163 35 1.3
Marking
N2 N2 10 10 10 10 18 2.5 0.10 6350 250 130
Ar N2 50 10 50 10 15 3.0 0.12 2540 100 75

Operation

N2
200 A Cutflow 135 / 287
220637 220762 220759 220346 220342 220307 220340
Metric
8 6000 0.3
10 158 4750 0.4
N2 N2 17 43 73 43 12 6.4 3500 9.0 140 0.5
15 166 2350 0.6
20 165 1000 0.8
English
5/16 236 0.3
3/8 158 200 0.4
N2 N2 17 43 73 43 1/2 0.25 120 0.35 140 0.5
5/8 166 80 0.6
3/4 165 50 0.8
Marking
N2 N2 10 10 10 10 18 2.5 0.10 6350 250 140
Ar N2 30 10 30 10 20 3.0 0.12 2540 100 66

Operation

H35 N2
200 A Cutflow 34 / 72 90 / 190
220637 220762 220759 220346 220342 220307 220340
Metric
8 5000
152 0.3
10 4400
H35 N2 17 43 73 43 12 6.4 3800 9.0 140 0.4
150
15 3000 0.5
20 159 1450 0.6
English
5/16 197
152 0.3
3/8 180
H35 N2 17 43 73 43 1/2 0.25 140 0.35 140 0.4
150
5/8 110 0.5
3/4 159 70 0.6
Marking
N2 N2 10 10 10 10 18 2.5 0.10 6350 250 140
Ar N2 30 10 30 10 20 3.0 0.12 2540 100 66

Operation

H35 N2
200 A Cutflow 13 / 27 126 / 267
220637 220762 220759 220346 220342 220307 220340
Metric
Pierce
Delay
Time
8 4350
0.3
10 158 4000
H35 N2 17 44 73 44 42 20 12 6.4 3650 9.0 140 0.4
15 162 2450 0.5
20 170 1050 0.6
English
Pierce
Delay
Time
5/16 171
0.3
3/8 158 160
H35 N2 17 44 73 44 42 20 1/2 0.25 140 0.35 140 0.4
5/8 162 80 0.5
3/4 170 50 0.6
Marking
N2 N2 10 10 10 10 18 2.5 0.10 6350 250 140
Ar N2 30 10 30 10 20 3.0 0.12 2540 100 66

Operation

N2 Air
N2 Plasma / Air Shield Preflow 125 / 265 0/0
260 A Cutflow 50 / 105 113 / 240
220637 220763 220758 220406 220405 220307 220340

Metric
6 7900 0.2
172
8 6.4 6415 9.0 140 0.3
10 171 4930 0.4
12 164 4290 0.5
15 165 3330 8.0 200
0.6
N2 Air 12 49 74 56 20 171 1940
25 177 1440 11.0 260 0.8
4.0
32 191 940
38 195 520
Edge start
44 202 320
50 205 215
English
1/4 300 0.2
172
5/16 0.25 253 0.35 140 0.3
3/8 171 200 0.4
1/2 164 160 0.5
5/8 165 120 0.32 200
0.6
N2 Air 12 49 74 56 3/4 171 80
1 177 55 0.42 260 0.8
0.16
1-1/4 190 40
1-1/2 195 20
Edge start
1-3/4 202 12
2 205 8
Marking
N2 N2 10 10 10 10 18 2.5 0.10 6350 250 120
Ar N2 30 10 30 10 20 3.0 0.12 2540 100 63

Operation

H35 N2
260 A Cutflow 33 / 70 118 / 250
220637 220763 220758 220406 220405 220307 220340

Metric
6 7200 0.2
11.0 11.0
8 170 6660 100 0.3
10 10.0 6120 10.0 0.4
12 162 5160 0.5
15 163 3720 8.5 110
0.6
H35 N2 12 49 76 58 20 166 2230
25 174 1930 11.0 150 0.8
7.6
32 175 1510
38 176 1150
Edge start
44 183 670
50 190 390
English
1/4 280 0.2
0.45 0.45
5/16 170 262 100 0.3
3/8 0.40 250 0.40 0.4
1/2 162 190 0.5
5/8 163 130 0.33 110
0.6
H35 N2 12 49 76 58 3/4 166 90
1 174 75 0.45 150 0.8
0.30
1-1/4 175 60
1-1/2 176 45
Edge start
1-3/4 183 25
2 190 14
Marking
N2 N2 10 10 10 10 18 2.5 0.10 6350 250 120
Ar N2 30 10 30 10 20 3.0 0.12 2540 100 63

Operation

N2 Air
N2 Plasma / Air Shield Preflow 42 / 90 146 / 310
400 A Cutflow 68 / 144 103 / 219
220637 220707 220712 220708 220405 220709 220571
Metric
12 155 4480 0.4
3.8 12.5 330
15 159 3770 0.5
20 163 2740 0.6
18.0 440
N2 Air 30 50 70 31 25 169 1850 0.7
30 175 4.1 1410
50 206 410
English
1/2 155 170 0.4
0.15 0.5 330
5/8 159 140 0.5
3/4 163 115 0.6
0.7 440
1 169 70 0.7
N2 Air 30 50 70 31
1-1/4 177 50
0.16
1-1/2 178 35
Edge start
1-3/4 198 25
2 206 16
Marking
N2 N2 10 10 10 10 22 2.5 0.10 1270 50 94
Ar N2 30 10 30 10 24 3.0 0.12 2540 100 50

Operation

N2 Air
400 A Cutflow 86 / 182 123 / 260
220637 220707 220712 220708 220405 220709 220571
Metric
20 170 2420 13.5 150 0.7
25 175 1820 1.0
30 177 1590 18.9 210 1.5
40 180 1190 2.0
H35 N2 30 45 86 45 9.0
50 188 790
60 200 450
Edge start
70 208 310
80 210 210
English
3/4 170 100 0.53 150 0.7
1 175 70 1.0
1-1/4 177 60 0.74 210 1.5
1-1/2 180 50 2.0
H35 N2 30 45 86 45 1-3/4 184 0.35 40
2 188 30
2-1/4 200 20 Edge start
2-1/2 208 15
3 210 10
Marking
N2 N2 10 10 10 10 22 2.5 0.10 1270 50 94
Ar N2 30 10 30 10 24 3.0 0.12 2540 100 50

Operation
Aluminum
Flow rates – lpm/scfh
400 A Preflow 0 / 0 194 / 410
Cutflow 36 / 77 194 / 410
220637 220707 220712 220708 220405 220709 220571

Metric
Pierce
Delay
Time
12 155 5190 0.4
15 157 4710 0.5
40 4.6 14
20 159 3620 0.7
300
25 166 2620 1.0
30 171 5.3 2170 16 1.5
H35 N2 30 45 88 45 60
40 175 1440 19 2.0
50 185 1000
60
60 195 6.4 450
Edge start
70 200 310
80 208 210
English
Pierce
Delay
Time
1/2 155 200 0.4
5/8 157 180 0.5
40 0.18 0.5
3/4 159 150 0.7
300
1 166 100 1.0
1-1/4 171 0.21 80 0.6 1.5
H35 N2 30 45 88 45 60 1-1/2 175 60 0.8 2.0
1-3/4 180 50
60 2 185 40
0.25
2-1/4 195 20 Edge start
2-1/2 200 15
3 208 10
Marking
N2 N2 10 10 10 10 22 2.5 0.10 1270 50 94
Ar N2 30 10 30 10 24 3.0 0.12 2540 100 50

Section 5
Maintenance
In this section:
Introduction..................................................................................................................................................................................................5-3
Routine maintenance.................................................................................................................................................................................5-3
Power and signal cables.................................................................................................................................................................5-4
Sequence of operation..............................................................................................................................................................................5-5
Gas system purge cycle............................................................................................................................................................................5-6
Gas system valve usage............................................................................................................................................................................5-6
Marking process...............................................................................................................................................................................5-8
Error codes...................................................................................................................................................................................................5-9
Error code troubleshooting – error codes 116 to 133, 316............................................................................................. 5-20
Error code troubleshooting – error codes 134 to 140, 334 and 338............................................................................ 5-21
Error code troubleshooting – error code 181, 182, and 383.......................................................................................... 5-26
Power supply states................................................................................................................................................................................ 5-27
Plasma system operation with pump time-out.................................................................................................................................. 5-28
CNC operation with pump time-out.................................................................................................................................................... 5-29
Initial checks.............................................................................................................................................................................................. 5-30
Power measurement............................................................................................................................................................................... 5-31

Maintenance
Air filter element replacement............................................................................................................................................................... 5-32

Coolant system servicing....................................................................................................................................................................... 5-33
Draining the coolant system........................................................................................................................................................ 5-33
Coolant system filter............................................................................................................................................................................... 5-34
Filter replacement.......................................................................................................................................................................... 5-34
Coolant flow troubleshooting chart..................................................................................................................................................... 5-35
Coolant flow tests.................................................................................................................................................................................... 5-36
Before testing................................................................................................................................................................................. 5-36
Bypass valve verification.............................................................................................................................................................. 5-37
Using the Hypertherm flow meter (128933)........................................................................................................................... 5-37
Manual pump operation............................................................................................................................................................... 5-38
Test 1 – return line...................................................................................................................................................................... 5-39
Test 2 – supply line at ignition console.................................................................................................................................. 5-39
Test 3 – change the torch......................................................................................................................................................... 5-40
Test 4 – supply line to the torch receptacle......................................................................................................................... 5-40
Test 5 – return line from the torch receptacle (remove at the ignition console).......................................................... 5-40
Test 6 – bucket test at the pump............................................................................................................................................ 5-41
Pump and motor troubleshooting.............................................................................................................................................. 5-42
Testing the flow sensor................................................................................................................................................................ 5-42
Gas leak tests........................................................................................................................................................................................... 5-43
Leak test 1 (inlet leak test).......................................................................................................................................................... 5-43
Leak test 2 (system leak test)..................................................................................................................................................... 5-44
Leak test 3 (proportional valve test in the metering console)............................................................................................. 5-44
Power supply control board PCB3..................................................................................................................................................... 5-45
Power supply power distribution board PCB2................................................................................................................................. 5-46
Start-circuit PCB1................................................................................................................................................................................... 5-47
Operation........................................................................................................................................................................................ 5-47
Start circuit functional schematic.............................................................................................................................................. 5-47
Start circuit troubleshooting....................................................................................................................................................... 5-47
Pilot arc current levels............................................................................................................................................................................ 5-49
Pump motor drive board PCB7............................................................................................................................................................ 5-50
Cooler power distribution board PCB1............................................................................................................................................. 5-51
Cooler sensor board PCB2.................................................................................................................................................................. 5-52
Selection console control board PCB2............................................................................................................................................. 5-53
Selection console power distribution board PCB1......................................................................................................................... 5-54
Selection console, AC valve-driver board PCB3............................................................................................................................. 5-55
Metering console control board PCB2............................................................................................................................................... 5-56
Metering console power distribution board PCB1.......................................................................................................................... 5-57
Chopper tests........................................................................................................................................................................................... 5-58
Phase-loss detection test...................................................................................................................................................................... 5-60
Torch lead test.......................................................................................................................................................................................... 5-61
Preventive maintenance.......................................................................................................................................................................... 5-62

Maintenance
Introduction
Hypertherm assumes that the service personnel performing the troubleshooting testing are high-level
electronic service technicians who have worked with high-voltage electro-mechanical systems. Knowledge
of final isolation troubleshooting techniques is also assumed.
In addition to being technically qualified, maintenance personnel must perform all testing with safety in
mind. Refer to the Safety section for operating precautions and warning formats.
WARNING
Shock Hazard
Use extreme care when working near the chopper modules. Each large electrolytic capacitor (blue-
cased cylinder) stores large amounts of energy in the form of electric voltage. Even if the power is
off, dangerous voltages exist at the capacitor terminals, on the chopper, and the diode heatsinks.
Never discharge any capacitor with a screwdriver or other implement… explosion, property
damage and/or personal injury will result.
Routine maintenance
For a complete list of routine maintenance recommendations, see the Preventive Maintenance Schedule, located at
the end of this section. Contact the Technical Services department listed at the front of this manual with any questions
regarding the maintenance schedule or procedures.

Maintenance
System description
Power and signal cables
Power cable: Provides 120 VAC to the

selection console.
CAN Bus signal cable: Provides process and

status signals between the power supply and
the selection console.
Power cable: Provides 120 VAC to the

ignition console.
Power cable: Provides 120 VAC

and 240 VAC to the cooler.
CAN Bus signal cable: Provides

process and status signals between the
power supply and the cooler.
Power cable: Provides 120 VAC to the metering console.
CAN Bus signal cable: Provides process and

status signals between the power supply and the metering
console.

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 overtemp off
Magnetics overtemp off
Coolant overtemp off
Plasma start off
2. Purge – Air or N2 gas flows through torch for 20 seconds

Contactor closes and the chopper performs a chopper test and a current sensor test
Plasma start off
Contactor remains closed when the purge cycle ends
3. Idle
Gas pressure ok
Coolant flow on
Chopper current off
Line voltage ok
4. Preflow – 2-second flow of gas
5. Pilot arc – Current flows between electrode and nozzle

Chopper, main contactor and pilot arc relay are on
High frequency present
Chopper current sensor = pilot arc current
6. Transfer – Pilot arc current sensed on the worklead
7. Ramp-up – Chopper current increases to its setpoint and gas changes to cutflow
Coolant flow on
Gas pressure ok
Phase-loss on
Line voltage ok
8. Steady state – normal operating parameters

Coolant flow on
Gas pressure ok
Phase loss on
Chopper 1 overtemp off
Magnetics overtemp off
Coolant overtemp off
9. Ramp-down – Current and gas flow decrease after plasma start has been removed
Cutflow gas off
10. Auto Off – 10-second postflow

Main contactors off
Choppers off

Maintenance
Gas system purge cycle

When the system is turned on, or the operator changes from one cut process to another, the system automatically goes
through a purge cycle. The purge cycle has 2 stages; a preflow purge and a cutflow purge.
The preflow purge gas flows for 8 seconds with an auto gas console, or 12 seconds with a manual gas console.
The cutflow purge gas flows for 8 seconds with an auto gas console, or 12 seconds with a manual gas console.
There are 2 exceptions to the cycle described above.

Exception 1 – if the operator changes from a non-fuel gas process (O2/Air, Air/Air, or N2/Air) to a fuel gas process
(H35/N2, or F5/N2) or the reverse, there will be 3 stages to the purge process. Nitrogen will purge the
gas system first, for 12 seconds. The preflow and cutflow purges will follow the nitrogen purge.
Note: Error code 42 (low nitrogen gas pressure) will be displayed, if nitrogen is not connected to the gas system.
If error code 42 is not resolved in 3 minutes, it will be replaced by error code 139 (purge time-out error).
Exception 2 – no purge cycle will occur if the operator changes from any cut process to a nitrogen or argon marking
process.
Gas system valve usage

The following tables show which valves are active for each cutting process.
O2/O2 Metering console

Selection console control board
process control board
LED number 38 39 28 37 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Preflow B4 B2 SV1 SV3 SV8 SV10
Cutflow B3 B1 SV1 SV3 SV8 SV10
O2/Air Metering console

LED number 38 39 28 37 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
N2/N2 Metering console

LED number 38 39 28 37 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Preflow B4 B1 SV9 SV11
Cutflow B4 B1 SV9 SV11

Maintenance
F5/N2 Metering console

LED number 38 39 28 37 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Cutflow B4 B1 SV6 SV9 SV14
H35/N2 Metering console

LED number 38 39 28 37 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
H35 & N2/N2 Metering console

LED number 38 39 28 37 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
N2/Air Metering console

LED number 38 39 28 37 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Preflow B3 B2 SV3 SV9 SV10
Air/Air Metering console

LED number 38 39 28 37 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Maintenance
Marking process
The valves that are active when marking are represented by the tables below. The active valves in the metering console
will differ depending on what process was used before marking.
Valves active when changing from a process that does not use a fuel gas
Metering console
N2/N2 Selection console control board
control board
LED number 38 39 28 37 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Preflow B4 B2 SV11
Cutflow B4 B2 SV11
Valves active when changing from a process that does use a fuel gas
Metering console
N2/N2 Selection console control board
control board
LED number 38 39 28 37 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Preflow B3 B1 SV9
Cutflow B3 B1 SV9
Metering console
Ar/N2 Selection console control board
control board
LED number 38 39 28 37 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Cutflow B4 B1 SV9 SV15
Ar/Air
Metering console
25 to 35 Selection console control board
control board
amps
LED number 38 39 28 37 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Ar/Air
Metering console
< 25 or Selection console control board
control board
> 35 amps
LED number 38 39 28 37 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Maintenance
Error codes
Error codes are displayed on the CNC screen. The diagnostic screen shown below is for reference. The screens you
work with may be different, but should include the functions described in the Operation section of this manual.

Maintenance
Error code troubleshooting – error codes 000 to 018
Error code
Name Description Corrective action
number
000 No error System is ready to run. None needed.
The flow switch is tested
when the pump restarts
after a pump timeout
Flow switch (30 minutes without a
009 Wait 10 seconds for the flow rate to stabilize.
test start signal). The test
ensures that the coolant
flow is correct before
firing the torch.
The current setting is

greater than the capability
No active 1. Verify that the secondary power supply is turned ON.
of the selected process.
processs
When this error code
011 HPR400XD 2. V
erify that the current for the selected process is within
occurs, the power supply
HPR800XD the range of the power supply capability (up to 400A for
will ignore the start signal
Only 400XD, and up to 800A for 800XD).
until a correct process is
chosen.
Test in One of the gas test

012 Wait for the test to finish.
progress modes is running.
013 Test passed The test was successful. No action required.
The gas pressure in

Cut gas Look for leaks and loose connections between the selection
014 channel 1 is decreasing,
channel 1 fail console and the metering console.
which indicates a leak.
The gas pressure in

Cut gas Look for leaks and loose connections between the selection
015 channel 2 is decreasing,
channel 2 fail console and the metering console.
which indicates a leak.
Plasma Plasma pressure did

016 rampdown not decrease in the time Verify that there is no obstruction in the plasma vent hose.
fail allowed.
Shield Shield pressure did not

Inspect the holes in the shield for obstructions. Replace the
017 rampdown decrease in the time
shield if the holes are blocked.
fail allowed.

Maintenance
Error code troubleshooting – error codes 020 to 028, 224 to 228
Error code
number
1. Verify that the consumable parts are in good condition.
2. Verify proper preflow and cut-flow settings.
3. Perform gas leak tests (see Maintenance section).
No current detected from
4. Verify spark across spark gap.
020 No pilot arc chopper at ignition and
5. Inspect CON1 and pilot arc relay for excessive wear.
before 1-second timeout.
6. Perform gas flow test (see Maintenance section).
7. Perform torch lead test (see Maintenance section).
8. Perform start circuit test (see Maintenance section).
No current detected
1. Verify proper pierce height.
No arc on work lead 500 milli-
021 2. Verify proper preflow and cut-flow settings.
transfer seconds after pilot arc
3. Inspect work lead for damage or loose connections.
current was established.

024
2. Verify proper cut-flow gas settings.
Primary Lost current Lost the current signal from
3. Verify pierce delay time.
224 Chopper 1 Chopper 1 after transfer.
4. Verify arc did not lose contact with plate while cutting
Secondary (hole cutting, scrap cutting, etc).
Lost current 1. Verify that the consumable parts are in good condition.
025
Chopper 2 2. Verify proper cut-flow gas settings.
Primary Lost the current signal from
HPR260XD 3. Verify pierce delay time.
225 Chopper 2 after transfer.
HPR400XD 4. Verify arc did not lose contact with plate while cutting
Secondary Only (hole cutting, scrap cutting, etc).

026 2. Verify proper cut-flow gas settings.
Primary 3. Verify pierce delay time.
Lost the transfer signal
Lost transfer 4. Verify arc did not loose contact with plate while cutting
226 after transfer completed.
(hole cutting, scrap cutting, etc).
Secondary
5. Inspect work lead for damage or loose connections.
6. Try connecting work lead directly to the plate.
1. Verify phase-to-phase voltage to power supply.

2. Disconnect power to power supply, remove cover on
027 contactor and inspect contacts for excessive wear.
Phase imbalance to
Primary 3. Inspect power cord, contactor, and input to chopper for
Lost phase chopper after contactor
227 loose connections.
engaged or while cutting.
Secondary 4. Inspect phase loss fuses on Power Distribution board.
Replace board if fuses are blown.
5. Perform phase loss test (see Maintenance section).
028 1. Verify that the consumable parts are in good condition.

Lost current
Primary 2. Verify proper cut-flow gas settings.
Chopper 3 Lost the current signal from
228 HPR400XD Chopper 3 after transfer.
4. Verify arc did not lose contact with plate while cutting
Secondary Only

Maintenance
Error code
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.
power cable) is not damaged and is properly connected
Gas system inside the power supply and to the rear of the gas
error A failure has occurred in the console.
030
Auto Gas gas system. 3. Verify that D1 (+5 VDC) and D2 (+3.3 VDC) are
Only illuminated on PCB2 inside the gas console. These LEDs
indicate power to PCB2.
4. If power is present at PCB2 and PCB3 and both gas
console cables are good, then PCB2 or PCB3 has failed.
Use the CAN tester to verify which board needs to be
replaced.
1. If a mechanical relay is being used to provide the HPR
with a start signal, this relay is either bouncing when
031 activated or the contacts are faulty. Replace the relay.
Start signal was received
Primary 2. Inspect interface cable for damage; faulty crimps, or poor
Start lost and then lost before an arc
231 electrical connections.
was established.
Secondary 3. If interface cable is good and a relay is not driving the
start input, the CNC is dropping the start signal before a
steady state arc has been established.
1. Check the interface cable for damage. The hold wires

may be short-circuiting inside.
Hold signal was active for 2. The CNC is maintaining this input, it could be waiting for
032 Hold timeout
longer than 60 seconds. an IHS complete input from another torch.
3. If CNC interface cable is good and it is a 1-torch system,
change PCB3.
Precharge
Selection console was not This is a warning for a possible gas restriction in the leads.
time-out
033 able to charge the lines to Verify that there are no restrictions in the plasma and shield
Auto Gas
the correct value. hoses, or low inlet-gas pressure.
Only
034 1. Verify that the consumable parts are in good condition.

Lost current
Primary 2. Verify proper cut-flow gas settings.
Chopper 4 Lost the current signal from
234 HPR400XD Chopper 4 after transfer.
4. V
erify arc did not lose contact with plate while cutting
Secondary Only
Nitrogen gas pressure

under lower limit of: 1.Verify that the nitrogen supply is turned on and inspect
2.07 bar (30 psi) – cutting gas supply pressure and volume of gas remaining in
Low nitrogen
0.34 bar (5 psi) – marking supply tanks.
042 (N2) gas
During N2 purge, when
pressure 2. Verify that the gas regulator is set to 8.27 bar (120 psi).
changing between a fuel
gas process and an oxidizer See Setting the supply regulators (Installation section).
process.

Maintenance
Error code
number
Plasma gas pressure under

1. Inspect gas supply pressure and volume of gas remaining
lower limit of
in supply tanks.
0.34 bar (5 psi) – preflow
Low plasma 2. Verify the gas regulator settings on gas console with the
044 3.45 bar (50 psi) – cutflow
gas pressure parameters in the cut charts.
(cutting)
3. See Setting the supply regulators (Installation section).
0.34 bar (5 psi) – cutflow
4. Perform gas leak tests (Maintenance section).
(marking)
1. Verify gas supply pressure settings.

Plasma gas pressure over 2. Verify gas regulator settings on gas console with cut chart.
upper limit of: 3. See Setting the supply regulators (Installation section).
High plasma
045 7.58 bar (110 psi) – 4. Solenoid at off-valve is not opening. Verify power to valves,
gas pressure
manual disconnect plasma and shield hoses exiting off-valve.
9.65 bar (140 psi) – auto If pressures decrease a valve is not functioning or no
power to the valve.
1. Verify input-line voltage at PCB2 in the power supply (also

PCB1 in the cooler for HPR400XD systems). Voltage
needs to be within 10% of nominal (120 VAC).
2. Verify fuses on PCB2 in the power supply.
3. Verify 120 VAC voltage on plug J2.4, pins 3 and 4 on
PCB2 in the power supply.
4. For HPR400XD systems, verify the voltage on PCB1 in the
cooler with a DC volt meter. It should be about 0.415 VDC
Line voltage is close to or between TP23 and TP2 on PCB1.
less than the lower limit 5. If AC voltage on PCB2, J2.4, pins 3 and 4, is greater than
of 102 VAC (120 VAC 108 VAC and DC voltage between TP23 and TP2 on
Low line
046 -15%). The normal lower PCB1 is less than 0.38 VDC, verify minimum 108 VAC
voltage
limit for operation is voltage on plug J4, pins 1 and 2 on PCB1. Verify the wiring
108 VAC (120 VAC between PCB2 in the power supply and J4 on PCB1. If
-10%). the voltage on plug J4 is greater than 108 VAC, but the
DC voltage on TP23 and TP2 is less than 0.38, replace
PCB1.
6. If the AC voltage on PCB2 in the power supply at J2.4,
pins 3 and 4, is greater than 108 VAC and the DC
voltage between TP23 and TP2 on PCB1 in the cooler
(HPR400XD only) is also greater than 0.38 VDC, verify the
CAN link between PCB3 in the power supply and PCB1 in
the cooler.

Maintenance
Error code
number
1. Verify input–line voltage at PCB2 in the power supply and
PCB1 in the cooler (HPR400XD only). Voltage needs to be
within 10% of nominal (120 VAC).
2. Verify fuses on PCB2 in the power supply.
3. Verify 120 VAC voltage on plug J2.4, pins 3 and 4 on PCB2
in the power supply.
4. Verify the voltage on PCB1 in the cooler (HPR400XD
Line voltage is close to or only) with a DC volt meter. It should be about 0.415 VDC
greater than the upper limit between TP23 and TP2 on PCB1.
of 138 VAC 5. If AC voltage on PCB2, J2.4, pins 3 and 4, is less than
High line
047 (120 VAC +15%). 132 VAC and DC voltage between TP23 and TP2 on PCB1
voltage
The normal upper limit for is greater than 0.44 VDC, verify maximum 132 VAC voltage
operation is 132 VAC on plug J4, pins 1 and 2 on PCB1. Verify wiring between
(120 VAC +10%). PCB2 in the power supply and J4 on PCB1. If the voltage
on plug J4 is less than 132 VAC, but the DC voltage on
TP23 and TP2 is greater than 0.44, replace PCB1.
6. If the AC voltage on PCB2 in the power supply on plug
J2.4, pins 3 and 4, is less than 132 VAC and the DC voltage
between TP23 and TP2 on PCB1 in the cooler (HPR400XD
only) is also less than 0.44 VDC, verify the CAN link
between PCB3 in the power supply and PCB1 in the cooler.
control cable) is not damaged and is properly connected to
PCB3 and to the rear of the gas console.
048 power cable) is not damaged and is properly connected
An error occurred with
Primary inside the power supply and to the rear of the gas console.
the CAN communications
CAN error 3. Verify that D1 (+5 VDC) and D2 (+3.3 VDC) are illuminated
248 between the power supply
on PCB2 inside the gas console. These LEDs indicate
Secondary and the gas console.
power to PCB2.
replaced.
1. Stop or clear the cutting program. The plasma start signal to
the plasma was not dropped after the last cut.
050 2. Verify that the CNC interface cable is not damaged.
Start signal Plasma start signal input is 3. Remove CNC interface cable from PCB3 and look for an
Primary
is on at active during power-up of open circuit between pins 15 and 34.
250 power-up power supply. 4. If the circuit is closed either the CNC is issuing a plasma
Secondary
start or the CNC interface cable is damaged.
5. If circuit is open, and LEDN300J is illuminated with CNC
Interface cable removed from PCB3, replace PCB3.
1. Verify gas supply pressure and that a sufficient volume of

Shield pressure is below gas remains in your supply.
Low shield
053 lower limit of 0.14 bar 2. Verify gas regulator settings on gas console with cut chart.
gas pressure
(2 psi). 3. See Setting the supply regulators (Installation section).
4. Perform gas leak tests (Maintenance section).

Maintenance
Error code
number
1. Verify gas supply regulator settings. See Setting the

supply regulators (Installation section).
Shield gas pressure is over
High 2. Verify pressure settings on gas console with cut chart.
upper limit of:
054 shield gas 3. Solenoid at off-valve is not opening. Verify power to
7.58 bar (110 psi) – manual
pressure valves, disconnect plasma and shield hoses exiting off-
9.65 bar (140 psi) – auto
valve. If pressures decrease, a valve is not functioning or
no power to the valve.
MV1 inlet Motor valve 1 inlet pressure

1. V
erify that gas pressure transducer P1 is between 3.45
pressure is less than 3.45 bar
055 bar (50 psi) and 9.65 bar (140 psi). Increase or decrease
Auto Gas (50 psi) or greater than
the inlet gas pressure to correct the problem.
Only 9.65 bar (140 psi).
MV2 inlet Motor valve 2 inlet pressure

1. Verify that gas pressure transducer P2 is between 3.45
pressure is less than 3.45 bar
Only 9.65 bar (140 psi).
Cut gas 1 outlet pressure is

Cut gas 1 less than 3.45 bar
1. Verify that gas pressure transducer P3 is between 3.45
pressure
Only 9.65 bar (140 psi) in the
selection console.
Cut gas 2 outlet pressure is
less than 3.45 bar
Cut gas 2
1. V
erify that gas pressure transducer P4 is between 3.45
pressure (50 psi) for non-mixing, or
Auto Gas less than 1.38 bar (20 psi)
Only when mixing or greater than
9.65 bar (140 psi) for non-
mixing and mixing.
Coolant flow is less than the 1. Verify that the correct consumables are properly installed.
Low coolant
060 required 2.3 lpm 2. Perform the coolant flow test procedure in the
flow
(0.6 gpm). Maintenance section of the manual.
1. Auto gas - the process parameters may not have been

downloaded. Verify that the process information can be
Manual gas - The gas viewed on the CNC screen.
console control board is not 2. Manual gas - the selector knob (2) may be set between
receiving signals from the positions. Reset the knob.
No plasma
061 gas selector knob. 3. Verify that there is power to the console by looking to
gas type
Auto gas - The selection see if any LED on any board in the selection console
console is not receiving the (auto) or gas console (manual) is illuminated. If no LED is
plasma gas type signal. illuminated, verify that the fuse on the power distribution
PCB is in proper working condition.
4. If the problem still exists, replace the control board.

Maintenance
Error code
number
1. Auto gas – The process parameters may not have been
downloaded. Verify that the process information can be
Manual gas – The gas viewed on the CNC screen.
console control board is 2. Manual gas – The selector knob (2) may be set between
not receiving signals from positions. Reset the knob.
No shield gas the gas selector knob.
062 3. Verify that there is power to the console by looking to see
type
Auto gas – The selection if any LED on any board in the selection console (auto)
console is not receiving or gas console (manual) is illuminated. If no LEDs are
the shield gas type signal. illuminated, verify that the fuse on the power distribution
PCB is in proper working condition.
4. If the problem still exists, replace the control board.
1. Verify that all chopper fans are operating properly.
Spinning fan blades should be difficult to see.
2. Blow dust out of system, especially from fans and heat
sink of chopper.
065
3. Verify that the voltage on rear side of J3.202, pins 2 and 3
Primary Chopper 1 Chopper 1 has
on PCB3, is less than or equal to 2.9 VDC.
265 overtemp overheated.
4. If the voltage is low, verify correct wiring between chopper
Secondary temperature sensor and J3.202 pins 1 and 2.
5. If wiring is good and overtemp error does not clear after
30 minutes of the power supply idling with the fans
running, replace the chopper.
066 Chopper 2 sink of chopper.
Primary overtemp 3. Verify that the voltage on rear side of J3.202, pins 5 and 6
Chopper 2 has
HPR260XD on PCB3, is less than or equal to 2.9 VDC.
266 overheated.
HPR400XD 4. If the voltage is low, verify correct wiring between chopper
Secondary
Only temperature sensor and J3.202 pins 4 and 5.
1. Verify that all the large fans are operating properly.

2. Blow dust out of system especially from fans and large
power transformer.
3. Verify that the voltage on the rear side of J3.202
067 pins 14 and 15, is equal to or less than 3.2 VDC.
Primary Magnetics Power transformer has 4. If voltage is low or near 0 VDC, inspect wiring between
267 overtemp overheated. the transformer’s temperature sensor and J3.202 pins 13
Secondary and 14. Look for shorts between wires or to ground.
5. If wiring is good, the transformer has overheated. Allow the
power supply to idle with the fans running for a minimum
of 30 minutes to cool the large power transformer.
6. Replace the transformer’s temperature sensor if it is open
or shorted. Replacement kit part number is 228309.

Maintenance
Error code
number
1. Verify that the large fan in the cooler (HPR400XD only) is
running.
2. Blow dust out of the coolerr (HPR400XD only), especially
from the heat exchanger.
3. Verify that the voltage on the rear side of J1.5
pins 6 and 8, is equal to or lower than 2.8 VDC.
Coolant Torch coolant has
071 4. If voltage is low, inspect wiring between coolant
overtemp overheated.
temperature sensor and J1.5, pins 5 and 6, for shorts to
wires or ground.
5. If wiring is good, the coolant has overheated; let system
idle with the fans running for 30 minutes to cool.
6. Replace the coolant temperature sensor if it is open or
shorted. Sensor part number is 229224.
Auto gas,
control board
Control board has
072 overtemp Verify that the airflow to the gas console is not restricted.
exceeded 90° C (194° F).
Auto Gas
Only
sink of chopper.
073 Chopper 3
3. Verify that the voltage on rear side of J3.202, pins 8 and 9
Primary overtemp Chopper 3 has
on PCB3, is less than or equal to 2.9 VDC.
273 HPR400XD overheated.
Secondary Only
temperature sensor and J3.202 pins 7 and 8.
074 sink of chopper.
Chopper 4
Primary 3. Verify that the voltage on rear side of J3.202, pins 11 and
overtemp Chopper 4 has
12 on PCB3, is less than or equal to 2.9 VDC.
274 HPR400XD overheated.
Secondaryy Only
temperature sensor and J3.202 pins 10 and 11.
075 Low current A current less than
Primary on CS3 10 amps has been
See the chopper test later in this section.
275 HPR400XD detected by
Secondary Only current sensor 3.

Maintenance
Error code
number
076 Low current A current less than

1. If this is a new system, follow start procedure.

2. Verify that the coolant filter is in good condition.
Coolant flow signal
No coolant 3. Perform coolant flow tests (Maintenance section).
093 was lost or never was
flow 4. Verify that the CNC drives the plasma start signal for at
satisfied.
least 10 seconds to allow the timed-out pump to turn on
again.
095 High current A current greater

Primary on CS4 than 35 amps has
295 HPR400XD been detected by
Secondary Only current sensor 4.
1. Verify phase-to-phase voltage to power supply.

2. Disconnect power to power supply, remove cover on
Phase loss at The system detected
contactor and inspect contacts for excessive wear.
initialization incoming line voltage
3. Inspect power cord, contactor, and input to chopper for
098 HPR400XD during power-up, before
loose connections.
HPR800XD the contactor was
4. Inspect phase loss fuses on Power Distribution board.
Only energized.
Replace board if fuses are blown.
5. Perform phase loss test (see Maintenance section).
099 1. Verify that the temperature sensor for the chopper has not
Chopper 1 been bypassed or that the wires to the temperature switch
Primary Chopper 1 is indicating
overtemp at are shorted out in the harness, or that the sensor is open.
299 an overtemp at power-up.
power-up 2. If no jumper is present, the chopper is overheated and
Secondary
needs time to cool to 83° C (181.4° F).
Chopper 2
100 1. Verify that the temperature sensor for the chopper has not
overtemp at
Primary been bypassed or that the wires to the temperature switch
power-up Chopper 2 is indicating
are shorted out in the harness, or that the sensor is open.
300 HPR260XD an overtemp at power-up.
2. If no jumper is present, the chopper is overheated and
Secondary HPR400XD
needs time to cool to 83° C (181.4° F).
Only
1. Verify that the transformer temperature sensor has not been

101 bypassed or the wires to the temperature sensor are not
Magnetics Main transformer is
Primary shorted out in the harness.
overtemp at indicating an overtemp at
301 2. Verify that the sensor is not open or shorted, if it is not
power-up power-up.
Secondary open or shorted, the main transformer is overheated and
needs time to cool to 150° C (302° F).

Maintenance
Error code
number
See wiring diagrams in section 7
102 1. Verify that the voltage at CS1 is correct.
Chopper 1
Primary Chopper 1 current signal 2. Verify that the wiring between CS1 and PCB3 is correct
current at
302 is active at power-up. and not damaged.
power-up
Secondary 3. Swap CS1 with CS2. If the error code changes to 156,
replace the original CS1.
103 A current greater

Primary High current than 35 Amps has
303 on CS1 been detected by
Secondary current sensor 1.
High current
104 A current greater
on CS2
Primary than 35 amps has
HPR260XD See the chopper test later in this section.
304 been detected by
HPR400XD
Only
105 A current less

Primary Low current than 10 amps has
305 on CS1 been detected by
106 Low current

A current less than
Primary on CS2
10 amps has been
HPR260XD See the chopper test later in this section.
306 detected by
HPR400XD
Secondary current sensor 2.
Only
107 High current A current greater than
1. Verify that the electrical connections to current sensors
108 CS1 and CS3 are correct and not damaged.
The system has detected
Primary Transfer at 2. Replace PCB3 if connections are correct and not
current on the work lead
308 power-up damaged.
during power-up.
Secondary 3. Verify that the main contactor (CON1) is not welded
closed, or closing at power-up.
“Coolant flow OK” signal
ither the coolant flow sensor was bypassed or it is faulty.
E
Coolant flow is active during power-up
109 1. Verify that there is power at the sensor.
at power-up and before pump motor
2. Verify that all the connectors have good connections.
is activated.
1. Verify that the coolant temperature sensor has not been
Coolant bypassed or the wires to the sensor are not shorted out in
Coolant is indicating an
111 overtemp at the harness.
overtemp at power-up.
power-up 2. If not, the coolant temperature is over the set point and
needs time to cool to 70° C (158° F).

Maintenance
Error code troubleshooting – error codes 116 to 133, 316
Error code
number
control cable) is not damaged and is properly connected
to PCB3 and the rear of the gas console.
power cable) is not damaged and is properly connected
inside the power supply and to the rear of the gas
console.
3a. (Manual gas console) Verify that D1 (+5 VDC) and
116 D2 (+3.3 VDC) are illuminated on PCB2 inside the gas
An error occurred with
Primary Watchdog console. These LEDs indicate power to PCB2.
the CAN communication
316 interlock 3b. (Auto gas console) Verify that D17 (+5 VDC) and
system.
Secondary D18 (+3.3 VDC) are illuminated on PCB2 inside the gas
console. These LEDs indicate power to PCB2.
replaced.
5. Verify that the gas console control PCB and power
distribution PCBs are securely mounted to the chassis at
all four corners.
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,
123 Auto Gas move into position within
replace the motor valve. If they do not illuminate, replace
Only 60 seconds.
PCB3.
Verify that LED D19 or D20 is illuminating on the AC valve

MV2 error Motor valve 2 did not
driver PCB in the selection console. If either illuminates,
124 Auto Gas move into position within
replace the motor valve. If they do not illuminate, replace
Only 60 seconds.
PCB3.
1. Verify that the part numbers of PCB2 and PCB3 are

correct.
2. Verify that the power supply-to-gas console control cable
is not damaged and is properly connected to PCB3 and
the rear of the gas console.
The power supply control 3. Verify that the power supply-to-gas console power cable
board does not recognize is not damaged and is properly connected inside the
Unknown gas
133 the gas console that power supply and to the rear of the gas console.
console type
is installed or has not 4. Verify that D1 (+5 VDC) and D2 (+3.3 VDC) are
received a CAN message. illuminated on PCB2 inside the gas console. These LEDs
indicate power to PCB2.
replaced.

Maintenance
Error code troubleshooting – error codes 134 to 140, 334 and 338
Error code
number
1. Verify that the wiring between CS1 and PCB3 is correct

and not damaged.
2. Measure voltage across current sensor.
a) Red to black = +15 VDC, Green to black = -15 VDC,
white to black = 0 VDC at idle and varies with current
output (4 VDC = 100 amps).
b) If possible, take a voltage reading on current sensor
134
Chopper 1 current while trying to cut. Ratio is 4 VDC = 100 amps.
Primary Chopper 1
feedback has exceeded c) If the current sensor voltage is approximately 6.4 VDC
334 overcurrent
160 amps. or greater at idle, replace the current sensor.
Secondary 3. Remove connector JA.1 from the chopper and verify that
LED1 is extinguished.
a) If LED1 is extinguished with the connector removed,
then reconnect JA.1 and try to fire the torch. If the
chopper still goes into overcurrent, replace the chopper.
b) If the chopper does not go into overcurrent, replace
PCB3.

and not damaged.
138 Chopper 2 b) If possible, take a voltage reading on current sensor
Primary overcurrent Chopper 2 current while trying to cut. Ratio is 4 VDC = 100 amps.
HPR260XD feedback has exceeded c) If the current sensor voltage is approximately 6.4 VDC
338
HPR400XD 160 amps. or greater at idle, replace the current sensor.
Secondary
Only 3. Remove connector JB.1 from the chopper and verify that
then reconnect JB.1 and try to fire the torch. If the
PCB3.
This is a warning for a possible gas restriction in the leads.

The purge cycle did 1. Verify that there are no restrictions in the plasma and
Purge
139 not complete within 3 shield hoses.
time-out error
minutes. 2. Verify that the inlet gas pressures are set to the proper
levels.
1. Verify that transducer P1 in the selection console is

Pressure
Faulty transducer or working properly. Replace if necessary.
transducer
control board in the 2. Verify that transducer P8 in the metering console is
140 1or 8 error
metering console or the working properly. Replace if necessary.
Auto Gas
selection console. 3. Verify that the control boards in the metering and selection
Only
consoles are working properly. Replace if necessary.

Maintenance
Error code
number
Pressure
transducer
141 2 or 7 error
Auto Gas
Only
Pressure
transducer
142 3 or 5 error
Auto Gas
Only
Pressure
transducer
143 4 or 6 error
Auto Gas
Only
Internal flash Communication problem
error to the flash chip on
144 Replace the control board.
Manual Gas the gas console control
Only board.
Internal flash Communication problem
error to the flash chip on
Auto Gas the selection console
Only control board.
146 Chopper 3 1. Verify that the temperature sensor for the chopper has not
Primary overtemp at been bypassed or that the wires to the temperature switch
Chopper 3 is indicating
power-up are shorted out in the harness, or that the sensor is open.
HPR400XD 2. If no jumper is present, the chopper is overheated and
Secondary
Only needs time to cool to 83° C (181.4° F).
Chopper 4 1. Verify that the temperature sensor for the chopper has not
147
Primary overtemp at been bypassed or that the wires to the temperature switch
Chopper 4 is indicating
power-up are shorted out in the harness, or that the sensor is open.
HPR400XD 2. If no jumper is present, the chopper is overheated and
Secondary
Only needs time to cool to 83° C (181.4° F).
151
Software has detected
Primary
Software fail an incorrect state or Replace power supply control board.
351 condition.
Secondary
Communication problem
Internal flash to the flash chip on
error the power supply control
board.

Maintenance
Error code
number
EEPROM memory on
PS EEPROM
153 power supply control Replace the control board.
error
board not working.

and not damaged.
b) If possible, take a voltage reading on current sensor
154 Chopper 3
Chopper 3 current while trying to cut. Ratio is 4 VDC = 100 amps.
Primary overcurrent
354 HPR400XD
Secondary Only
3. Remove connector JC.1 from the chopper and verify that
then reconnect JC.1 and try to fire the torch. If the
PCB3..
and not damaged.
155 b) If possible, take a voltage reading on current sensor
Chopper 4
Primary Chopper 4 current while trying to cut. Ratio is 4 VDC = 100 amps.
overcurrent
355 HPR400XD
Secondary Only
3. Remove connector JD.1 from the chopper and verify that
then reconnect JD.1 and try to fire the torch. If the
PCB3.

Chopper 2
156 current at
Primary 1. Verify that the voltage at CS2 is correct.
power-up Chopper 2 current signal
356 HPR260XD is active at power-up.
and not damaged.
Secondary HPR400XD
3. Swap CS2 with CS3. If the error code changes to 157,
Only

Maintenance

Error code
number

Chopper 3
current at
power-up
HPR400XD
Secondary 3. Swap CS3 with CS2. If the error code changes to 156,
Only

Chopper 4
current at
power-up
HPR400XD
Secondary Only 3. Swap CS4 with CS2. If the error code changes to 156,
1. Verify that the circuit breaker on PCB7 has not tripped. If it

has tripped, reset the breaker by pressing the button until
it is even with the top of the circuit breaker. If the circuit
breaker is not tripped and there is no power to PCB7,
verify that the fuse on PCB2 in the power supply is good.
2. If D32 on PCB7 illuminates, the solenoid valve and motor
are drawing too much current. D32 will only illuminate
for a short time, and extinguishes after the outputs from
the pump-motor-drive turn-off in response to the fault
The pump-motor-
condition. Verify the wiring to the solenoid valve and the
drive board (PCB7) is
motor. Verify that the pump spins freely and is properly
indicating a drive fault.
mounted to the motor. Look for obstructions in the torch,
consumables, coolant lines, and in-line filter. Verify that the
Note: The secondary
solenoid valve is operating. Any of these can cause the
159 Motor-drive error code (359) may
motor or solenoid valve to draw excessive current. Test
Primary fault display if the secondary
for low coolant flow by using the coolant flow test in this
HPR400XD power supply is turned off
359 section.
and individually, or when the
Secondary 3. If D32 on PCB7 illuminates immediately at power-up, and
HPR800XD entire system is turned
all the items above have been verified, replace PCB7.
off. Customers with a
4. If D30 on PCB7 illuminates, the IGBT drive has
manual gas console will
encountered an over current condition. D30 will only
not see this error code
illuminate for a short time, and extinguishes after the
when the entire system is
outputs from the pump motor-drive turn off. Follow the
turned off.
same steps for D32 above.
5. If D31 on PCB7 illuminates, the heatsink thermistor is
indicating that the heatsink is too hot. Wait 10 minutes
for it to cool. If the error remains, verify that the wires
from heatsink on PCB7 are properly connected to the J6
connector on PCB7. If the error still remains, turn OFF all
power to the system and measure the resistance on the
J6 connector between pins 1 and 2. At 25° C (77° F) the
resistance should be 10k.

Maintenance
Error code
number
Communication between
the control board (PCB3 1. Verify that the cable connections from the power supply to
HPR cooler’s
in the power supply) and the cooler are good.
CAN fault
160 the cooler sensor board 2. Verify that D1 (+ 5 VDC) and D2 (+3.3 VDC) are
HPR400XD
(PCB1 in the cooler) was illuminated on PCB1 inside the cooler.
Only
interrupted for more than 3. Verify that the CAN bus LEDs, D7 and D8 are blinking.
1 second.
Coolant flow has

Maximum
exceeded 6.8 lpm 1. Verify proper coolant flow.
coolant flow
161 (1.8 gpm) for a cooler, 2. Look for air bubbles in the coolant.
has been
8.52 lpm (2.25 gpm) for 3. Verify that the coolant is mixed in the proper proportions.
exceeded
a chiller.
1. Verify that the power supply-to-selection console

CONTROL and POWER cables are not damaged and are
properly connected to PCB3, and the rear of the selection
console.
2. Verify that D17 (+5 VDC) and D18 (+3.3 VDC) are
illuminated on PCB2 inside the selection console. These
LEDs indicate power to PCB2. Also verify that D26
Selection
The power supply did not (CAN – RX) and D27 (CAN – TX) are illuminated on
console CAN
receive a CAN message PCB2 inside the selection console. These LEDs indicate
180 time-out
from the selection communication between the selection console and the
Auto Gas
console within 1 second. power supply.
Only
3. If power is present at PCB2 and PCB3 and both selection
replaced.
all four corners.

Maintenance
Error code troubleshooting – error code 181, 182, and 383
Error code
number
1. Verify that the power supply-to-metering console

CONTROL and POWER cables are not damaged and are
properly connected to PCB3, and the rear of the metering
console.
2. Verify that D17 (+5 VDC) and D18 (+3.3 VDC) are
illuminated on PCB2 inside the metering console. These
LEDs indicate power to PCB2. Also verify that D26
Metering
The power supply did not (CAN – RX) and D27 (CAN – TX) are illuminated on
console CAN
receive a CAN message PCB2 inside the metering console. These LEDs indicate
181 time-out
from the metering communication between the metering console and the
Auto Gas
console within 1 second. power supply.
Only
3. If power is present at PCB2 and PCB3 and both metering
replaced.
all four corners.
Secondary
The secondary power 1. The primary power supply to secondary power supply CAN
power supply
supply fails before communication cable was disconnected after power-up.
182 time-out
transmitting the error to 2. The cable has electrical interference (noise) or the cable
HPR800XD
the primary power supply. shielding has been compromised.
Only
The secondary power

No ramp-up supply is ready to provide 1 Turn off the power to the system and then turn on the
message current output but does power again.
383
HPR800XD not receive the control 2. The cable has electrical interference (noise) or the cable
Only signal from the primary shielding has been compromised.
power supply.

Maintenance
Power supply states

Power supply states are displayed on the CNC screen. The diagnostic screen shown below is for reference.
State State
Name Name
code code
00 Power-up (idle) 11 Cycle complete (auto off)
02 Purge 12 Test cutflow
03 Ready for start (idle2) 14 Shutdown
04 Preflow 15 Reset
05 Pilot arc 16 Maintenance
06 Transfer 20 Test preflow
07 Ramp-up 22 Manual pump control
08 Steady state 23 Inlet leak check
09 Ramp-down 24 System leak check
10 Final ramp-down 25 Burkert valve flow check

Maintenance
Plasma system operation with pump time-out
HPR Purge cycle begins, NOT

power supply READY FOR START
power-up signal is active
Purge timer done Error output

on
PLASMA START
signal active Yes
No
System is in IDLE state

waiting for a START signal,
NOT READY FOR START
signal is inactive
START signal
removed
If 30 minutes has
passed since the last
start, turn OFF
the pump
Fire the torch

and begin
START signal
cutting
No
Yes Yes
If the pump has timed out,

Is the flow
turn on the NOT READY
sensor satisfied?
FOR START signal and
turn on the pump
No

Maintenance
CNC operation with pump time-out
User presses Assert the PLASMA

START on START and HOLD
CNC signals to all
plasma systems
Remove the Is the NOT READY FOR

START and START signal active on
HOLD signals Yes any plasma system?
No
Apply the START

signal and remove
the HOLD signal
Complete the
cut cycle

Maintenance
Initial checks
Before trouble-shooting, do a visual check and verify that proper voltages are present at the power source, transformers
and power distribution board.
DANGER
SHOCK HAZARD: Always use caution when servicing a power supply when plugged in and the
covers are removed. Dangerous voltages exist within the power supply which could cause injury or
death.
1. Disconnect line power by turning OFF the main disconnect switch.
2. Remove the power supply’s top panel and 2 side panels.
3. Inspect interior of power supply for discoloration on PC boards, or other apparent damage. If a component or module
is obviously defective, replace it before doing any testing. Refer to the Parts List section to identify parts and part
numbers.
4. If no damage is apparent, connect power to the power supply, and turn ON the main disconnect switch.
5. Measure the voltage between the W, V and U terminals of TB1 located on the right side of the power supply. See
figure on next page. Also refer to the wiring diagram in Section 7, if required. The voltage between any 2 of the 3
terminals should be equal to the supply voltage. If there is a problem at this point, disconnect main power and check
connections, power cable, and fuses at line disconnect switch. Repair or replace any defective component.

Maintenance
Power measurement
DANGER
Shock Hazard
There is line voltage at the contactor and the power distribution board (PCB2) when the line
disconnect switch is on. Use extreme care when measuring primary power in these areas. Voltages
present at the terminal block and contactors can cause injury or death.
Main power in
U V W
Ground
Note: Check lines in the following order:

U to V
U to W
V to W
Check each line to ground. If one
line is 10% greater, or more, than the
other 2, put that leg on U.

Maintenance
Air filter element replacement

1. Turn OFF all electrical power and disconnect the air hose from the filter.
2. Remove the filter bowl by turning it counter clockwise until it releases.
3. Pull the clear filter housing down firmly to remove it. The filter housing has an o-ring around the top. Apply a thin film
of silicone lubricant on the o-ring to extend it’s life. The o-ring should look shiny, but there should not be any excess
or built-up grease.
Clear filter housing
Filter bowl
4. Use a screwdriver to remove the filter element from the filter housing. Then install the new filter element.
Note: Do not allow the filter element to turn when loosening the screw.
5. Reinstall the clear filter housing and the filter bowl.

Maintenance
Coolant system servicing
Draining the coolant system
2. Remove the return coolant hose (red washer on the cooler fitting) from the rear of the cooler and put it in a 20 liter
(5 gallon) container.
ON the pump manually, using the manual pump control button on your CNC screen.
3. Turn
4. Turn OFF the pump when the coolant stops flowing.

Maintenance
Caution: Coolant will flow from the filter when its housing is removed. Drain coolant
before servicing the filter.
Coolant system filter

Filter replacement
2. Remove housing.
3. Remove and discard filter element.
4. Install new filter element 027664.
5. Re-install housing.
6. Refill with new coolant.
2 3 4 5

Coolant flow troubleshooting chart
Replace the pump, and inspect

the shaft for damage
Coolant error
(093) or (060)
Flow
rate from
bucket test
Go to “steps to take before testing” on the next page < 0.9 gpm
Flow Flow
Go to “pump/motor rate from rate from
No flow Go to test 1 flow tube Go to test 2 bucket test Go to test 6
troubleshooting”
< 0.8 gpm < 0.9 gpm
Flow Flow Flow

rate from rate from rate from
flow tube bucket test bucket test
HPR400XD Auto Gas – 806160 Revision 3

> 0.8 gpm > 0.9 gpm > 0.9 gpm
Flow
Replace the torch
rate from Go to test 3
Go to test 7 If the flow shown Check your power supply outlet hose for
CNC
On the CNC is kinks. If there are no kinks, replace the
> 0.8 gpm
> 0.9 gpm hose set between the power supply and
Flow the high frequency console.
Flow rate from
rate from CNC
Order a replacement CNC
Check valve or your < 0.9 gpm
< 0.8 gpm
coolant will drain out at
each consumable change
Go to test 4
Replace the flow switch
Flow Flow There is a kink or clog between the

rate from rate from high frequency console and the
bucket test bucket test power supply. If there is not a kink,
> 0.9 gpm < 0.9 gpm replace the leads.
Flow Flow There is a kink in the leads between

There is a kink in the return hose to rate from rate from the high frequency console and the
the power supply. If there is not a kink, bucket test Go to test 5 bucket test torch. If there is not a kink,
replace the hose. > 0.9 gpm < 0.9 gpm replace the leads.
5-35
Maintenance
Maintenance
Coolant flow tests

If the CNC screen shows a coolant flow error (093 or 060), turn OFF the system and then ON again to clear the error.
Then perform the following tests to find the cause of the problem.
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
without custom fittings. An in-line flow meter (part number 128933) is available from Hypertherm. The following “bucket”
tests give a good idea of the flow rate.
Note: The CNC screens shown here are for reference. The screens you work with may look different, but should
have the same functions shown here.
Before testing
Notes: It is important to follow the troubleshooting steps in the order in which they are shown in the flow chart on
the previous page.
Coolant must be drained from the system before the in-line filter is cleaned (step 1 below). The coolant in
the system will drain out as soon as the in-line filter is removed.
1. Clean the in-line filter.

2. Replace the filter element on the rear of the cooler.
3. Verify that the system has the correct level of coolant when refilling the system after completing steps 1 and 2. See
fill the cooler with coolant in the Installation section.
Filter on the rear

of the cooler
In-line filter

Maintenance
Bypass valve verification

1. Remove the cooler’s filler cap.
2. Stand in front of the cooler with the pump running, and look inside the coolant tank.
3. Coolant should be flowing from the orifice on the right. If coolant is flowing from the orifice on the left, look for a
restriction in the coolant path. Install a new bypass valve if there is no obstruction.
Left side orifice Right side orifice

Filler cap
Bypass valve
Using the Hypertherm flow meter (128933)

Use the steps below to get an accurate reading from the flow meter.
1. Hold the flow meter upright. Square in both axis.
2. Take your reading from the edge shown below.
2.0
1.8
1.6
1.4
1.2
1.0
Read from this edge

Example shown 1.1
1.2 Float .8
.6
.4
1.0 .2
Flow
direction

Maintenance
Manual pump operation

1. Go to the CNC screen that turns on the pump manually (refer to the operation instructions for the CNC being used).
If the selection console shows coolant flow error 093, the pump must be turned on manually within 8 seconds of
turning on the power supply, or the power will have to be turned off and then on again.
2. Turn ON the power. Turn ON the pump manually, and allow the coolant to flow for 60 seconds.
3. Write down the coolant flow rate on the CNC screen. The recorded flow rate will be used for comparison during
some of the tests. Coolant flow must be greater than 2.3 lpm (0.6 gpm) for the system to operate.
Note: A flow diagram can be found on schematic 013374, sheet 19 of 24

Maintenance
Test 1 – return line

Note: An in-line flow meter is required to complete this test.
1. Turn OFF the power. Remove the return coolant line

(red washer on the cooler fitting), and connect the flow
meter to measure the flow rate.
2. Measure the flow rate on the flow meter. Turn ON the

power. Turn ON the pump manually using the manual
pump control button on your CNC screen (see step 1
under “Manual pump operation”). Write down the flow
rate from the flow meter.
3. Reconnect the return coolant line (red washer on the
cooler fitting).
If the flow rate is 0.8 gpm or more, replace the flow switch.
If the flow rate is less than 0.8 gpm, Go to test 2.
If there is no flow, go to pump and motor troubleshooting.
Test 2 – supply line at ignition console
Torch-lead
Note: Remove the torch-lead coolant hoses to access the supply line. coolant hoses
1. Turn OFF the power. Remove the supply coolant line (blue hose with
green tape) from the RHF/LHF console, and place it in a 3.8 liter
(1 gallon) container. A Hypertherm coolant container works well.
2. Measure how long it takes to fill the container. Turn ON the power.
Turn ON the pump manually using the manual pump control button
on your CNC screen (see step 1 under “Manual pump operation”).
Write down how long it takes to fill the container.
3. Reconnect the coolant lines.
If the container is full in 65 seconds or less, go to test 3.

If it takes more than 65 seconds to fill the container, go to test 6.

Maintenance
Test 3 – change the torch

1. Replace the torch and consumables with a new torch and new consumables.
2. Turn ON the pump manually using the manual pump control button on your CNC screen (see step 1 under “Manual
pump operation”), let it run for 60 seconds, and look at the flow rate on the CNC screen.
If the flow rate on the CNC screen is 0.9 gpm or more, the torch is clogged.
If the flow rate is still less than 0.9 gpm, go to test 4.
Test 4 – supply line to the torch receptacle

1. Turn OFF the power. Remove the coolant supply line at the torch receptacle, and place it in a 3.8 liter ( 1 gallon)
container. A Hypertherm coolant container works well.
Caution: Coolant will flow from the hose very quickly.
2. Measure how long it takes to fill the container. Turn ON the power. Turn ON the pump manually using the manual
pump control button on your CNC screen (see step 1 under “Manual pump operation”). Write down how long it
takes to fill the container.
3. Reconnect the coolant supply line to the torch receptacle.
If it takes more than 65 seconds to fill the container, look for an obstruction or kink in the coolant hose between the
torch and the LHF/RHF console. If there is no obstruction or kink, replace the torch leads.
If the container is full in 65 seconds or less, go to test 5.
Test 5 – return line from the torch receptacle (remove at the ignition console)
1. Turn OFF the power. Remove the return coolant line (blue hose with
red tape) from the RHF/LHF console, and place it in a 3.8 liter
(1 gallon) container. A Hypertherm coolant container works well.
2. Measure how long it takes to fill the container. Turn ON the power.
Turn ON the pump manually using the manual pump control button
on your CNC screen (see step 1 under “Manual pump operation”).
Write down how long it takes to fill the container.
3. Reconnect the return coolant line.
If it takes more than 65 seconds to fill the container, there is an

obstruction in the torch receptacle. Replace the torch receptacle.
If the container is full in 65 seconds or less, there is an obstruction in the return coolant line (from the RHF/LHF console
to the power supply). Replace the return coolant line.

Maintenance
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 using the manual
pump control button on your CNC screen (see step 1 under “Manual pump operation”). Write down how long it
takes to fill the container.
If it takes more than 65 seconds to fill the container, replace the pump and check the motor shaft for damage.
If it takes less than 65 seconds to fill the container, check the coolant supply line (from the power supply to the RHF/
LHF console) for kinks. If no kinks are found, replace the by-pass valve and perform this test again. If it still takes more
than 65 seconds to fill the container, replace the hoses between the power supply and RHF/LHF console.

Maintenance
Pump and motor troubleshooting

Is the motor LED illuminated on the control board?
Is the motor on?
If the LED is illuminated, but the pump is not running, turn the pump on manually.
If the motor will not turn on, verify that the fuse is OK, and make sure there is power to the motor.
If you are still not getting flow from the pump, verify that the solenoid valve and relief valve are working correctly.
Testing the flow sensor

1. Turn ON the power.
2. Measure the VDC between TP2 and TP9.
TP9 is 67% scaled voltage from the flow sensor. Normal flow is 3.8 lpm (1.0 gpm), which will equal 0.67 VDC at
TP9.
TP7
+24V
WDI
SW1
SW0
CAN
TP8 TP21 TP22 D1

+15V –15V +5V
PWR GND
S2
TP6
+3.3V
TP18
TP4 D2 D8
RX RESET
+5V
TX
TP1 D7
+A3.3V TP17
TP23
TP16
TP10 TP3
TP15
TP2
TP9
TP 9 TP 2

Maintenance
Gas leak tests

Notes: The CNC screen shown below is from a Hypertherm Automation controller, using version 6 software, and
is for reference only. Other controllers should have a test screen similar to the one shown. Contact the
original equipment manufacturer for instructions on how to access the test screen needed.
See sheet 20 of 24 on schematic 013374, in this manual, for more details on the gas delivery
system.
Leak test 1 (inlet leak test)

Purpose: Tests the inlet-valve solenoids in the selection console for leaks.
Test description: T
he valves in the metering console (B1-B4) open to release all gas pressure to the atmosphere, then
the valves close and pressure is monitored by P3 and P4 in the selection console. The pressure will
increase if an inlet valve is leaking. Code number 14 (cut gas channel number 1 failed) or 15 (cut gas
channel number 2 failed) will be displayed if there is a leak. Code number 13 (test passed) will be
displayed if no leak is detected.
Procedure:
1. Turn ON power to the plasma system.
2. Perform Inlet Leak Check on the CNC controller.
3. Turn OFF power and then turn ON power. This will purge gases from the system.

Maintenance
Leak test 2 (system leak test)

Purpose: Tests for leaks to the atmosphere from the gas system.
Test description: The gas for the process selected is purged through the gas system. The metering console valves
(B1-B4), and the inlet valves (for the selected process) in the selection console are closed. Gas
pressure is now trapped in the system. The trapped pressure is monitored. Code number 14 (cut gas
channel number 1 failed) or 15 (cut gas channel number 2 failed) will be displayed if the pressure
drops faster than 0.14 bar/minute (2 psi/minute). Code number 13 will be displayed if the pressure
decreases within the acceptable limit of 0.14 bar/minute (2 psi/minute).
Procedure:
1. Perform System Leak Check on the CNC controller.
2. Turn OFF power and then turn ON power. This will purge gases from the system.
Leak test 3 (proportional valve test in the metering console)

Purpose: Tests the Burkert valves (B1 and B3) in the metering console to ensure that they are working within the
correct parameters.
Test description: 130-amp mild steel consumables, and the 30-amp O2/O2 mild steel process are used for this test,
because there is a known flow rate.
Gas flows from the torch, and the Burkert valve that controls the plasma gas channel (B3) attempts to
maintain the set plasma gas pressure (monitored by P7 and P8) by adjusting the valve dynamically. The
signal percentage to the valve is measured (example – 65% on), and the value is checked against the
expected range (55% – 75%). The test is successful if the signal percentage is within the expected
range. Code number 14 (shield gas channel failed) or 15 (plasma gas channel failed) will be displayed
if the test fails. The same test is repeated for the Burkert valve that controls the shield gas channel
(B1).
For the next part of the test, the Burkert valve that controls the plasma gas channel (B3) is closed, and
the pressure is measured milliseconds later (pressure should decrease). The test is successful if the
pressure is below a given limit (0.69 bar [10 psi]). The same test is repeated on the shield gas channel
(B1).
Code number 16 (plasma ramp-down test failed) or 17 (shield rampdown test failed) will be displayed
if the signal percentage is out of the expected range. Code number 13 (test passed) will be displayed
if the signal percentage is within the expected range.
Procedure:
1. Install 130-amp mild steel consumables in the torch and select the 30-amp O2/O2 mild steel process.
2. Perform Metering Valve Flow Check on the CNC controller (test 3).
3. Turn OFF the power and then turn ON the power. This will purge gases from the system.

Maintenance
Power supply control board PCB3
+5V +3.3V
TP214 TP210 TP211 TP213
D329 TP114
TP212 D107
D108
1 TP113
TP104 TP102
TP112
TP203 TP100
TP208 D317
TP110
TP202
TP111
TP118 TP106 TP101
SPARE
D316
TP200 TP109
TP201
PA
PILOT ARC
PHASE
LOST
TP107
MOTION D324
Rd ERROR
TP103
D323
D322
D321
D320
TP105 D308 D310
TP209 D309 D311
TP206
ERROR NOT READY
MARK RELAY
PILOT RELAY
CONTACTOR
HF
TP119
TP207
Tx Rx
D110 D111
D312
D313
D314
D315
TP204
TP205
HOLD
PIERCE
CORNER
START
TP117
141030
TP116
TP115 TP120
Control PCB LED list

LED Description Status LED Description Status
D107 + 5 V OK Steady D312 Hold
Firmware
D108 + 3.3 V OK Steady D313 Pierce
Item Part number
D110 CAN transmit LED Blinking D314 Corner
U110 081135 EVEN
D111 CAN receive LED Blinking D315 Start redundant
D308 Motion D316 Pilot arc enable U109 081135 ODD
D309 Error D317 Spare
D310 Ramp-down error D324 Phase loss
D311 Not ready D329 Pump motor-drive OK Steady when OK
Control PCB test points

Test point Test point Test point
number Description number Description number Description
TP105 WDI TP117 CAN ground TP206 Chopper 4 analog input
TP108 Reset TP118 CCA+ TP207 Chopper control D
TP109 Reset TP119 CCC+ TP208 DAC output A
TP110 Digital ground TP120 CRXD (CANL) TP209 DAC output B
TP111 Analog ground TP200 Chopper 1 analog input TP210 Chopper A temperature sensor
TP112 A + 3.3 V TP201 Chopper control A TP211 Chopper B temperature sensor
TP113 + 3.3 V TP202 Chopper 2 analog input TP212 Chopper C temperature sensor
TP114 +5V TP203 Chopper control B TP213 Chopper D temperature sensor
TP115 CANH TP204 Chopper 3 analog input TP214 Work lead analog input
TP116 CANL TP205 Chopper control C

Maintenance
Power supply power distribution board PCB2
D1
D2
D5
D7
D25
D33
D32
D3
D31
D35
D26
D12
D23
Power distribution PC board LED list
LED Output Color

D1 Contactor Red
D2 Pilot arc relay Red
D3 120 VAC (switched) Green
D5 HF ignition Red
D7 Surge select Red
D25 + 24 VDC Red
D26 Pump motor Green
D31 + 5 VDC Red
D32 – 15 VDC Red
D33 + 15 VDC Red
D35 24 VAC Green

Maintenance
Start-circuit PCB1
Operation
The start circuit is a high-speed switch that quickly transfers the pilot arc current from the pilot arc lead to the work lead.
The start circuit performs 2 functions:
1. It allows the initial pilot arc current to flow through the pilot arc lead quickly, with little impedance.
2. After initial pilot arc current is established, the start circuit introduces impedance to the pilot arc lead to aid in
transferring the arc to the workpiece. See schematic below.
Start circuit functional schematic
Plasma power supply
Chopper
Choke
Power
resistor
ALEL Caps
Cutting
IGBT arc
Control
logic Diode
Start circuit Pilot

arc
Start circuit troubleshooting
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.

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:
2. Remove wires from H8 (WORK) and H9 (NOZZLE) studs on the board.
3. Verify a resistance of about (≈) 5.5 kΩ between H8 and D50 (–). If the
resistance value is not correct, replace the board.
Note: Resistance value may slowly increase to the correct value due to
the capacitance in the circuit.
4. Verify a resistance of about (≈) 15 kΩ between snubber and H8.
• The work lead should not have any cuts or breaks. Verify a resistance of 1Ω or less. The work lead connection
to the cutting table should be clean and have good contact to the table.
• Verify that LED-D2 is illuminated. If it is not illuminated, the board may need to be replaced or the board may
not be receiving power.
• Fire the torch in the air and verify that D1 is illuminated. If it is not illuminated, but a pilot arc is established, the
board may need to be replaced.
• Verify a resistance of about (≈) 1 Ω across the R1 resistor.
D1
D2
15kΩ
or
H8
WORK + –
H9
NOZZLE 5.5kΩ
R1
1Ω

Maintenance
Pilot arc current levels

The pilot arc current level will vary according to the arc current selected, and the process. See table below.
Pilot arc current

Plasma gas 30-amps 45-amps 50-amps 80-amps 130-amps 200-amps 260-amps 400-amps
O2 25 30 30 30 30 40 40 60
N2 25 30 30 30 35 40 40 60
H35 25 30 30 30 35 40 40 60
F5 25 30 30 30 35 40 40 60
Air 25 30 30 30 35 40 40 60
Transfer current
Plasma gas 30-amps 45-amps 50-amps 80-amps 130-amps 200-amps 260-amps 400-amps
O2 10 10 10 10 15 20 20 30
N2 10 10 10 10 15 20 20 30
H35 10 10 10 10 15 20 20 30
F5 10 10 10 10 15 20 20 30
Air 10 10 10 10 15 20 20 30

Maintenance
Pump motor drive board PCB7

Note: The inductor on the pump motor-drive board makes a noise during operation that has been
described as a “hum”, “sing”, and “click”. This is normal and can be disregarded.
141027
D1
D30 D32
D31
TP3
D10
D36
TP4
D35
TP10
TP2
TP1
TP6
TP5 TP12
Control PCB LED list

LED Description Status
D1 + 15 V OK On when +15 voltage is OK
D10 + 5 V OK On when +5 voltage is OK
D16 + 3.3 V OK On when +3.3 voltage is OK
D30 IPM temperature alarm output Off when OK. On when there is a sustained over-current condition
D31 Temperature Off when OK. On when there is a temperature fault
Off when OK. On when there is an internal overtemp, over-current, or bad gate supply-
D32 IPM alarm output
drive voltage
D35 Pump motor drive OK On when pump-motor-drive is OK
D36 Pump motor drive enable On when enabled

Test point Test point Test point
number Description number Description number Description
TP1 Analog ground TP5 +5V TP9 Digital ground
TP2 Digital ground TP6 A + 3.3 V TP10 + 3.3 V
TP3 Reset\ TP7 + 3.3 V TP11 SCIRXD
TP4 Reset TP8 SCITXD TP12 LINEFB +

Maintenance
Cooler power distribution board PCB1
Gas console control board LED list

LED Signal name Color
D2 SV16 Red
D4 + 5 VDC Green

Maintenance
Cooler sensor board PCB2
TP7
+24V
WDI
SW1
SW0
CAN
TP8 TP21 TP22 D1
+15V –15V +5V
PWR GND
S2
TP6
+3.3V
TP18
TP4 D2 D8
RX RESET
+5V
TX
TP1 D7
+A3.3V TP17
TP23
TP16
TP10 TP3
TP15
TP2
TP9

D1 + 5 VDC red
D2 + 3.3 VDC Green
D7 CAN TX
D8 CAN RX

Test point Test point
number Description number Description
TP1 A + 3.3 V TP12 Digital ground
TP2 Analog ground TP13 + 3.3 V
TP3 Pressure sensor (for use in the future) TP14 SCIRXD (RS422 transmit)
TP4 +5V TP15 Digital ground
TP6 + 3.3 V TP16 Analog ground
TP7 + 24 V TP17 Reset\
TP8 Power ground TP18 Reset
TP9 Coolant flow sensor input TP21 + 15 V
TP10 Chiller flow input (for use in the future) TP22 – 15 V
TP11 SCIRXD (RS422 receive) TP23 Line voltage input

Maintenance
Selection console control board PCB2
Control PCB2 firmware list Note: CAN termination resistor. The jumper

must be removed.
Item Part number
U9 081110 EVEN
U10 081110 ODD

D17 + 3.3 VDC Green
D18 + 5 VDC Green
D26 CAN – RX Green
D27 CAN – TX Green
D28 Not used Red
D37 Not used Red
D38 Not used Red
D39 Not used Red
D40 + 15 VDC Green
D45 + 24 VDC Green

Maintenance
Selection console power distribution board PCB1

D2 SV16 Red
D4 + 5 VDC Green

Maintenance
Selection console, AC valve-driver board PCB3
LED Signal name Color LED Signal name Color

D1 SV1 Red D11 SV11 Red
D5 SV5 Red D15 (not used) Red
D6 SV6 Red D16 Metering console vent solenoid Red
D7 SV7 Red D17 MV1 close Red
D8 SV8 Red D18 MV1 open Red
D9 SV9 Red D19 MV2 close Red
D10 SV10 Red D20 MV2 open Red
P2
P4
P3
P1
SV14
SV 7 SV13
SV15
SV12
SV4
SV11
SV5
SV10
SV6
SV1
SV9
SV2
SV8
SV3

Maintenance
Metering console control board PCB2
Control PCB2 firmware list Note: CAN termination resistor. The jumper

must be installed.
Item Part number
U9 081110 EVEN
U10 081110 ODD

D17 + 3.3 VDC Green
D18 + 5 VDC Green
P5 (not visible)
D26 CAN – RX Green
B1
D27 CAN – TX Green
SV16
D28 Burkert valve 2 Red B2
B3
D37 Burkert valve 1 Red B4
D38 Burkert valve 4 Red
P7
D39 Burkert valve 3 Red
D40 + 15 VDC Green P6
P8
D45 + 24 VDC Green

Maintenance
Metering console power distribution board PCB1

D2 SV16 Red
D4 + 5 VDC Green

Maintenance
Chopper tests
WARNING
Shock Hazard
Use extreme care when working near the chopper modules. Each large electrolytic capacitor (blue-
cased cylinder) stores large amounts of energy in the form of electric voltage. Even if the power is
off, dangerous voltages exist at the capacitor terminals, on the chopper, and the diode heatsinks.
Never discharge any capacitor with a screwdriver or other implement… explosion, property
damage and/or personal injury will result.
Automatic chopper tests during power-up

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

Maintenance
3. Locate dipswitch S301 on the control board (PCB3) and move switch 5 to the ON position. The switch must be
returned to its original position before cutting.
4. Measure the open circuit voltage (OCV)
Attach the test leads of a DC volt meter to the NEG terminal and the WORK terminal on the I/O board. Turn ON the
power to start the chopper test. After the contactor (CON1) closes, read the OCV which should be about 360 VDC.
• If the OCV is 0, the chopper is probably faulty. Swap chopper 1 with chopper 2 for verification. If chopper 1 is
faulty, the error code should change to 106. Replace chopper 1.
• If OCV is about 360 VDC, continue to step 5.
5. Swap current sensor 1 (CS1) with current sensor 2 (CS2). Move the sensor, but leave the power cable and the
control wiring in place.
• If the error remains on chopper 1, replace the I/O PCB.
• If the error changes to chopper 2, replace CS1.
Chopper 2, 3, or 4 failure
1. Swap the current sensor for the chopper that failed with the current sensor for the next chopper in sequence.
• If the error moves to the next chopper in sequence, replace the current sensor for the chopper that failed.
• If the error remains on the original chopper, continue to step 2.
2. Measure the OCV
• The chopper outputs are connected in parallel at the I/O board, and the choppers are tested in sequence (1, 3, 2,
and 4). This means that if you measure the OCV at the NEG and WORK terminals on a fully functional HPR400XD,
the voltage will be 0 until the contactor (CON1) closes. Chopper 1 will turn on and you will measure 360 VDC.
Chopper 1 will turn off and the voltage will decrease to 0. Chopper 3 (1, 3, 2, and 4) will turn on next, and the
voltage will increase to 360 VDC and then decrease to 0 when chopper 3 turns off. This sequence repeats until all
4 choppers are tested.
Example:
If you get error 075 or 107, you know chopper 3 failed the test. Because chopper 1 and chopper 2 passed the
test, you know the incoming power and the I/O board are OK. If you measure the OCV at the NEG terminal and the
WORK terminal on the I/O board, you will see the voltage cycle from 0 to 360, back to 0, and then to 360 again,
because chopper 1 and chopper 2 are OK. If you do not get the third reading of 360 VDC from chopper 3, that
means chopper 3 is faulty. You can swap chopper 3 with chopper 2 for verification. The error code will move to
chopper 2, if chopper 3 is faulty. If the error does not move, or you measure an OCV of about 360 VDC for chopper 3,
contact Hypertherm Technical Service at 800-643-9878.
Note: Return switch 5 on S301 to the OFF position before returning to normal cutting operations.

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 or more of the contacts are worn excessively,
replace CON1 and restart the system. If the error remains, perform the following steps.
OK Excessive wear
3. Test the fuses F5, F6, and F7 on the power

distribution board (PCB2). If any of the fuses
D1
D2
D5
D7
are blown, replace PCB2.

D25
D33
D32
D3
D31
D35
D26
D12
D23
4. Remove J2.8 from PCB2 and place a jumper between pins 1 and 2 on the cable connector.
a. Make a test cut. If the phase-loss error continues, verify wiring between J2.8 on PCB2 and J3.302 on PCB3 by
verifying the continuity between
– J2.8 pin1 to J3.302 pin14
– J2.8 pin2 to J3.302 pin15.
b. If the wiring is OK, replace PCB3. If any wiring is damaged, repair or replace any damaged wires.
c. If the phase-loss error goes away while the jumper is on J2.8, make another cut and measure the phase-to-
phase voltage across the fuses F5, F6, and F7. The voltage should be 220 VAC +/-15%. If 1 of the 3 voltage
readings is less than 187 VAC, check the contacts to the contactor, and check for loose connections between
the power cord, contactor, power transformer, and the chopper.

Maintenance
WARNING
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

2. Locate the start-circuit assembly.
3. Install a temporary jumper wire
D1
between H8 (work) and H9 H8
D2
(nozzle) on the start circuit WORK
PCB1.
H8
WORK + –
H9
NOZZLE
H9
NOZZLE
4. Locate the pilot arc relay (CR1) and remove the dust cover. Have a second person close the contact.
5. Measure the ohm value between the nozzle and the plate. The reading should be less than 3 ohms. A measurement
of greater than 3 ohms indicates a faulty connection between the torch and ignition console or between the ignition
console and the power supply.
6. Verify that the pilot arc wire on the torch lead is not damaged. If it is damaged replace the lead. If it is not damaged,
replace the torch head.

Maintenance
Preventive maintenance
Introduction
Deteriorating consumable parts life is one of the first indications that something is wrong with a plasma system.
Reduced parts life increases operating costs in 2 ways: The operator must use more electrodes and nozzles to cut the
same amount of metal, and the work of cutting must stop more often to change consumables.
Proper maintenance often eliminates the problems that shorten the life of consumable parts. Since labor and overhead
can a ccount for 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.
The power supply
DANGER
Turn off all electrical power before removing the power supply cover and
set the line disconnect switch to OFF. In the U.S., use a “lock-out and
tag-out” procedure until the service or maintenance is complete. In other
countries, follow appropriate local and national safety procedures.
1. With power to the power supply turned off, remove all side panels. Use compressed air to blow out any accumulation
of dust and particulates.
2. Inspect wiring harnesses and connections for wear, damage or loose connections. If you see any discoloration that
might indicate overheating, contact Hypertherm Technical Service.
3. Inspect the main contactor for excessive pitting on the contacts, characterized by a blackened, rough surface on any
of the contacts. If this condition exists, replacement is r ecommended.
4. Inspect the pilot arc relay (CR1) for excessive pitting on the contacts, characterized by a roughened, black surface.
Replace if necessary.

Maintenance
Cooling system
5. Inspect the coolant-circulating system’s filter element at the rear of the cooler. If the filter is a brownish color,
replace it. Consult the Parts List in this manual for part numbers.
6. Perform a coolant flow test as described in this manual, then check for coolant leaks. Primary locations to inspect
are these:
A. The rear of the cooler;
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. Verify that the water tube is straight and has no pitting on the end.
8. Inspect the current ring inside the torch main body. The current ring should be smooth and not pitted. If no pitting is
observed, clean the current ring with a clean cotton swab and hydrogen peroxide. Do not use alcohol. Pitting on the
current ring generally indicates improper maintenance (i.e. lack of regular cleaning).
9. Clean all threads on the front end of the torch head with hydrogen peroxide and a cotton swab, pipe cleaner or
clean cloth. Do not use alcohol. Damage to the threads usually results from not cleaning the torch and retaining cap
threads properly, so that dirt and particulates accumulate in the threads.
10. Inspect the torch insulator for cracks. Replace the torch if you find cracks.
11. Inspect all o-rings on the torch body and consumables. Make sure that the correct amount of lubricant – a thin film –
is applied to these o-rings. Too much lubricant may obstruct gas flows.
12. Check that the retaining or shield cap is tightened securely to the torch main body.
13. Inspect all hose fittings at the rear of the torch for wear. Damage to the fitting threads mayindicate that
overtightening has occurred.
14. Check that all connections between the torch and torch leads are tight, but do not overtighten. See torque specs in
the Installation section of this manual.
When removing consumables, always place them on a clean, dry, oil-free surface, since dirty consumables may cause
the torch to malfunction.
Gas flows
15. Check each gas line from the gas supply, as follows:
A. Remove and plug the inlet gas fitting at the gas console.
B. Pressurize the gas line to 8 bar (115 psi).
C. Close the gas supply valve at the source. Watch for a pressure drop. If the gas supply line is a hose, there may
be a 0.3 to 0.5 bar (5 to 7 psi) drop due to hose-stretch.
D. Repeat for each line from a gas supply source. If any pressure continues to drop, find the leak within the system.

Maintenance
16. If the gas line pressures hold steady, perform a system gas leak tests as specified in this manual.
17. Check for hose restrictions, as follows:

A. Check all hoses to verify that they have no kinks or sharp bends, which can restrict gas flow.
B. If the cutting table uses a power track system to support leads from the power supply to the gas console or
torch, check the position of the leads in the power track to ensure the leads do not twist or kink, causing a
possible restriction.
Cable connections
18. All cables should be checked for chafing or unusual wear. If the outside insulation has been cut or otherwise
damaged, replace the cable.
Ignition console
19. Open the cover and use compressed air to blow out any accumulation of dust and particulates. If moisture is present,
dry the inside of the console with a cloth and try to identify the source of the moisture.
20. Inspect the spark gap assembly. Ensure that the wiring connections to the spark gap assembly are secure. Check
that the console doors close properly.
21. Inspect the torch leads. Ensure that they are fastened tightly to the outside of the ignition console.
System grounding
22. Verify that all components of the system are individually grounded to a driven earth ground, as described in the
Installation and Grounding sections of this manual.
A. All metal enclosures, such as the power supply, ignition console and selection console, should be connected
individually to a ground point. These connections should be made with 10 mm2 (No. 8 AWG) wire (USA), or
equivalent-size wire.
23. Check the work lead (+) connection, particularly where the work lead (+) connects to the cutting table. This must
be a good, clean connection because a poor connection may cause arc-transfer problems.
24. Complete the Preventive Maintenance worksheet on the next page, for future reference.

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 Jan Feb March April May June July Aug Sept Oct Nov Dec
1
2
3
4
5
• Clean the power supply with dry, oil-free compressed air, or a vacuum cleaner.
• Verify cooling fans are working properly.
• Clean torch threads and current ring.
• Verify proper coolant level.
Semi-Annually:
Year 1st Service 2nd Service
• Replace service parts per the Service Part Replacement Schedule.
Annually:
Year
• Replace service parts per the Service Part Replacement Schedule.

Maintenance
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

* *
P NP 1. Inspect for particulates and blow out *P *NP 16. Perform gas leak test
*P *NP 2. Inspect wiring harnesses A. Oxygen pressure drop at ____________
psi in 10 minutes ( ____________ bar)
*P *NP 3. Inspect main contactor
B. Nitrogen pressure drop at ____________
*P *NP 4. Inspect pilot arc relay
psi in 10 minutes ( ____________ bar)
Coolant system * * 17. Inspect for hose restrictions
P NP
*P *NP 5. Inspect filter element *P *NP A. metering console hoses

*P *NP 6. Perform coolant flow test *P *NP B. Selection console to Metering
console
A. C
oolant flow checked at _________
gallons per minute ( _________ l/min) * * C. metering console to torch
P NP
*P *NP D. Hoses in power track

Torch main body
*P *NP 7. Inspect water tube Cable connections
*P *NP 8. Inspect current ring *P *NP 18. Inspect cables
*P *NP 9. Clean threads on torch front end *P *NP A. CommandTHC
*P *NP 10. Inspect Vespel torch insulator *P *NP B. Control cable from metering
console to selection console
*P *NP 11. Inspect torch and consumable o-rings
*P *NP C. From metering console to
*P *NP 12. Verify proper fit of retaining or shield cap power supply
*P *NP 13. Inspect hose fittings *P *NP D. From ignition console and
*P *NP 14. Inspect torch-to-torch-lead connections selection console to power supply
Gas flows Ignition console

*P *NP 15. Inspect plumbing from gas supply *P *NP 19. Inspect for moisture, dust and
particulates
*P *NP A. Oxygen *P *NP 20. Inspect spark gap subassembly
*P *NP B. Nitrogen *P *NP 21. Inspect torch leads
*P *NP C. Air
*P *NP D. Nitrogen-Hydrogen System grounding
*P *NP E. Argon-Hydrogen *P *NP 22. Inspect for proper system component
*P *NP F. Inspect compressed air filter system grounding
*P *NP 23. Inspect connection from cutting
table to workpiece (+) lead
General comments and recommendations:
Preventive maintenance performed by: Date:

Maintenance
Service parts replacement schedule – 1 of 2

228369 – annual preventive maintenance parts kit (200-240 volt)
228370 – annual preventive maintenance parts kit (380-600 volt)
The kits include all the parts in the shaded boxes below
Timeline Component Part number Qty.
Coolant filter element 027664 1

Coolant solution 70/30 028872 6
6 months or 300 arc hours Torch kit 128879 1
Quick-disconnect kit 128880 1
Air filter element 011110 1
Main contactor (200 VAC-240 VAC) 003218 1
1 Year or 600 arc hours Main contactor (380 VAC-600 VAC) 003233 1
Torch main body 220706 1
Pilot arc relay 003149 1
1.5 Years or 900 arc hours+ Torch kit 128879 1

2 Years or 1200 arc hours Torch main body 220706 1
Coolant pump kit 228171 1
Torch leads System dependent 1

2.5 Years or 1500 arc hours Torch kit 128879 1
3 Years or 1800 arc hours Torch main body 220706 1
Cooling fan 6 in. 127039 8

Maintenance
Service parts replacement schedule – 2 of 2
Timeline Component Part number Qty.

4 Years or 2400 arc hours
Coolant pump motor kit 128385 1


5 Years or 3000 arc hours
High voltage transformer 129854 1
Power distribution board 041802 1
Metering console 078535 1
Pilot arc lead System dependent 1
Gas leads System dependent 1


6 Years or 3600 arc hours Pilot arc relay 003149 1
6.5 Years or 3900 arc hours Repeat schedule starting at 6 months or 300 arc hours

Section 6
Parts List
In this section:
Power supply...............................................................................................................................................................................................6-2
Cooler............................................................................................................................................................................................................6-6
Ignition console ..........................................................................................................................................................................................6-8
Selection console.......................................................................................................................................................................................6-9
Metering console..................................................................................................................................................................................... 6-11
HyPerformance torch.............................................................................................................................................................................. 6-12
Torch assembly.............................................................................................................................................................................. 6-12
Torch leads..................................................................................................................................................................................... 6-13
Ohmic contact wire....................................................................................................................................................................... 6-13
Consumable parts kits............................................................................................................................................................................ 6-14
Consumables for mirror-image cutting............................................................................................................................................... 6-16
Mild steel (straight cutting)......................................................................................................................................................... 6-16
Mild steel (bevel cutting)............................................................................................................................................................. 6-17
Recommended spare parts................................................................................................................................................................... 6-18

Parts List
Power supply
Power supplies Note: The Hypernet option is currently used with the

ArcGlide® torch height control. See the ArcGlide
Without With Voltage instruction manual (806450) for more information.
Hypernet Hypernet (AC)
078523 078570 200/208
078524 078571 220
078525 078572 240
078526 078573 380 1 2 3
078527 078574 400
078528 078575 440
078529 078576 480
078530 078577 600
Part
Item Number Description Designator Qty.
1 See table above Power supply
2 228363 Panel: Left side, with labels and handles (not shown) 1
3 228362 Panel: Top, with labels 1
4 075241 Sheet metal screws 1
5 228395 Panel: Right side, with labels and handles 1
6 228361 Panel: Front, with labels 1
7 129633 Green power lamp assembly
8 228604 Kit: Hypernet upgrade (not shown) 1

Parts List
Power supply
3
1
4b 4c
4a
4d
5a
5b
5c
5d
Part
1 229214* Terminal block: Input power TB1 1
229033** Terminal block: Input power TB1 1
2 229195 EMI filter (400 volt power supply only) 1
3 027079 10” fan: 450-550 CFM, 120 VAC 50-60 HZ 3
4a 129792 Chopper assembly CHA 1
4b 129792 Chopper assembly CHB 1
4c 129792 Chopper assembly CHC 1
4d 129792 Chopper assembly CHD 1
127039 6” fan: 230 CFM, 115 VAC 50-60 HZ 8
5a 014080 Inductor: 100 amp, 4 mH L1 1
5b 014080 Inductor: 100 amp, 4 mH L2 1
5c 014080 Inductor: 100 amp, 4 mH L3 1
5d 014080 Inductor: 100 amp, 4 mH L4 1
6 003218* Contactor CON1 1
003233** Contactor CON1 1
* 200, 220, and 240 volt power supplies

** 380, 400, 440, 480, and 600 volt power supplies

Parts List
Power supply
4 5a
3 5b
2 5c
5d
Part
1 108847* Fuse: 7.5 amp, 600 volt, high surge F1, F2 2
008709** Fuse: 20 amp, 500 volt, slow blow F1, F2 2
2 229213 PCB: I/O 1
3 003149*** Relay: Pilot arc, 120 VAC CR1 1
4 229238 Start circuit assembly PCB1 1
5a 109004 Current sensor: Hall 100 amp, 4 volt CS1 1
5b 109004 Current sensor: Hall 100 amp, 4 volt CS2 1
5c 109004 Current sensor: Hall 100 amp, 4 volt CS3 1
5d 109004 Current sensor: Hall 100 amp, 4 volt CS4 1
6 014321 200 volt main transformer: 80KW, 3 ph, 50 HZ T2 1
014322 220 volt main transformer: 80KW, 3 ph, 50 HZ 1
228309 Kit: Thermistor replacement for main transformer 1
* 200, 220, and 240 volt power supplies
** 380, 400, 440, 480, and 600 volt power supplies
*** CR1 is located under the cover

Parts List
Power supply
3
1 4
2
Part
1 141027 PCB: Pump motor drive PCB7 1
2 229212 Inductor: 5 amp, 1.4 mH 2
3 041802 PCB: Power distribution PCB2 1
108028 Fuse: 3 amp, 250 volt F5, F6, F7 3
108075 Fuse: 6.3 amp, 250 volt (slow-blow) F1, F2, F3 3
108709 Fuse: 10 amp, 250 volt F4 1
4 141030 PCB: Control PCB3 1
5 229225 Control transformer: 400 volt, 50-60 HZ T2 1
229226 Control transformer: 380 volt, 50-60 HZ 1
229227 Control transformer: 480 volt, 60 HZ 1
229231 Control transformer: 200 and 208 volt, 50-60 HZ 1

Parts List
Cooler
3
2
1
4
Part
078531 Cooler
1 101022 Panel: Right side 1
2 127014 Filler cap 1
3 228366 Panel: Top, with labels 1
4 110507 Panel: Left side 1
5 027634 Filter housing 1
027664 Filter element 1

Parts List
Cooler
3 4 7
5
2
6
8
1
12
11 10
Part
1 006113 Check valve 1
2 229235 Flow sensor: 23 lpm (6 gpm) FS1 1
3 141033 PCB: Cooler sensor 1
4 009040 EMI filter: 250 VAC, 2 amp, 1 phase 1
5 041897 PCB: Console power distribution 1
008756 Fuse: 5 amp, 250 volt (slow-blow) F1 1
6 027658 Fan: 240 volt, 240 watt, 2910 cfm 1
7 229224 Temperature sensor TS1 1
8 027926 Filter assembly: 1/2”, NPT, low profile 1
9 228171 Kit: Pump with clamp 1
10 228230 Kit: Motor with clamp, 1/3 hp 1
11 229229 Solenoid valve 1
12 006132 Check valve (bypass valve): 1/4” NPT, 200 psi 1

Parts List
Ignition console
Part
1 078172 Ignition Console
2 129831 Coil assembly T2 1
3 041817 HF/HV Ignition PCB PCB IGN 1
4 129854 Transformer T1 1
5 009045 EMI filter 1

Parts List
Selection console
1
2
4
Part
1 078533 Selection console
2 129633 Green power lamp 1
3 011109 Filter assembly: Auto drain, 1/4” NPT 1
4 228069 Kit: Control PCB PCB2 1
5 005263 Pressure sensor P1-P4 4
6 006136 Solenoid valve SV3 and SV10 2
7 006109 Solenoid valve SV1, SV2, SV4-SV9, SV11-SV15 13
006112 Replacement solenoid coil
8 041897 Power distribution PCB PCB1 1

Parts List
Selection console
Part
1 041822 Valve driver PCB PCB3 1
2 129999 Motor valve assembly MV1, MV2 2

Parts List
Metering console
1
2
4 5
3
Part
1 078535 Metering console 1
2 129633 Green power lamp 1
3 041897 Power distribution PCB PCB1 1
4 228069 Kit: Control PCB PCB2 1
5 006077 Check valves 2
6 006109 Solenoid valve SV16 1
006112 Replacement solenoid coil
7 005263 Pressure transducer (3 of 4 shown) P5-P8 4
8 006128* Proportional valve B1-B4 4
228023** Kit: HPR gas metering manifold upgrade 1
* Gas consoles with a serial number of 500134 or later take this part number
** Gas consoles with a serial number of 500133 or earlier must order this kit

Parts List
HyPerformance torch
Torch assembly
1
2 3 4 5
Part
Item Number Description
1 228354 HPR400XD machine torch assembly
2 220706 Quick-disconnect torch
3 220571 Water tube
4 220705 Quick-disconnect receptacle
5 220789 Torch mounting sleeve assembly: Standard, 181 mm (7 in)
220788 Torch mounting sleeve assembly: Short, 114 mm (4.5 in)
220790 Torch mounting sleeve assembly: Long, 248 mm (9.75 in)
6 104269 2” spanner wrench
128879 Torch kit: O-rings, water tube and seal
128880 Quick disconnect kit: O-ring and connector

Parts List
Torch leads
Part no. Description

228291 2 m (6 ft)
228292 3 m (10 ft)
228293 4.5 m (15 ft)
228294 6 m (20 ft)
228295 7.5 m (25 ft)
228296 10 m (35 ft)
228297 15 m (50 ft)
Note: A 20 m (65 ft) torch lead is not available for HPR400XD systems
Ohmic contact wire (Not part of the HPR400XD system. Shown for reference only.)
Note: The ohmic contact wire is not part of the HPR260XD system. Shown for reference only
Part no. Length

123983 3 m (10 ft)
123984 6 m (20 ft)
123985 7.5 m (25 ft)
123986 9 m (30 ft)
123987 12 m (40 ft)
123988 15 m (50 ft)
123989 23 m (75 ft)
123990 30 m (100 ft)
123991 45 m (150 ft)

Parts List
Consumable parts kits

Note: See Consumable selection or Cut charts in section 4 for specific applications
Mild steel parts kit – 228367
Part
026009 O-ring: 0.208” X 0.070” 5
027055 Lubricant: Silicone 1/4-oz tube 1
044028 O-ring: 1.364” X 0.070” 2
104119 Tool: Consumable removal / replacement 1
104269 Wrench: Spanner 1
220747 Shield cap 1
220194 Shield 1
220754 Nozzle retaining cap 1
220193 Nozzle 2
220180 Swirl ring 1
220192 Electrode 2
220555 Shield 1
220554 Nozzle 2
220553 Swirl ring 1
220552 Electrode 2
220189 Shield 1
220188 Nozzle 2
220179 Swirl ring 1
220187 Electrode 2
220183 Shield 2
220182 Nozzle 3
220181 Electrode 2
220665 SilverPlus electrode 1
220340 Water tube with o-ring 1
220637 Shield cap 1
220761 Shield 2
220354 Nozzle 3
220353 Swirl ring 1
220352 Electrode 2
220764 Shield 2
220439 Nozzle 3
220436 Swirl ring 1
220435 Electrode 2
220636 Shield 2
220632 Nozzle 3
220631 Swirl ring 1
220629 Electrode 3

Parts List
Stainless steel and aluminum parts kit – 228368
Part
026009 O-ring: 0.208” X 0.070” 5
027055 Lubricant: Silicone 1/4-oz tube 1
044028 O-ring: 1.364” X 0.070” 2
104119 Tool: Consumable removal / replacement 1
104269 Wrench: Spanner 1
220747 Shield cap 1
220202 Shield 1
220201 Nozzle 2
220180 Swirl ring 1
220308 Electrode 2
220338 Shield 1
220337 Nozzle 2
220179 Swirl ring 1
220339 Electrode 2
220198 Shield 1
220197 Nozzle 2
220307 Electrode 4
220637 Shield cap 1
220762 Shield 1
220343 Nozzle 2
220342 Swirl ring 1
220763 Shield 1
220406 Nozzle 2
220405 Swirl ring 1
220707 Shield 2
220708 Nozzle 3
220709 Electrode 3
220346 Nozzle 1
220181 Electrode 1

Parts List
Consumables for mirror-image cutting

Mild steel (straight cutting)
Nozzle Water
30 A
220194 220810 220193 220306 220192
50 A
220555 220810 220554 220549 220552
220747 80 A
220189 220755 220188 220305 220187

220340
130 A
220183 220755 220182 220305 220181
200 A
220761 220811 220354 220350 220352
260 A
220764 220812 220439 220442 220435

220637
400 A
220571
220636 220783 220632 220782 220629

Parts List
Mild steel (bevel cutting)

Nozzle Swirl Water
80 A
220742 220996 220806 220305 220802

220700
130 A
220742 220794 220646 220305 220649
220637 260 A
220741 220794 220542 220442 220541

220571
400 A
220636 220783 220632 220782 220629

Parts List
Recommended spare parts

Power supply
Part
Number Description Designator Qty.
129633 Green power lamp assembly 1

129792 Chopper assembly CH1, CH2, CH3, CH4 1
127039 6” fan: 230 CFM, 115 VAC 50-60 HZ 1
027079 10” fan: 450-550 CFM, 120 VAC 50-60 HZ 1
003149 Relay: Pilot arc, 120 VAC CR1 1
229213 PCB: I/O 1
003232* Contactor CON1 1
003228** Contactor CON1 1
109004 Current sensor: Hall 100 amp, 4 volt CS1, CS2, CS3, CS4 1
229238 Start circuit assembly PCB1 1
008551 Fuse: 7.5 amp, 600 volt F1, F2 2
141030 PCB: Control PCB3 1
041802 PCB: Power distribution PCB2 1
108028 Fuse: 3 amp, 250 volt F5, F6, F7 3
108075 Fuse: 6.3 amp, 250 volt (slow-blow) F1, F2, F3 3
108709 Fuse: 10 amp, 250 volt F4 1
228171 Kit: Pump with clamp 1
228230 Kit: Motor with clamp 1
141027 PCB: Pump motor drive PCB7 1
* 200/208, 220 and 240 volt power supplies

** 380, 400, 440, 480 and 600 volt power supplies
Cooler
Part
041897 PCB: Console power distribution 1

027634 Filter housing (on the rear panel of the cooler) 1
027926 Filter housing (under the coolant tank) 1
229235 Flow sensor FS1 1
006113 Check valve: 3/8” FPT 1
229229 Solenoid valve 1
141033 PCB: Cooler sensor 1
Ignition console
Part
041817 HFHV Ignition PCB 1

129854 Transformer T1 1

Parts List
Selection and metering consoles
Part
228069 Kit: Control PCB PCB2 1

041897 Power distribution PCB PCB1 1
041822 Valve driver PCB PCB3 1
006136 Solenoid valve SV3 and SV10 2
006109 Solenoid valve SV1, SV2, SV4-SV9, SV11-SV15 13
005263 Pressure sensor 1
011109 Air filter housing (on the rear panel of the selection console) 1
011110 Air filter element 1

Parts List

Section 7
Wiring Diagrams
Introduction
This section contains the wiring diagrams for the system. When tracing a signal path or referencing with the Parts List or
Troubleshooting sections, please be aware of the following format to assist you in understanding the wiring diagrams’
organization:
• Sheet numbers are located in the lower right-hand corner.

• Page-to-page referencing is done in the following manner:
SHEET
C 4-D3
Source Connection Source Reference Block Destination Sheet # Destination

Coordinates
SHEET
4-D3 C
Source Sheet No. Source Coordinates Source Reference Block Destination

Coordinates
Destination and Source Coordinates refer to letters A-D on the Y-axis of each sheet and numbers 1-4 on the
X-axis of each sheet. Lining up the coordinates will bring you to the source or destination blocks (similar to a road map).
Wiring diagram symbols

Wiring diagram symbols and their identification precede the system wiring diagrams in this section.
HPR400XD Auto Gas – 806160 Revision 3 7-1

7-2
Battery Fuse Push Button,
Normally Closed
Cap, polarized Ground Clamp Push Button,

Normally Open
Cap, non-polarized Ground, Chassis Receptacle

Wiring Diagrams
Cap, feed-thru Ground, Earth Relay, Coil
Circuit breaker IGBT Relay, Normally Closed
Coax shield Inductor Relay, Normally Open
Current Sensor LED Relay, Solid State, AC
Current sensor Lamp Relay, Solid State,

DC
DC supply MOV Relay, Solid State, Dry
Pin Resistor
Diode
Door interlock Socket SCR
Plug Shield
Fan
Feedthru LC PNP Transistor Shunt
Potentiometer Spark Gap

Filter, AC
HPR400XD Auto Gas – 806160 Revision 3

Switch, Flow Time Delay Open,
NC/On Torch Symbols
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
HPR400XD Auto Gas – 806160 Revision 3

Transformer Coil
Switch, 1 Pole, 2 Throw Shield
Switch, 1 Pole, 1 Throw,

Center Off Triac
Switch, Temperature, Torch

Normally Closed VAC Source
Switch, Temperature,
Normally Open Valve, Solenoid
Torch, HyDefinition™
Terminal Block
Voltage Source
Time Delay Closed,

NC/Off Zener Diode
Time Delay Open,

NO/Off
7-3
Wiring Diagrams
Wiring Diagrams
7-4 HPR400XD Auto Gas – 806160 Revision 3

Discrete output functionality
HPR400XD Auto Gas – 806160 Revision 3 7-5

Wiring Diagrams
7-6 HPR400XD Auto Gas – 806160 Revision 3

4 3 2 1
Cooler Power Cable

3 Phase 12x1
Power Unit 7
w/ Ground Cooler
Cooling Supply Lead

Cooling Return Lead
D D
12X2
1x12
Torch Lead Assembly
Negative Lead
Air
1X3
HF/PS Cable
2X1 O2 Unit M
Unit 2 N2
Unit 3
Atm Vent Torch
Ar Unit 4 72"
Lifter
Pilot Arc Lead Ignition Console F5 Selection Console
Cut Gas 1 Plasma
Metering Console
H35 Cut Gas 2
Shield (Optional Unit)
H5
128930
C 3X1 3X4 3X3 3X2 4X1 4X2 4X3 C

Cooler Control Cable Power Cable
1X6
Gas Power Cable
1X1 Gas Control Cable
Gas Control Cable
1X2 Torch
Work Lead
Workpiece
Unit 1
Power Supply
CNC Interface Cable

1X5
CNC Interface Cable
Unit 6 Unit N
1X6 CNC Operator
B Interface B
CNC Interface Cable Pendant
(Customer Supplied) (Optional Unit)
Pendant Ext. Cable

Unit 5
Plasma Interface Cable
Lifter I/O Interface Cable
1X4 THC
(Optional Unit) Motor Drive Cable
A A
ELEC SCH:HPR400XD PWR SPLY W/AUTO

013374
SHEET 1 OF 24 E
4 3 2 1 7-7
4 3 2 1
SHEET B
3-D4 E SHEET SHEET M N SHEET AF SHEET
3-C1 4-B2 4-B3 10-A4
RED/BLK
PWM
DRV A
SHLD
RED
RED
RED
BLK
BLK
YEL/BLK
RED/BLK
L3 SEE SHEET 12 OF 14 FOR JA.1 JA.6
D L2 ALL SUPPLY VOLTAGE AJ SHEET D
1
3
4
5
6
3
2
YEL
C
RED
L1 J1 J6 18-C2
INPUT WIRING
PE 1A 1A CHOPPER SA CHA
CABLE: 123662
129792 J4.4
1B 1B – 38
1
3
2
Handle T2 J4
1C 1C
E-Stop CUSTOMER SUPPLIED CS1 38 J1
FUSED DISCONNECT + 39 39
Fuse (–)NEGATIVE
L1
RED/BLK
E SHEET R9 R8 R1 C1
2
4
3
1
RED/BLK
PWM 3-C1 350UF
RED
DRV B J12 9.1K 9.1K 9.1K
SHLD
RED
RED
RED
BLK
WHT
GRN
RED
BLK
BLK
K1
JB.1 JB.6
1
3
4
5
6
3
2
2
I/O
J1 J6 SHEET F C3
SURGE INJECTION R5
2A 2A CHOPPER SA CHB 6-A2 100K .22UF
141039
129792 K1 A2
C C
2B 2B – 38 A1 K2
2C 2C CS2
+ 39 39 R2 10 R3 100R4 10
CON1 L2
J3
(++)POSITIVE
RED/BLK
E SHEET
2
4
3
1
PWM 3-C1 J13
DRV C
RED
SHLD
BLK
WHT
GRN
RED
RED
RED
BLK
BLK
.022UF C2 R7 10K
JC.1 JC.6
CS5
1
3
4
5
6
3
2
2
SHEET G + 39 J2
J1 J6 (+)POSITIVE
A1 A2 3A 6-A2
3A CHOPPER SA CHC .22UF
129792 C4 R6 10K
3
4
2
3B 3B
H9
– 38
J10 CR1
AD SHEET
4-B3 3C 3C
WHT
GRN
Fuse 21 22
RED
B CS3 B
BLK
+ 39 39 H9 40
L3
BLK
39
H8
E SHEET
2
4
3
1
RED/BLK
3-C1
BLK
PWM J14 SHEET
DRV D J
6-A1
SHLD
BLK
WHT
GRN
RED
RED
RED
RED
BLK
BLK
T1 H9 H8
JD.1 JD.6
J1.4 J4
ORG
ORG
J1 J1.1
RED
RED
1
3
4
5
6
3
2
2
YEL
YEL
J1 J6 SHEET H 1 RED
240VAC 1
6-A2 2
120VAC 4A 4A CHOPPER SA CHD RED 2
24VAC 3 ENABLE RED/BLK
BLK PCB1 3
129792 4
4B 4B – 38 PILOT ARC PA
A SHEET CONTROLLER L SHEET CONTROL
Supply Vac 3-D4 4C 229238 3-C1 POWER
4C CS4 SHEET K
+ 39 39 5-D1
L4
A A
2
4
3
1
J15
C SHEET
5-C1 ELEC SCH:HPR400XD PWR SPLY W/AUTO
BLK
WHT
GRN
RED
SHEET Z
PCB: 041562
ASSY: 041564
D SHEET
5-D4
013374
5-C4 SCH: 041564 SHEET I
6-A1
SHEET 2 OF 24 E
4 3 2 1
7-8
4 3 2 1
SHEET B
2-D3 J2.15 J15
BLK 1A F5
1 PCB2
2 POWER DISTRIBUTION U5
BLK 1B F6
3 PHASE LOSS INPUT J8 J2.8 T SHEET PHASE LOSS
4
041802 5-D1
BLK 1C F7 + 1 BLU
5 PHASE LOSS OUTPUT – WHT
SHEET BC 2
11-D4 6
WHT
D SHEET A D
2-A4 J2.4 J2.A RED J2.B J4
PUMP MOTOR DRIVE
1 1 F2 J11 J2.11 U SHEET
7-D4 POWER
YEL 24VAC 2 YEL 24VAC 2 24VAC F4 1 BLK
240VAC HOT BLK
3 3 2
RED 120VAC 4 RED 120VAC 4 120VAC 3
5 5 4
ORN 240VAC 6 ORN 240VAC 6 240VAC 5 WHT
240VAC RTN 6 WHT
HARNESS: 229329 COOLOANT SOLONOID
FOR ARCGLIDE THC ONLY D3 120VAC J1 J2.1 BB SHEET
19-A4 POWER
D12 24VAC 1
2
D26 Pump motor signal RED/BLK
K2 3
D25 +24V RED
4
F3 120VAC HOT COOLER
D23 240VAC 5 AA SHEET
SHEET O J2.14 J14 6 19-A4 POWER
6-D4 BLU D31 +5V RED/BLK
1 +24V 7
WHT D32 -15V RED/BLK
2 +24V COM 8
C D33 +15V
K1
9 RED/BLK C
3 RED
BLU D35 Remote 10
4 +5V F1 RED
WHT 11 CHOPPER
RED
5 +5V COM K3 RED E SHEET POWER
6 +15V 12 2-D2
BLK 7 +/–15V COM 13 PA
LINE VOLTAGE OUTPUT

YEL RED/BLK L SHEET CONTROL
AC1
AC2
8 –15V 14 2-A1
+ POWER
–
15
REMOTE ON/OFF
16
PUMP MOTOR CNTRL

RED
TEST CONNECTOR
17
PUMP MOTOR
120VAC RTN 18
24VAC HOT
240VAC HOT
24VAC RTN
2
1
240VAC
SIGNAL
24VAC
AC
+24V
COM
COM
COM
COM
POWER
B LIGHT B
7 RED/BLK
+
–
J16 J12 J13 J2 J7 J9
1 2 1 2 1 2 1 2 1 2 1 2 3 4 5 6
6 RED
J2.7
WHT
RED
WHT
RED
TB2 1 2 3 4 5 6 7
1 2 3 4 5 6 7
RED
RED/BLK
HARNESS: 229329 WHT
FOR ARCGLIDE THC ONLY
WHT
RED
RED
SHEET BD
11-B4 REMOTE ON/OFF 1X1
1
7
6
4
3
5
2
CABLE: 123674
WHT
SHD
RED
EE SHEET
BLK
BLK
12-A4
A A

013374
SHEET 3 OF 24 E
4 3 2 1
7-9
4 3 2 1
PCB2
POWER DISTRIBUTION
041802
D D
SHEET Y
5-D1 J2.5 J5
BLU 1 + CONTACTOR
WHT 2 D1 CONTACTOR
BLU 3 + PA RELAY
WHT 4 D2 PA RELAY
BLU 5 + HV XFMR
WHT 6 D5 HV XFMR
BLU 7 + MARKING SURGE RELAY
C WHT 8 D7 MARKING SURGE RELAY C
MARKING SURGE RELAY

9
10
HF TRANSFORMER
11
PILOT ARC RELAY

12
120VAC RTN
CONTACTOR
J3
1 2 3 4 5 6 7 8 9 10 1112
J2.3
B B
RED/BLK
RED/BLK
RED/BLK
RED
RED/BLK
RED
RED
RED
SHEET AD
2-D1 M
2-D1 N
SHEET
SHEET
2-B4
1 2 3 4
CABLE: 123670
A A
SHEET ELEC SCH:HPR400XD PWR SPLY W/AUTO

18-D3 AC
013374
SHEET 4 OF 24 E
4 3 2 1 7-10
4 3 2 1
PCB3 J308 J3.308

K SHEET PILOT ARC ENABLE
RED 2-A1
POWER SUPPLY CONTROL PA-C 1
BLK
141030 PA-E 2
3 T SHEET PHASE LOSS
4 BLU 3-D1
D PHASE LOSS WHT D
SHEET D 5
2-A3 J3.202 J202 D107 +5V D320 CONTACTOR 6
RED 1 FA+3.3V D108 +3.3V D321 PA RELAY
BLK 2 CHOPPER A TEMP SENSOR
CLR D110 TXLED D322 HF J307 J3.307
RED
3
D111 RXLED D323 MARKING SURGE RELAY Y SHEET
4 +24V BLU 4-C4
1
BLK 5 CHOPPER B TEMP SENSOR WHT
D308 MOTION D324 PHASE LOSS CONTACTOR 2
CLR 6 BLU
D309 ERROR D328 OVERPRESSURE 3
RED 7 WHT
PA RELAY 4
BLK 8 CHOPPER C TEMP SENSOR D310 RD ERROR D329 PMD OK\ BLU
5
CLR 9 WHT
D311 NOT READY D335 CONTACTOR HF 6
RED 10 BLU
D312 HOLD IGNITION INPUT 7
BLK 11 CHOPPER D TEMP SENSOR WHT
MARKING SURGE RELAY 8
CLR 12 D313 CNC PIERCE COMPLETE INPUT
SHEET Z
2-A4 BLU 13 D314 CNC CORNER CURRENT INPUT J302 J3.302 C SHEET
WHT 14 TRANSFORMER TEMP SENSOR 2-A3
+5V 1 RED
15 D315 PLASMA START INPUT
PWM DRV A 2 BLK
16 D316 PA ENABLE SHLD
C 3 C
D317 SPARE 4 RED
PWM DRV B 5 BLK
6 SHLD
7 RED
PWM DRV C 8 BLK
J301 SHLD
9
CNC +24V 10 RED
1 2
RX+
BLK
TX+
RX–
TX–
+24V PWM DRV D 11
12 SHLD
CORNER CURRENT+
CORNER CURRENT–
SPARE-C 13
R129 SPARE-E 14
121 OHMS CNC INTERFACE
R127
NOT READY-C
NOT READY-E
MOTION 1-C
MOTION 2-C
MOTION 3-C
MOTION 4-C
MOTION 1-E
MOTION 2-E
MOTION 3-E
MOTION 4-E
121 OHMS
CNC +24V
PWR GND
ERROR-C
RDERR-C
ERROR-E
RDERR-E
PIERCE+
PIERCE–
START+
J304
HOLD+
START–
HOLD–
RS422
GND
B B
RX37+
TX37+
RX37–
TX37–
RX9+
RX9–
TX9+
TX9–
J105 J104 J305 A&B J303A

1 2 1 2 1 2 3 4 5 6 7 8 1 20 2 21 3 22 4 23 5 24 6 25 7 26 8 27 9 28 10 29 11 30 12 31 13 32 14 33 15 34 16 35 17 36 18 37 19
J3.105 J3.104
123887
1 20 2 21 3 22 4 23 5 24 6 25 7 26 8 27 9 2810 291130123113 32 1433 1534 16351736 183719
A A

013374
SHEET 5 OF 24 E
4 3 2 1
7-11
4 3 2 1
D D
PCB3
SHEET O
3-C4 J3.100 J100
POWER SUPPLY CONTROL
BLU +24V 141030
1 PUMP ENABLE/ALARM
WHT PWR GND
2
3 AY SHEET
BLU +5V 0 J306 J3.306 7-D1
4 PUMP ENABLE\ - C
WHT GND 1 RED
5 PUMP ENABLE\ - A BLK
RED +15V 2
6
BLK COM 3 CLR
7 FAULTOUT\ RED
YEL –15V 4
8 F+5V
5 BLK
CLR
6
TP200 TP202 TP204 TP206 7
J106 8
TMS
1 9
TRST\
2 10
C TDI C
3 1/2 1/2 1/2 1/2
COM TP214
4
+5V
5
6
CHOPPER SENSOR C
CHOPPER SENSOR D
CHOPPER SENSOR B
TDO
CHOPPER SENSOR A
7 JTAG
8 1/4
TCK
9
10
WORK LEAD
11
CAN +24V
CAN GND
12
EMU0 CANH
13
CANL
+15V
+15V
+15V
COM
COM
COM
–15V
–15V
–15V
EMU1
14
121
to
B B
J108 J102 J103 J101 J200 J201 J203
E 1 2 1 6 2 7 3 8 4 9 5 1 6 2 7 3 8 4 9 5 1 2 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 111213 14 1 2 3 4 5 6
CAN A CAN B
J3.200 J3.201 J3.203
WHT
GRN
RED
WHT
WHT
WHT
GRN
GRN
GRN
WHT
GRN
RED
RED
RED
BLK
RED
BLK
BLK
BLK
BLK
SHIELD
RED
RED
BLK
BLK
CABLE: 123886
SHEET AG
13-A3 WORK LEAD
SENSOR
SHIELD
RED
RED
BLK
BLK
SHEET G
CABLE: 123886
SHEET H
SHEET F
SHEET J
SHEET I
SHEET AK
19-D4
2-B2
2-C2
2-B1
2-A2
2-A2
A A

013374
SHEET 6 OF 24 E
4 3 2 1
7-12
4 3 2 1
D PUMP ENABLE/ALARM D
PCB7 AY SHEET
SHEET U J11 J7.10 6-D1
3-D1 J7.8 J8
PUMP MOTOR DRIVE CONTROLLER
CB1 PUMPEN\ - C RED
BLK
1
ACIN1 141027 D36 PUMPEN\ - A BLK
WHT ACIN2 2
2 CLR
3
3 FAULTOUT\ RED
D35 4
4 F+5V BLK
5
6 CLR
7
D1 +15V 8
9
10
D10 +5V
J9
TMS D16 +3.3V
1
TRST\
2
C TDI D30 OUTPUT OVER CURRENT C
3
COM J11
4
+5V PUMPAC1
5 D31 HEAT SINK OVERTEMP 1
6 PUMPAC2
TDO 2
7 JTAG D32 IPM ALARM 3
8
TCK
9
10
11
12 RT2
EMU0
13
240VAC OUT
EMU1 J6 PUMP
AC RTRN
14 A+3.3V MOTOR
1
120VAC
THMS- O DRIVE
2 t HEATSINK
B B
J3 J2 J1 J5 J4
1 2 3 4 5 6 7 8 9 10 11 12
J7.1
2.5mH 2.5mH
6A 6A
J16 FAN 1 FAN 2

RED/BLK CHP CHP
1 1
RED 2 2
RED/BLK FAN 3 FAN 4
J17 CHP CHP
RED
PUMP MOTOR PWR SHEET P BLK 1 1
19-A4 MAGNETICS
WHT FANS 2 2
J18 FAN 5 FAN 6

A COOLER FAN PWR SHEET W BLK 1
CHP CHP
A
19-A4 1
WHT 2 2
J19 FAN 7 FAN 8

CHP CHP
1 1
2 2 013374
SHEET 7 OF 24 E
4 3 2 1
7-13
4 3 2 1
440/50 480/60
INPUT POWER INPUT POWER
FROM FACILITY FROM FACILITY
PE PE
L1 440 VAC L1 480 VAC
3 Phase 3 Phase
L2 L2
50 Hertz 50 Hertz
L3 L3
D D
TB1 TB1
1 W T1 1 W T1
2 V 2 V
3 U A4 3 U A4
4 PE V W 4 PE V W
L1 A4 L1 A4
L2 B4 B4 L2 B4 B4
L3 C4 L3 C4
CON1 CON1
0 VAC 0 VAC
C4 C4
F1 F2 F1 F2
T2 T2
400VAC
WHT
GRY
WHT
BLU
C T1 T1 C
400/50 CE 380/50

PE PE
L1 400 VAC L1 380 VAC
3 Phase 3 Phase
L2 L2 50 Hertz
50 Hertz
L3 L3
TB1 TB1
1 W T1 1 W T1
B 2 V 2 V B
3 U A4 3 U A4
4 PE V W 4 PE V W
L1 L1 A4 L1 A4
L2 B4 B4
EMI FILTER L2 L2 B4 B4
L3 L3 C4 L3 C4
CON1
CON1 0 VAC
0 VAC C4
C4
F1 F2 F1 F2
T2 T2
WHT
BLK
WHT
BLU
T1 T1
A A

013374
SHEET 8 OF 24 E
4 3 2 1
7-14
4 3 2 1
600/60 240/60
PE PE
L1 600 VAC L1 240 VAC
3 Phase 3 Phase
L2 L2
60 Hertz 60 Hertz
L3 L3
D D
TB1 TB1
1 W T1 1 W T1
2 V 2 V
3 U A4 3 U A4
4 PE V W 4 PE V W
L1 A4 L1 A4
L2 B4 B4 L2 B4 B4
L3 C4 L3 C4
CON1 CON1
0 VAC 0 VAC
C4 C4
F1 F2 F1 F2
T2 T2
600VAC 240VAC
WHT
WHT
GRY
BLK
C T1 T1 C
200/50-60 220/50-60

PE PE
L1 440 VAC L1 380 VAC
3 Phase 3 Phase
L2 L2
50 Hertz 50-60 Hertz
L3 L3
TB1 TB1
1 W T1 1 W T1
B 2 V 2 V B
3 U A4 3 U A4
4 PE V W 4 PE V W
L1 A4 L1 A4
L2 B4 B4 L2 B4 B4
L3 C4 L3 C4
CON1 CON1
0 VAC 0 VAC
C4 C4
F1 F2 F1 F2
T2 T2
200VAC 220VAC
WHT
WHT
BRN
BLK
T1 T1
A A

013374
SHEET 9 OF 24 E
4 3 2 1 7-15
4 3 2 1
D CABLE: 123760 D
THC OPTION
COMMAND PLASMA INTERFACE PCB3
J303A
041842 POWER SUPPLY CONTROL
J2B
J12.2B J3.303A
J2A
141030
RX– 1 1 RX–
1
20 RX+ 20 20 RX+
2 TX– 2 2 TX–
21 TX+ 21 21 TX+
3 3 3 422 GND
22 22 22
4 4 MOTION 1-E
4
23 23 MOTION 1-C
23
5 5 ERROR-E
5
24 24 ERROR-C
24
6 6 RDERR-E
6 RDERR-C
25 25 25
TO POWER SUPPLY 7 7 NOT READY-E
7
C 26 26 26 NOT READY-C C
8 8 MOTION 2-E
8 MOTION 2-C
27 27 27
9 9 9 MOTION 3-E
28 28 28 MOTION 3-C
10 TO COMMAND CONTROL MODULE 10 10 MOTION 4-E
29 29 29 MOTION 4-C
11 11 11
30 30 30
SPARE OUT 1– 12 12 CORNER–
12 SPARE OUT 1+ 31 31 CORNER+
31 PIERCE COMPLETE OUT– 13 13 PIERCE–
13 PIERCE COMPLETE OUT+ 32 32 PIERCE+
32
HOLE IGNITION OUT– 14 14 HOLD–
14 HOLD IGNITION OUT+ HOLD+
33 33 33
PLASMA START OUT– 15 15 START–
15 PLASMA START OUT+ START+
34 34 34
16 16 16
B 35 35 35 B
17 17 17
36 36 36
ELECTRODE
18 GND 18 18 PWR GND

37 37
EMI GND
37
SHIELD
+24VDC 19 19 CNC +24V

WORK
19
J301
1
2 0
+24V
J5 1 2 3 4 5 t
YEL/BLK 2
3
YEL
A SHEET AF A
2-D1

013374
SHEET 10 OF 24 E
4 3 2 1 7-16
4 3 2 1
SHEET BC
3-D4
D D
THC OPTION CABLE: 123760
ARCGLIDE ETHERNET INTERFACE PCB3
141162 POWER SUPPLY CONTROL
J303B
141030
J5
E
J13.5 J3.303B
RX– 1 1 RX–
J7 RX+ 20 20 RX+
J13.7 TX–
TX– 2 2
RED/BLK 1 TX+ 21 21 TX+
24VAC RTN
RED 2 3 3 422 GND
24VAC
22 22
MOTION IN 4 4 MOTION 1-E
+5V 23 23 MOTION 1-C
ERROR IN 5 5 ERROR-E
J1
+5V 24 24 ERROR-C
1 RAMPDOWN ERROR IN 6 6 RDERR-E
2 +5V 25 25 RDERR-C
NOT READY IN 7 7 NOT READY-E
3
C 4 +5V 26 26 NOT READY-C C
5 TO ARCGLIDE MODULE(S) 8 8 MOTION 2-E
6 27 27 MOTION 2-C
7 9 9 MOTION 3-E
TO POWER SUPPLY
8 28 28 MOTION 3-C
10 10 MOTION 4-E
29 29 MOTION 4-C
11 11
30 30
CORNER OUT– 12 12 CORNER–
CORNER OUT+ 31 31 CORNER+
PIERCE COMPLETE OUT– 13 13 PIERCE–
PIERCE COMPLETE OUT+ 32 32 PIERCE+
HOLE IGNITION OUT– 14 14 HOLD–
HOLD IGNITION OUT+ HOLD+
J6
J13.6 33 33
RED PLASMA START OUT– 15 15 START–
1 ON/OFF OUT+ PLASMA START OUT+ START+
WHT 34 34
2 ON/OFF OUT– 16 16
B 35 35 B
17 17
36 36
ELECTRODE
18 18 PWR GND
37 37
19 19 CNC +24V
WORK
SHEET BD
J301
3-A2
1
2 +24V
J4 2 1 t0
YEL/BLK 2
1
YEL
A SHEET AF A
2-D1

013374
SHEET 11 OF 24 E
4 3 2 1 7-17
4 3 2 1
D D
J1.3 J3 PCB1
RED/BLK AC1 F1 AC IN 120V HOT
1 HPR AUTO GAS J6 J1.6
RED AC2 SELECTION CONSOLE RED/BLK
2 120V RTN 1
POWER DISTRIBUTION 120VAC RED LED
3 041897 2
J1.4 J4
BLU 1 +24V
WHT 2 +24V COM
3 GAS CONSOLE
BLU 4 +5V DC POWER
WHT 5
BLU
+5V COM J5 J1.5 Y SHEET
6 +15V SV16 1 13-D3
WHT 7 +15V COM D4 120VAC 2
8 AC2 3 RED
SHEET AA D2 SV16 ENABLED RED/BLK
13-D4 AC IN 4
C C
J2
1 +5V
2 5V GND
3 SV16
4 5V GND
5
6
B B
RED/BLK
RED
RED/BLK
RED
GRN/YEL
GAS CSL PWR 3X1 3X2

1
1
7
6
4
3
7
6
4
3
5
A A

WHT
WHT
SHD
SHD
RED
RED
BLK
BLK
BLK
BLK
TO METERING CONSOLE
SHEET EE SHEET Z
3-A1 15-A4 013374
SHEET 12 OF 24 E
4 3 2 1
7-18
4 3 2 1
MV1 POT MV2 POT
RED
RED
BLK
BLK
YEL
YEL
POT 1 POT 2
P1 P2 P3 P4
8
6
6
7
7
RED
RED
BLK
BLK
YEL
YEL
BRN
BRN
BRN
BRN
BLU
BLU
BLU
BLU
BLK
BLK
BLK
BLK
BLK
D J2.2 J2.9 D
11
12
13
14
15
16
10
1
1
2
3
4
5
6
7
8
9
2
8
6
4
7
3
J2 J9
SHEET AA
12-C4 J2.11 J11
BLU +24V
1
PT1
PT1
PT1
PT1
WHT 2 PWR GND
MIXING ENABLE
COM
A+3.3V
MV POT 1
MV POT 2
A COM
3 J1
BLU +5V
+15V
COM
4 +5V 1
WHT 5 GND 2
TP16
TP13
BLU +15V
TP3
TP5
6 SV16 3
WHT 7 COM 4
8 –15V LINE FREQ. 5
COM 6
PCB2
HPR AUTO GAS
SELECTION CONSOLE
C CONTROL C
041828
J10
1
TMS POWER INDICATORS
TRST\ D45 +24V
2
TDI
3 D40 +15V
COM J4
4 D18 +5V
+5V COM
5 1
D17 +3.3V 422B 6
6
TDO
7 JTAG 2
8 RS-422 7
TCK 422Y
9 3
10 121 CANH 8
422Z 4
11
B 12
CANL
9 B
EMU0 CAN +24V 422A
13 5
EMU1 CAN GND
14
J15 J13 3X4 J14 3X3

1
1
2
6
3
3
9
9
8
8
7
7
4
5
2
2
CANA CANB
TO METERING CONSOLE
SHLD
SHLD
RED
RED
RED
RED
BLK
BLK
BLK
BLK
SHEET AG BB SHEET
6-A4 16-A3
A A

013374
SHEET 13 OF 24 E
4 3 2 1
7-19
4 3 2 1
PCB3 SV1.A RED/BLK

J3.1 J1 HPR AUTO GAS J3 J3.3 RED SV1
120V HOT SELECTION CONSOLE SV4
RED/BLK RED/BLK SV1.B
SHEET Y 1 1 SV4.A RED/BLK
PCB2 12-C1 RED 2 120V RTN RELAY RED/BLK SV2.A
SV3 2 SV3.A RED SV2
HPR AUTO GAS 3 041822 RED/BLK SV2.B
SELECTION CONSOLE SV2 3 SV2.A
D CONTROL SV1 4 RED/BLK SV1.A SV3.A
RED/BLK D
SV5 5 RED/BLK SV5.A RED SV3
041828 RED
SV3.B
J3 J2.3 J3.4 J4 120V RTN 6 SV1.B RED/BLK
RED SV4.A
120V RTN 7 SV3.B RED SV4
NOT USED 1 1 RED SV4.B
120V RTN 8 SV4.B
NOT USED 3 3 RED/BLK RED/BLK
SV6 9 SV6.A SV5.A
NOT USED 5 5 RED RED SV5
120V RTN 10 SV6.B SV5.B
+5V 7 7 RED RED/BLK
120V RTN 11 SV5.B SV6.A
J12 +5V 9 9 RED RED SV6
1 +24V +5V 11 11 RED/BLK
SV7 13 SV7.A
2 PWM4 SPARE 4 13 13 RED RED/BLK
3 D38 SPARE 3 15 15 RED RED SV7
SPARE 2 17 17
4 120V RTN 16 RED SV9.B SV8.A RED/BLK
SPARE 1 19 19 SV8
5 PWM3 SV8 17 RED SV8.A SV8.B RED
6 D39 SV20 21 21 D20
120V RTN 18
7 SV19 23 23 D19 RED RED/BLK
8 PWM2 SV18 25 25 D18 RED SV9
120V RTN 20 SV9.B
9 D28 SV17 27 27 D17 RED/BLK SV9.A RED/BLK
SV9 21 SV10.A
10 SV16 29 60 COND RIBBON 29 D16 RED RED SV10
C SV15 31 123704 31 D15
120V RTN 22 SV12.B SV10.B C
11 PWM1 120V RTN 23 RED SV13.B
12 SV14 33 33 D14 RED/BLK
D37 120V RTN 24 SV11.A
SELECTION SV13 35 35 D13 RED SV11
13 SV10 25 RED/BLK SV10.A SV11.B
14 CONSOLE ENABLE SV12 37 37 D12 RED RED/BLK
SV11 39 39 D11 RED RED SV12
SV10 41 41 D10 RED
120V RTN 28 SV14.B RED/BLK
SV9 43 43 D9 RED/BLK SV13.A
SV11 29 SV11.A RED SV13
SV8 45 45 D8 SV13.B
120V HOT 30 RED/BLK
SV7 47 47 D7 SV14.A
120V HOT 31 RED SV14
SV6 49 49 D6 SV14.B
120V HOT 32
SV5 51 51 D5 RED/BLK
SV12 33 SV12.A RED/BLK
SV4 53 53 D4 RED/BLK SV15.A
SV13 34 SV13.A RED SV15
SV3 55 55 D3 RED/BLK SV15.B
SV14 35 SV14.A
SV2 57 57 D2 RED/BLK
SPARE OUTPUT 36 SV15.A
SV1 59 59 D1
J2 J3.2
B SV16 1 B
120V RTN 2
SV17 3 RED CLOSE 1 RED
120V RTN 4 BLU 2 BLU MV1
SV18 5 BLK OPEN 3 BLK
120V RTN 6 MOTOR VALVES
SV19 7 RED CLOSE 1 RED
120V RTN 8 BLU 2 BLU MV2
SV20 9 BLK OPEN 3 BLK
120V RTN 10
A A

013374
SHEET 14 OF 24 E
4 3 2 1 7-20
4 3 2 1
J1.3 J3
D RED/BLK
1 AC1 F1 AC IN 120V HOT PCB1 J6 J1.6 D
RED AC2 POWER IN POWER RED/BLK
2 120V RTN HPR AUTO GAS 1
INDICATOR 120VAC RED LED
3 2
METERING CONSOLE
POWER DISTRIBUTION
041897
J1.4 J4
BLU 1 +24V
WHT +24V COM
2
3 GAS CONSOLE
BLU 4 +5V DC POWER
WHT 5 +5V COM J5 J1.5
BLU 6 +15V RED/BLK
SV16 1
WHT 7 +15V COM RED SV16
D4 120VAC RAMPDOWN VALVE 2
8 OUTPUT AC2 3
SHEET CC D2 SV16 ENABLED
16-D4 AC IN 4
C C
J1.2 J2
BLU 1 +5V
WHT 2 5V GND
BLU RAMPDOWN VALVE
3 SV16 CONTROL INPUT
WHT 4 5V GND
5
SHEET DD 6
16-D1
B B
RED/BLK
RED
GAS CSL PWR 4X1

1
7
6
4
3
5
2
WHT
A A
SHD
RED
BLK
BLK
TO SELECTION CONSOLE
SHEET Z
12-A3 ELEC SCH:HPR400XD PWR SPLY W/AUTO
013374
SHEET 15 OF 24 E
4 3 2 1
7-21
4 3 2 1
P8 P7 P5 P6
BRN
BRN
BRN
BRN
BLU
BLU
BLU
BLU
BLK
BLK
BLK
BLK
D J2.9 D
11
12
13
14
15
16
10
1
1
2
3
4
5
6
7
8
9
2
8
6
4
7
3
J2 J9
SHEET CC
15-C4 J2.11 J11 DD SHEET
BLU +24V 15-C4
1
PT1
PT1
PT1
PT1
WHT 2 PWR GND
MIXING ENABLE
COM
A+3.3V
MV POT 1
MV POT 2
A COM
3 J1 J2.1
BLU BLU
+15V
COM
4 +5V POWER IN +5V 1
WHT GND 2 WHT
5 RAMPDOWN VALVE
TP3
TP5
TP16
TP13
BLU +15V SV16 3 BLU
6 CONTROL OUTPUT
WHT COM 4 WHT
7
8 –15V PRESSURE INPUTS LINE FREQ. 5
METERING VALVE COM 6
POT FEEDBACK INPUTS
PCB2
HPR AUTO GAS
C METERING CONSOLE C
CONTROL
041828
J10 POWER INDICATORS

TMS D45 +24V
1
TRST\
2 D40 +15V
TDI
3 D18 +5V
COM J4
4
+5V D17 +3.3V COM
5 1
6 422B 6
TDO
7 JTAG 2
8 RS-422 7
TCK 422Y
9 3
10 121 CANH 8
422Z 4
11
B 12
CANL
9 B
EMU0 CAN +24V 422A
13 5
EMU1 CAN GND
14
J15 J13 4X2 J14 4X3

1
1
2
6
3
3
9
9
8
8
7
7
4
5
2
2
SHLD CANA
RED
RED
CABLE: 128930
BLK
BLK
SHEET BB
13-A1
A A

013374
SHEET 16 OF 24 E
4 3 2 1
7-22
4 3 2 1
D PCB2 D
HPR AUTO GAS
METERING CONSOLE
CONTROL
041828
J3
NOT USED 1
NOT USED 3
NOT USED 5
+5V 7
J2.12 J12 +5V 9
1 +24V +5V 11
BURKERT 4 2 PWM4 SPARE 4 13
3 D38 SPARE 3 15
4 SPARE 2 17
BURKERT 3 5 PWM3 SPARE 1 19
6 D39 SV20 21
7 SV19 23
C BURKERT 2 8 PWM2 SV18 25 C
9 D28 SV17 27
10 SV16 29
BURKERT 1 11 PWM1 SV15 31
12 D37 SV14 33
BLK 13 METERING SV13 35
14 CONSOLE ENABLE SV12 37
SV11 39
SV10 41
SV9 43
SV8 45
SV7 47
SV6 49
SV5 51
SV4 53
SV3 55
SV2 57
SV1 59
B B
A A

013374
SHEET 17 OF 24 E
4 3 2 1 7-23
4 3 2 1
D CABLE: 123670 D
SHEET
4-B2 AC
RED/BLK
GRN
RED
1 2 3 4
2X1
009045 FLTR
CATHODE AJ SHEET
2-D1
BLOCK
CABLE: 123662
C C
HPR HFHV IGNITION
041817
TORCH C2
0.22uF 1kVDC PILOT ARC
T1 J4 009224
J5
129854 C1
0.22uF 1kVDC
009224 COIL SECONDARY IN
J6
J1 C3
1400pF 20kV
SG1 009975 COIL PRIMARY 2
109344
5kV C4
1400pF 20kV
SG2 009975 T2
109344 C5 009793
1400pF 20kV
5kV 009975
COIL PRIMARY 1 NOZZLE
B COIL CONNECTION B
J2 J3 SECONDARY
OUT
A A

013374
SHEET 18 OF 24 E
4 3 2 1
7-24
4 3 2 1
FS1
COOLING SYS. 229235
PCB1 FLOW SENSOR
141033
Cooler Sensor Board
SHEET AK
6-A3 12X2 J2 J5 J1.5 J7
1 +24V 1 RED +24V

1
2 CANL 2 BLK GND
2
D 3 FLOW SENSOR 3 WHT D
4 S2-1 4
J6 TS1 J9
5 CAN FA+3.3V 5
6 GND COOLANT TEMP 6
D
7 +24V 7 1 FLOW
CANH
8 8 2 GND
9 CHILLER FLOW 9 Cooler
+24V 10
FLOW SENSOR
11 1 COM CHECK VALVE
J18.3 J3 PRESS SENSOR 12 2 N.O.
LINE VOLT IN 13 FILTER
RESERVOIR HEAT EXCHANGER
2 14
1 +24V RHF
0
t Negative lead
6'-250' Coolant return
D1 +5V
D2 +3.3V Bypass
C PCB2 C
D7 CAN TX THERMISTOR
D8 CAN RX 041897
J6 PUMP
J1 J1.1 J2.4 J4 POWER DIST BOARD FILTER SHUT OFF VALVE
TMS
1
TRST\ 1 +24V
2 1
TDI 2 5'-50'
3 2
4 3 3
4 4 +5V
5 +5V POWER IN
6 5 5
JTAG TD0 6 +15V
7 6
8 7 7 TORCH
TCK 8 -15V
9 8
10 PWR
GND
11
12
EMU0 J4 J1.4 J2.6 J6
13 D4 +5V
EMU1
14 RED/BLK
1 1
B AC LINE DETECT RED B
2 2
POWER SUPPLY 009040

RED/BLK
1 1 RED/BLK J8 EMI Filter
COOLER RED RED J2.3 J3 F1
POWER 2 2 5A
SHEET AA RED/BLK AC1
3-C1 3 3 1
WHT WHT J5 RED AC2
13 13 2
BLK BLK V1 240 VAC
8 8 3
SHEET BB COOLANT 4 4
3-D1 SOLONOID V1 14 14
9 9
5 5
17 17
18 18
19 19 J12
WHT WHT
16 16 M2 240 VAC
A BLK
12 12
BLK A
SHEET W COOLER FAN J11
7-A3 7 7
WHT 15 15 WHT J21
SHEET P PUMP MOTOR

BLK 11 11 BLK M1 240 VAC
7-A3 6 6
1X12 12X1 013374

CABLE: 123979
SHEET 19 OF 24 E
4 3 2 1
7-25
4 3 2 1
O2 Air N2 Ar H5 H35 F5
5 Micron Filter
Torch connections
V7 V15 V5
V4 V6 Shield gas
D V1 Plasma vent D
V2
V3 P1 P2 V14 Pilot arc
V8 V9 V10 MV1
Selection
MV2 Ohmic contact pin
V11 Console
Plasma gas Coolant return
V12 V13
Coolant in
P3 P4
C C
Cut Gas 1 Cut Gas 2
P5 P6
Metering
B1 B2 B3 B4 Console
V16
Vent
P7 P8
B B
Shield Plasma
Vent
HPR400 Auto
A Gas Schematic A
Torch

013374
SHEET 20 OF 24 E
4 3 2 1
7-26
4 3 2 1
Optional Multi-System Interface
D D
Unit 1 Unit 2 Unit 3 Unit 4
HPR PAC HPR PAC HPR PAC HPR PAC

Dry Cutting System Dry Cutting System Dry Cutting System Dry Cutting System
C C
141030 141030 141030 141030
CONTROL BOARD CONTROL BOARD CONTROL BOARD CONTROL BOARD
J104 J105 J104 J105 J104 J105 J104 J105
1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2
S301 J300 S301 J300 S301 J300 S301 J300

ON 4 3 2 1 4 3 2 1 ON 4 3 2 1 4 3 2 1 ON 4 3 2 1 4 3 2 1 ON 4 3 2 1 4 3 2 1
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
Serial ID Machine Motion Serial ID Machine Motion Serial ID Machine Motion Serial ID Machine Motion
Dipswitch Jumper Block Dipswitch Jumper Block Dipswitch Jumper Block Dipswitch Jumper Block
J303A J303B J303A J303B J303A J303B J303A J303B
CNC Interface Cable CNC Interface Cable CNC Interface Cable

B B
CNC Interface Cable
Dipswitch setting example: As shipped
Notes: S301
ON 8
ON 5 6 7
1) For single system installations set Serial ID (S301), and Machine Motion (J300) as shown in Unit 1, 3 4
jumpers J104 and J105 must be closed. 1 2 3 4 5 6 7 8 1 2
2) On multi-system installations refer to the illustration.
Jumpers J104 and J105 are left open on all systems except for the very last system where All switches are in the OFF position
they are in the closed position.
Termination resistors (120-ohm) or termination jumpers must be installed/set at the CNC for CNC
each of the RS-422 RX and TX signal pairs.
3) If a Hypertherm Automation Controller is being used, and there are intermittent communication Interface
failures (PS Link Failure), try removing the jumpers on J104 and J105 on the control board, and the
termination jumper (J6 or J8) on the serial isolation board in the controler. Only remove
(Customer Supplied)
A A
the termination jumper on the serial isolation board that is connected to the HPR
power supply. See sheet 19 for more details. RX TX
Termination Termination ELEC SCH:HPR400XD PWR SPLY W/AUTO
120 120 013374
SHEET 21 OF 24 E
4 3 2 1
7-27
4 3 2 1
Optional Remote On/Off
D D
Notes:
HPR PAC
1) For single system installation set Serial ID (S301), Machine
Dry Cutting System Motion (J300), J104 & J105 as shown.
Relocate the white wire on TB2 from position #3 to position

#2. Connect customer supplied Remote On/Off cable in series
with the power supply and the gas console power switch.
Connect one terminal of the Remote On/Off cable to position
#2 on TB2 and the other terminal to position #3.
Refer to page 3 of the wiring diagram
Depress the Gas Console Power switch to the closed position (on position).
C 2) For a multi-system installation set up as described above, set jumpers as shown on the C
TB2 multi-system interface page
RED/BLK RED/BLK 3) The CNC will need a dedicated I/O for each system using the Remote On/Off feature
141030 J104 J105 (contact should be rated for min. 24Vac, 0.5 Amp)
7
7
CONTROL BOARD
1 2 1 2 RED RED
21
6
6
5
5
S301 J300
4
4
ON 4 3 2 1 4 3 2 1 WHT
Gas Power Cable * If a Hypertherm Automation controller is being used, and there are intermittent communication
3
3
RED failures (PS Link Failure), try removing the jumnpers on J104 and J105 on the control board, and the
76
termination jumper (J6 or J8) on the serial isolation board in the controler. Only remove
2
2
1 2 3 4 5 6 7 8 WHT
RED the termination jumper on the serial isolation board that is connected to the HPR
Serial ID Machine Motion
1
1
1X1
Dipswitch Jumper Block power supply. See figure below for details.
J303A J303B J1
SV
RIBBON CABLE
B B
078170 BMD AMD
Gas Console
J2 J3
Remote On/Off
Customer Supplied BHST AHST
CNC Interface Cable J5 J6
BTR RS-232 RS-232 ATR

J7 J9 J10 J8
Dipswitch setting example: As shipped CNC RS-422 RS-422

S301 Interface
8
ON
ON 5 6 7 (Customer Supplied) Serial isolation board in a Hypertherm Automation controller
3 4
1 2 3 4 5 6 7 8 1 2
A A
All switches are in the OFF position

013374
SHEET 22 OF 24 E
4 3 2 1
7-28
4 3 2 1
Optional Command THC Interface
HPR PAC Torch

D D
Dry Cutting System Lifter
(Optional Unit)
Torch
141030 041842 Operator

Workpiece
CONTROL BOARD J104 J105 PLASMA INTERFACE BD Pendant
1 2 1 2 (Optional Unit)
C C
S301 J300 CNC Interface Cable Pendant Ext. Cable
ON 4 3 2 1 4 3 2 1 See Command Command
THC Manual for
THC
J2A
internal Power Lifter I/O Interface Cable
1 2 3 4 5 6 7 8 Supply wiring
Serial ID Machine Motion (Optional Unit)
Dipswitch Jumper Block Motor Drive Cable
J303B J303A J2B
CNC Interface Cable

CNC Interface Cable
Command I/O Cable-Second THC
Command I/O Cable-Third THC
Command I/O Cable-Fourth THC
B CNC Interface Cable

B
CNC
Interface
Dipswitch setting example: As shipped
(Customer Supplied)
Notes: S301
ON S301 ON 7 8
1) For a single system installation set Serial ID (S301), ON 5 6
Serial ID 3 4
Machine Motion (J300), J104 & J105 as shown above. Dipswitch 1 2 3 4 5 6 7 8 1 2
2) For a two system installation duplicate a second power supply and Command THC 1 2 3 4 5 6 7 8 for second system
as illustrated for a single system, set Serial ID as shown for the second system. All switches are in the OFF position
3) For a three system installation set up as described above, set Serial ID as shown ON
for the third system. S301
Serial ID
4) For a four system installation set up as described above, set Serial ID as shown Dipswitch
for the fourth system. 1 2 3 4 5 6 7 8 for third system
5) All machine interface cables (Pwr. supply-CNC) used for serial communication between
A Pwr. supply-CNC will have a common connection node with the CNC.
A
ON S301
6) The CNC will need a dedicated I/O port for each Command THC.
7) If a Hypertherm Automation controller is being used, and there are intermittent communication Serial ID
failures (PS Link Failure), try removing the jumpers on J104 and J105 on the control board,
1 2 3 4 5 6 7 8
Dipswitch
for fourth system ELEC SCH:HPR400XD PWR SPLY W/AUTO
and the termination jumper (J6 or J8) on the serial isolation board in the controler.
Only remove the termination jumper on the serial isolation board that is connected
to the HPR power supply. See figure on Sheet 19 for details. 013374
SHEET 23 OF 24 E
4 3 2 1
7-29
4 3 2 1
Optional ArcGlide/EdgePro Multi-System Interface
D D
Unit 1 Unit 2 Unit 3 Unit 4
HPR PAC HPR PAC HPR PAC HPR PAC

Dry Cutting System Dry Cutting System Dry Cutting System Dry Cutting System
141030 141030 141030 141030

CONTROL BOARD CONTROL BOARD CONTROL BOARD CONTROL BOARD
J104 J105 J104 J105 J104 J105 J104 J105
1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2
J300 J300 J300 J300

C 4 3 2 1 4 3 2 1 4 3 2 1 4 3 2 1 4 3 2 1 4 3 2 1 4 3 2 1 4 3 2 1 C
141131 141131 141131 141131

Machine Motion ETHERNET INTERFACE Machine Motion ETHERNET INTERFACE Machine Motion ETHERNET INTERFACE Machine Motion ETHERNET INTERFACE
Jumper Block BOARD Jumper Block BOARD Jumper Block BOARD Jumper Block BOARD
S301 S301 S301 S301
ON 0 ON 0 ON 0 ON 0
5 67
5 67
5 67
5 67
1 23
1 23
1 23
1 23
SW1 SW1 SW1 SW1
4 4 4 4
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
Serial ID UNIT ADDRESS Serial ID UNIT ADDRESS Serial ID UNIT ADDRESS Serial ID UNIT ADDRESS
Dipswitch Dipswitch Dipswitch Dipswitch
J303A J303B J5 J1 J303A J303B J5 J1 J303A J303B J5 J1 J303A J303B J5 J1
B B
CNC Interface Cable CNC Interface Cable CNC Interface Cable CNC Interface Cable
ArcGlide Ethernet Cable ArcGlide Ethernet Cable
ArcGlide Ethernet Cable ArcGlide Ethernet Cable
Notes:
Dipswitch setting example:
1) For the 141030 control board, set Serial ID (S301), and Machine Motion (J300) as shown.
Jumpers J104 and J105 should be installed. S301
All 141030 DIPSWITCH and jumper settings are the same; serial IDs are determined ON 7 8
by the 141131 board setting. ON 5 6
3 4
2) For a single system installation, set SW1 on the 141131 board as shown in Unit 1. 1 2 3 4 5 6 7 8 1 2
3) For a two system installation, set SW1 on the 141131 boards as shown in Units 1 through 2.
4) For a three system installation, set SW1 on the 141131 boards as shown in Units 1 through 3. ArcGlide THC Switch 1 is in the On position
5) For a four system installation, set SW1 on the 141131 boards as shown in Units 1 through 4. Switches 2-8 are in the Off position
and/or EdgePro Module(s)
A A

013374
SHEET 24 OF 24 E
4 3 2 1 7-30
Appendix A
Hypertherm torch coolant Safety Data
In this section:
1 – Identification of the substance/mixture and of the company undertaking............................................................................a-2
2 – Hazards identification.......................................................................................................................................................................a-2
3 – Composition/information on ingredients......................................................................................................................................a-3
4 – First aid measures.............................................................................................................................................................................a-3
5 – Fire-fighting measures......................................................................................................................................................................a-3
6 – Accidental release measures..........................................................................................................................................................a-3
7 – Handling and storage.......................................................................................................................................................................a-4
8 – Exposure controls/personal protection........................................................................................................................................a-4
9 – Physical and chemical properties..................................................................................................................................................a-4
10 – Stability and reactivity....................................................................................................................................................................a-5
11 – Toxicological information...............................................................................................................................................................a-5
13 – Disposal considerations................................................................................................................................................................a-6
14 – Transport information.....................................................................................................................................................................a-6
16 – Other information............................................................................................................................................................................a-7
Freezing Point of Propylene Glycol Solution........................................................................................................................................a-8
Hypertherm Plasma systems a-1

12/15/2010
Date SAFETY DATA SHEET Revision
6 Dec 2010 Torch Coolant 30% PG Mixture 2.01CLP
1 – Identification of the substance/mixture and of the company undertaking
Product identifier – Torch Coolant 30% PG Mixture

GHS Product Identifier – Not applicable.
Chemical Name – Not applicable.
Trade name – Torch Coolant 30% PG Mixture
CAS No. – Not applicable.
EINECS No. – Not applicable.
REACH Registration No. – Not available.
Relevant identified uses of the substance or mixture and uses advised against
Identified use(s) – Industrial use only.
Uses advised against – Not available.
Details of the supplier of the safety data sheet
Company Identification – Hypertherm
Telephone – +1 (603) 643-5638 (USA), +31 (0) 165 596 907 (Europe)
E-Mail (competent person) – technical.service@Hypertherm.com
Address – P.O. Box 5010, Hanover, NH 03755 USA (USA),
Vaartveld 9, 4704 SE Roosendaal, Nederlands (Europe)
Emergency telephone number – (800) 255-3924 (USA), +1 (813) 248-0585 (International)  
2 – Hazards identification
EC Classification NONE GHS Classification NONE

Signal word(s)
NONE NONE NONE NONE
According to Regulation (EC) No. 1272/2008 (CLP) – NONE

According to Directive 67/548/EEC & Directive 1999/45/EC – NONE
Preparation is not classified as hazardous in the sense of directive 1999/45/EC and 2006/121/EC.
Risk Phrases – NONE
Safety Phrases – NONE
Hazard statement(s) – NONE
Precautionary statement(s) – NONE
a-2 Hypertherm Plasma systems

12/15/2010
3 – Composition/information on ingredients
HAZARDOUS INGREDIENT 1 % W/W CAS No. EC No. EC Classification

Propylene Glycol 30-50 57-55-6 200-338-0 NONE
GHS Classification
Not classified NONE
HAZARDOUS INGREDIENT 2 % W/W CAS No. EC No. EC Classification
Benzotriazole <1.0 95-14-7 202-394-1 Xn, F
GHS Classification
Acute Tox. 4 (Oral, Dermal, Inhalation)
WARNING Eye Irrit. 2, Aquatic Chronic 3
H302, 312, 319, 332, 412
For full text of R phrases see section 16. For full text of H/P phrases see section 16. Non-hazardous components are not listed.
4 – First aid measures
Inhalation Unlikely to be hazardous by inhalation unless present as an aerosol.

Remove patient from exposure.
Skin Contact Wash skin with water
Eye Contact If substance has gotten into the eyes, immediately wash out with plenty of water for several
minutes
Ingestion Laxative. Do not induce vomiting. If swallowed, seek medical advice immediately and show this
container or label.
Further Medical Treatment Unlikely to be required but if necessary treat symptomatically
5 – Fire-fighting measures
Combustible but not readily ignited.

Extinguishing media Extinguish preferably with dry chemical, foam or water spray
Unsuitable Extinguishing Media None known
Fire Fighting Protective Equipment A self contained breathing apparatus and suitable protective clothing should be worn in
fire conditions
6 – Accidental release measures
Personal Precautions Put on protective clothing

Environmental Exposure Controls Absorb spillages onto sand, earth or any suitable adsorbent material
Other None

12/15/2010
7 – Handling and storage
Handling Unlikely to cause harmful effects under normal conditions of handling and use
Storage Keep container tightly closed and dry. Keep away from heat. Keep out of the reach of
children. Keep away from oxidizing agents.
Storage Temperature: Ambient
Storage Life: Stable at ambient temperatures
Specific Use: Industrial use only
8 – Exposure controls/personal protection
Respirators
Normally no personal respiratory protection is necessary. Wear suitable respiratory
protective equipment if exposure to levels above the occupational exposure limit is
likely. A suitable dust mask or dust respirator with filter type A/P may be appropriate.
Eye Protection Safety spectacles.
Gloves Wearing of chemical protective gloves is not necessary.

Body protection None.
Engineering Controls Ensure adequate ventilation to remove vapors, fumes, dust etc.
Other None.
occupational exposure limits

LTEL LTEL STEL STEL
SUBSTANCE CAS No. Note:
(8 hr TWA ppm) (8 hr TWA mg/m3) (ppm) (mg/m3)
AIHA WEEL
Propylene Glycol 57-55-6 ne 10 * ne ne
in the USA
Benzotriazole 95-14-7 ne ne ne ne None
9 – Physical and chemical properties
Information on basic physical and chemical properties

Appearance – Liquid Vapor Pressure (mm Hg) – Not available
Color - Pinkish – Reddish Vapor Density (Air=1) – Not available
Odor – Slight Density (g/ml) – 1.0 ± 0.1 g/ml
Odor Threshold (ppm) – Not available Solubility (Water) – Soluble
pH (Value) – 5.5-7.0 (Concentrated) Solubility (Other) – Not established
Melting Point (°C) / Freezing Point (°C) – < -0°C / (< 32°F) Partition Coefficient (n-Octanol/water) – Not available
Boiling point/boiling range (°C): >100°C (>212°F) Auto Ignition Temperature (°C) – Not available
Flash Point (°C) – >95°C (>203°F) Decomposition Temperature (°C) – Not available
Evaporation rate – Not available Viscosity (mPa.s) – Not available
Flammability (solid, gas) – Non-flammable Explosive properties – Not explosive
Explosive limit ranges – Not available Oxidizing properties – Not oxidizing
Other information – None

12/15/2010
10 – Stability and reactivity
Reactivity None
Chemical stability Stable under normal conditions
Possibility of hazardous reactions None
Conditions to avoid None anticipated
Incompatible materials Keep away from oxidizing agents
Hazardous Decomposition Product(s) Carbon monoxide, Carbon dioxide, Nitrogen oxides
11 – Toxicological information
11.1.1 – Substances
Acute toxicity
Ingestion Low oral toxicity, but ingestion may cause irritation of the
gastrointestinal tract
Inhalation Unlikely to be hazardous by inhalation
Skin Contact Mild irritant to rabbit skin
Eye Contact Mild irritant to the eye
Hazard label(s) None
Serious eye damage/irritation Mild irritant to the eye
Respiratory or skin sensitization Mild irritant to rabbit skin
Mutagenicity Not known
Carcinogenicity IARC, NTP, OSHA, ACGIH do not list this product or any
components thereof as known or suspected carcinogen
Reproductive toxicity Not known
STOT-single exposure Not known
STOT-repeated exposure Not known
Aspiration hazard Not known
12 – Ecological information
Toxicity Do not let this chemical/product enter the environment.

Persistence and degradability Biodegradable
Bioaccumulative potential None anticipated
Mobility in soil The product is predicted to have moderate mobility in soil
Results of PBT and vPvB assessment None assigned
Other adverse effects None anticipated

12/15/2010
13 – Disposal considerations
Waste treatment methods - Disposal should be in accordance with local, state or national legislation. No special measures are
required. No specific waste water pretreatment required.
Additional Information – None
14 – Transport information
Not classified as dangerous for transport.

Transport in bulk according to Annex II of MARPOL73/78 and the IBC Code.
15 – Ecological information
USA
TSCA (Toxic Substance Control Act) – Listed.
SARA 302 - Extremely Hazardous Substances – Not applicable.
SARA 313 - Toxic Chemicals – Not applicable.
SARA 311/312 - Hazard Categories – None.
CERCLA (Comprehensive Environmental Response Compensation and Liability Act) – Not applicable.
CWA (Clean Water Act) - CWA 307 - Priority Pollutants – None.
CAA (Clean Air Act 1990) CAA 112 - Hazardous Air Pollutants (HAP) – None.
Proposition 65 (California) – Not applicable.
State Right to Know Lists – CAS No. 95-14-7 Listed in MA, NJ, PA.
Canada
WHMIS Classification (Canada) – Not classified.
CANADA INGREDIENT DISCLOSURE LIST – Not applicable.
Canada (DSL/NDSL) – Listed.
EU
EINECS (Europe) – Listed.
Wassergefährdungsklasse (Germany) – None.

12/15/2010
16 – Other information
The following sections contain revisions or new statements: 1-16.
Legend
LTEL Long Term Exposure Limit
STEL Short Term Exposure Limit
STOT Specific Target Organ Toxicity
DNEL Derived No Effect Level
PNEL Predicted No Effect Concentration
References:
Risk Phrases and Safety Phrases
None. Preparation is not classified as hazardous in the sense of directive 1999/45/EC and 2006/121/EC.
Hazard statement(s) and Precautionary statement(s).
None. Preparation is not classified as hazardous in the sense of directive 1999/45/EC and 2006/121/EC.
Training advice – None.

Additional Information
USA - NFPA (National Fire Protection Association) - NFPA Rating: Flammability-1, Health-0,
Instability/Reactivity – 0.
Information contained in this publication or as otherwise supplied to Users is believed to be accurate and is given in
good faith, but it is for the Users to satisfy themselves of the suitability of the product for their own particular purpose.
Hypertherm gives no warranty as to the fitness of the product for any particular purpose and any implied warranty or
condition (statutory or otherwise) is excluded except to the extent that exclusion is prevented by law. Hypertherm
accepts no liability for loss or damage (other than that arising from death or personal injury caused by defective
product, if proved), resulting from reliance on this information. Freedom under Patents, Copyright and Designs cannot
be assumed.
Note: Original safety data sheet authored in English

12/15/2010
Hypertherm torch coolant Safety Data
°C °F
4 40
-1 30
-7 20
-12 10
-18 0
Temperature
-23 -10
-29 -20
-34 -30
-40 -40
-46 -50
-51 -60
-57 -70
0 10 20 30 40 50 60
% of Propylene Glycol
Freezing Point of Propylene Glycol Solution

12/15/2010
Appendix B
CNC Interface Protocol
In this section
Interface hardware......................................................................................................................................................................................b-2
Signal list......................................................................................................................................................................................................b-2
Signals................................................................................................................................................................................................b-2
Hardware............................................................................................................................................................................................b-3
Multi-drop wiring...............................................................................................................................................................................b-4
Multi-drop addressing.....................................................................................................................................................................b-5
Serial commands........................................................................................................................................................................................b-5
Format.................................................................................................................................................................................................b-5
Framing...............................................................................................................................................................................................b-5
Commands.........................................................................................................................................................................................b-5
Command table (1 of 14).........................................................................................................................................................................b-6
Error responses............................................................................................................................................................................. b-20
Calculating checksums................................................................................................................................................................ b-20
Error codes................................................................................................................................................................................................ b-21
Status codes............................................................................................................................................................................................. b-25
Gas type codes........................................................................................................................................................................................ b-25
CNC requirements.................................................................................................................................................................................. b-26
Auto gas console........................................................................................................................................................................... b-26
Serial interface guidelines...................................................................................................................................................................... b-27
Checksum....................................................................................................................................................................................... b-27
Message retries............................................................................................................................................................................. b-27
Cable shielding.............................................................................................................................................................................. b-27
HPR800XD Auto Gas – 806500 Revision 1 b-1

Appendix B – CNC Interface Protocol
Interface hardware
• The interface will use a combination of discrete signals (5 inputs, 3 outputs, and 24 VDC active low) and an
addressable RS422 interface.
• The hardware will provide 4 unique addresses, which allows 4 systems to be connected to one serial port on the
CNC. The addressing mechanism will be inside the power supply, on a PC board (Note: A total of 32 I/O
(20 Inputs, 12 Outputs) points will be required for 4 systems).
• The RS422 hardware will have tri-stateable transmitter to disconnect itself from the line when not
communicating.
• Mounting holes for footprint of CommandTHC plasma interface board.
• Must have an interface compatible with the CommandTHC/HD4070.
Signal list
Signals
Signal name Type Description

Plasma Start Input When active, the plasma system will fire an arc.
Machine Motion 1 Output Indicates the arc has transferred to the plate. This signal is selected
using jumper on power supply control board. Only 1 motion signal
is needed per system. The remaining motion signals can be used to
wire multiple systems in a daisy chain configuration.
Hold Ignition Input hen active, the system will stay in preflow and delay torch ignition.
W
The signal should be applied at the same time the start signal is
applied.
System Error Output Indicates that an error has occurred in the plasma system. Use the
serial interface to query for the specific error code number.
b-2 HPR800XD Auto Gas – 806500 Revision 1

Signal list (continued)
Signal name Type Description

Pierce Complete Input hen active, the system will use shield preflow gases during
W
piercing. When the signal is removed, the system will switch to shield
cutflow gases. The signal should be applied at the same time the
start signal is applied.
Corner Current Input When active, the system will switch to user specified corner current.
Remote Power Input Used to turn the power on or off
Not Ready for Start Output When on, this signal indicates that the plasma system is not ready for
a plasma start signal. This could be because the system is purging or
in test gas mode.
Ramp-down Error Output Indicates the arc did not ramp-down properly. Consumable life is
shortened.
TX+ Serial Transmitting from the system
Connect to CNC RX+
TX– Serial ransmitting from the system
T
Connect to CNC RX–
RX+ Serial eceiving by the system
R
Connect to CNC TX+
RX– Serial eceiving by the system
R
Connect to CNC TX–
Hardware
Inputs – active low, dry contact, opto-isolated

Inactive: 2
4 V or open circuit, 0 mA
Active: 0
V or closed contact (0 ohm min, 6.5 mA; 200K ohm max, 0.1 mA)
Outputs – active low, open collector, opto-isolated

Inactive: Up to 40 V open circuit/open collector, 0 mA
Recommended 24 V pull-up into high impedance load
Active: 0.3 V max output into high impedance load, sinking capacitor up to 5 mA
Or 2k ohm minimum load resistance
Serial – RS422 serial communications

Multi-drop wiring
Plasma start
Hold ignition
Pierce complete ––DB37

Corner current
Machine motion 1
Machine motion 2
Machine motion 3
Machine motion 4
System error
Rampdown error
RS422 serial
Remote power “ON/OFF”
HPR system 1
CNC

HPR system 2

HPR system 3
HPR system 4

Multi-drop addressing
The power supply control has DIP switches to set the power supply ID.
DIP switches 2, 3, 4 are used to set the ID.
2 3 4 ID
Off Off Off 0
On Off Off 1
Off On Off 2
On On Off 3
Off Off On Reserved
On Off On Reserved
Off On On Reserved
On On On Reserved
Systems with ID 0 power-up with the serial interface enabled. Systems with any other ID power-up with the serial
interface disabled.
To implement the multi-drop interface, the CNC must send the SLEEP command (086) which will put all systems on
the line into sleep mode. The WAKE command (085) with specific system ID will wake the system that the CNC wants
to communicate with. Any command can now be sent to that power supply, while all other systems will ignore the
communications. When the CNC is finished communicating with that power supply the SLEEP command must be sent,
then the WAKE command is used to communicate with the next system.
Serial commands
Format
ASCII-based protocol
Baud 19200
8 Data bits
1 Stop bit
No parity
No flow control
Framing
> = Start of message
3 byte command ID
Data
2 byte checksum
< = End of message
Sample: >0011C2<
Commands
Responses will echo the ID of the command, unless there is an error in the command.

Command table (1 of 14)

ID Command System Description
000 HELLO Manual gas system Establish communications with the plasma system. Use this command
Auto gas system to determine if the system is configured as an 800XD or 400XD. This
command will return “HPR800XD” in place of “HPR400XD” when the
secondary power supply is connected and the power is on.
Data:
None
Return value:
String identifying the system
Sample:
>00090<
>000HYPERFORMANCE130MANUALB5<
or
>000HYPERFORMANCE130AUTO30<
or
>000HYPERFORMANCE130AUTOMIX1E<
001 VERSION Manual gas system Get the version of the power supply firmware.
Auto gas system Data:
None
Return value:
Power supply firmware then Gas console firmware, space-delimited
Sample:
>00191<
>001A.0 A.25< (power supply rev A, gas rev A)
002 GET_STATE Manual gas system Get the current state of the plasma system.
None
Return value:
Status code (see table V)
Sample:
>00292<
>002000052< (status code 0)
003 LAST_ERROR Manual gas system Get the last error that occurred at the system.
None
Return value:
Error code (see table IV)
Sample:
>00393<
>00301165B< (error code 116)
004 REMOTE_MODE Manual gas system Switch system into remote mode, to allow remote control of the plasma
Auto gas system system.
Data:
None
Return value:
1 = accepted, 0 = not accepted
Sample:
>00494<
>0041C5<


028 READ_PLASMA_AMPS Manual gas system Read actual power supply current.
None
Return value:
Power supply current in amps
Sample:
>0289A<
>02801305E< (130 amps)
058 SET_NOMINAL_AMPS Auto gas system Set the power supply current in amps.
Data:
5-260 Amps (Limited to 130 amps on the HPR130)
Return value:
Actual current value set
Sample:
>05813031<
>058013061< (set 130 amps)
064 GAS_PREFLOW_TEST_START Manual gas system Turn on the preflow gases. Not allowed when cutting.
None
Return value:
Sample:
>0649A<
>0641CB<
065 GAS_PREFLOW_TEST_STOP Manual gas system Turn off the preflow gases. Not allowed when cutting.
None
Return value:
Sample:
>0659B<
>0651CC<
066 GAS_CUTFLOW_TEST_START Manual gas system Turn on the cutflow gases. Not allowed when cutting.
None
Return value:
Sample:
>0669C<
>0661CD<
067 GAS_CUTFLOW_TEST_STOP Manual gas system Turn off the cutflow gases. Not allowed when cutting.
None
Return value:
Sample:
>0679D<
>0671CE<)


068 SYSTEM_RESET Manual gas system Clear error conditions and resume operation. Only accepted
Auto gas system if system is in a shutdown error condition (Error code > 79
and State = 14).
Data:
None
Return value:
Sample:
>0689E<
>0681CF<
070 SET_CORNER_CURRENT Manual gas system When CORNER CURRENT input is activated the power
Auto gas system supply will switch to the current percentage specified.
Data:
% of cutting current (50-100%)
50=50%
Return value:
% achieved
Sample:
>0707503<
>070007563< (set 75%)<
071 MANUAL_PUMP_CONTROL Manual gas system Used to override software control of the coolant pump. If the
Auto gas system system has a fatal error, the pump cannot be overridden.
Data:
1 = override software to force pump on, 0 = system software
controls the pump, override off
Return value:
Sample:
>0711C9<
>0711C9<
072 GET_CONTROL_VOLTAGE Manual gas system Returns the internal control voltage of the power supply
None
Return value:
Voltage (1/10 V)
1200 = 120.0 V
Sample:
>07299<
>07212005C< (120.0 volts)


074 GET_IO_STATUS Manual gas system Read the status of the I/O ports of the DSP. Refer to I/O
Auto gas system listing for description of each bit in Ports A-F.
Data:
None
Return value:
PA00000000 PB00000000 PC00000000 PD00000000
PE00000000 PF00000000
Ports A-F are returned space-delimited. The numbers are the
decimal representation of the binary value of the port. 1 = on,
0 = off.
Sample:
>0749B<
>074PA00000100 PB00000000 PC00010101
PD00100000 PE00010000 PF10000000B7<
078 SET_ALL_GAS_FLOWS Auto gas system Set all gas flow rates.
N2 mix setpoint and Gas 2 mix setpoint are only applicable
when using a mixed plasma gas such as H35 – N2.
Otherwise, these 2 values should be set to 0.
A value of 0 for N2 mix setpoint will cause the system to close
SV12, the solenoid valve for N2 mixing. A value of 0 for Gas 2
Mix Setpoint will cause the system to close SV13 and open
SV14. This will cause the inlet gas to bypass motor valve 2
and pass directly to the outlet of the mixing console.
Data:
Space-delimited:
Plasma cutflow (0 –99 psi),
Plasma preflow (0 – 99 psi),
Shield cutflow (0 – 99 psi),
Shield preflow (0 – 99 psi),
N2 mix setpoint (0 – 100 psi),
Gas2 mix setpoint (0 – 100 psi).
Return value:
Sample:
>07855 45 35 25 50 50AB<
>0781D0<


079 GET_PS_INFO Manual gas system Returns pressures, system state, and system error,
Auto gas system space‑delimited
Data:
None
Return value:
Plasma cutflow pressure (0044 = 44 psi)
Plasma preflow pressure (0044 = 44 psi)
Shield cutflow pressure (0044 = 44 psi)
Shield preflow pressure (0044 = 44 psi)
Current setpoint (amps)
System state (see table V) (0003 = state 3)
System error (see table IV) (0000 = error 0)
Cut gas 1 pressure (0044 = 44 psi)
Cut gas 2 pressure (0044 = 44 psi)
N2 Mix inlet pressure (0044 = 44 psi)
Gas2 Mix inlet pressure (0044 = 44 psi)
Note: Cut gas 1, Cut gas 2, N2 mix inlet, and Gas 2 mix inlet are
not measured in the manual gas console configuration.
Sample:
>079A0<
>079PC0044 PP0042 SC0034 SP0035 CS0040 ST0003
ER0000 CG0000 CG0000 MV0000 MV0000DE<
084 DOWNLOAD_SOFTWARE TBD Download new firmware to the plasma system.
Data:
Not currently implemented on the TBD
HD4070 or the HPR systems
Return value:
1 = packet accepted, 0 = not accepted
Sample:
TBD
085 WAKE Manual gas system This command is used to wake a system and enable its
Auto gas system transmitter to communicate on a multi drop line.
Data:
System ID, which is set by dipswitches on PC board.
Return value:
Echo of the command
Sample:
>0850CD<
>0850CD<
086 SLEEP Manual gas system Tell all systems on the line to disconnect their transmitters
None
Return value:
None
Sample:
>0869E<
No response


087 BROADCAST MODE Manual gas system Tell all systems to listen but not respond.
None
Return value:
None
Sample:
>0879F<
no response
094 READ_GAS_PRESSURES Manual gas system Read the gas pressures.
None
Return value:
Plasma cutflow pressure (psi),
Plasma preflow pressure (psi),
Shield cutflow pressure (psi),
Shield preflow pressure (psi),
Cut gas 1 pressure (psi),
Cut gas 2 pressure (psi),
N2 Mix inlet pressure (psi),
Gas2 Mix inlet pressure (psi)
space-delimited
Values are in psi (0007 = 7 psi)
Sample:
>0949D<
>094PC0007 PP0036 SC0016 SP0003 CG0000
CG0000 MV0000 MV00005D<
095 SET_ALL_PARAMETERS Auto gas system Set all variables to run the plasma system. If inlet gases
change power supply will enter the purge state. Gas
type changes are not allowed when the system is
cutting (state 4 – state 10).
N2 mix setpoint and Gas 2 mix setpoint are only applicable
when using a mixed plasma gas such as H35 – N2 otherwise
these 2 values should be set to 0.
A value of 0 for N2 Mix setpoint will cause the system to close
SV12, the solenoid valve for N2 mixing. A value of 0 for Gas 2
Mix Setpoint will cause the system to close SV13 and open
SV14. This will cause the inlet gas to bypass motor valve 2
and pass directly to the outlet of the mixing console.
Data:
Current setpoint (5 – 130/260/400 amps),
Corner current percent (50 - 100%),
Plasma gas type code (use table VI),
Shield gas type code (use table VI),
Plasma cutflow setpoint (0 – 99 psi),
Plasma preflow setpoint (0 – 99 psi),
Shield cutflow setpoint ( 0 – 99 psi),
Shield preflow setpoint (0 – 99 psi),
N2 mix setpoint (0 – 100 psi),
Gas 2 mix setpoint (0 – 100 psi),
space-delimited.
Return value:
1= accepted, 0 = not accepted
Sample:
>095100 75 1 6 55 45 35 25 00 0084<
>0951CF<


096 SET_INLET_GASES Auto gas system Set inlet gases for auto console. If inlet gases change, the
power supply will enter the purge state. Gas type changes
are not allowed when the system is cutting (state 4 – state
10).
Data:
Plasma gas type code (See table VI),
Shield gas type code (See table VI),
space-delimited.
Return value:
1= accepted, 0 = not accepted
Sample:
>0961 626< (Set plasma gas = O2 and set shield gas = N2)
>0961D0<
097 READ_CORNER_CURRENT Manual gas system Read the corner-current percentage
None
Return value:
Percentage
Sample:
>097A0<
>09700756C< (75%)
098 GET_INLET_GASES Manual gas system Read the inlet gas types
None
Return value:
space-delimited
Sample:
>098A1<
>0980001 000648< (Plasma gas = O2 and shield gas = N2)
099 GET_GAS_FLOWS Auto gas system Read the gas setpoints
Data:
None
Return value:
Plasma cutflow setpoint (psi),
Plasma preflow setpoint (psi),
Shield cutflow setpoint (psi),
Shield preflow setpoint (psi),
N2 Mix setpoint (psi),
Gas 2 mix setpoint (psi)
space-delimited.
(55 = 55 psi)
Sample:
>099A2<
>0990055 0045 0035 0025 0050 0050EE<


100 GET_CONTROL_DATA Manual gas system Read internal control data:
Auto gas system Chopper A used in HPR130/HPR260
Chopper B used in HPR260
Return string is the same whether the system is an HPR130 or
HPR260. Chopper B data can be ignored for HPR130.
Chopper A temp (raw A/D, 0 - 1023),
Chopper B temp (raw A/D, 0 - 1023),
Line voltage (1/10 volts, 0 - 2400), 240.0 vac
Coolant flow (1/100 gpm, 0 - 440), 4.40 gpm
Coolant temp (raw A/D, 0 - 1023),
Transformer temp (raw A/D, 0 - 1023),
Chopper A current (0 – 130 amps),
Chopper B current (0 – 130 amps),
Work lead current (0 – 130/260 amps),
Chopper A setpoint (5 – 130 amps),
Chopper B setpoint (5 – 130 amps),
PWM chopper A (100% = 1070),
PWM chopper B (100% = 1070).
Data:
None
Return value:
Above info is space-delimited.
Sample:
>10091<
>100CAT0482 CBT0021 LVO0118 CFL0009 CTP0481
TTP0481 CAC0001 CBC0014 WLC0005 CAS0000 CBS0534
PWMA0000 PWMB00000B<
101 SET_IO_STATUS Manual gas system This command will allow the user to turn on or off each output of
Auto gas system the processor. After sending this command, the SYSTEM_RESET
command must be issued to restore the processor state. The I/O
are in the following order:
Data:
1 = On, 0 = Off for each I/O point
Return value:
Power Supply
Pilot arc Relay
Marking surge relay
Pilot arc enable
Coolant pump motor
Soft-start enable
CNC error
CNC ramp-down error
Igniter
Contactor
CNC machine motion
CNC spare output
Spare output
Sample:
>101111111111111DD< = All outputs on
>1011C3<


102 SET_GAS_IO_FROM_PS Manual gas system This command will allow the user to turn on or off each output
Auto gas system of the processor. After sending this command, the SYSTEM_
RESET command must be issued to restore the processor state.
The I/O are in the following order:
Data:
1 = On, 0 = Off for each I/O point
Return value:
Manual Gas Console
Shield cutflow (SV16)
Calibrate bypass (SV13)
Plasma cutflow 1 (SV14)
Ramp-down valve (SV20)
Shield preflow (SV17)
Plasma preflow (SV18)
Plasma cutflow 2 (SV19)
H35 plasma cutflow 2 (SV12)
Spare valve (SV15)
O2 shield cutflow (SV4)
Air shield cutflow (SV5)
N2 shield cutflow (SV6)
Air preflow (SV7)
N2 preflow (SV8)
Air plasma cutflow 2 (SV9)
Air plasma cutflow 1 (SV1)
O2 plasma cutflow 1 (SV2)
H35 plasma cutflow 1 (SV3)
O2 plasma cutflow 2 (SV10)
N2 plasma cutflow (SV11)
Auto Gas Console
O2 inlet (SV1)
Air inlet (SV2)
Air inlet 2 (SV3)
H5 inlet (SV4)
H35 inlet (SV5)
F5 inlet (SV6)
Spare out 1 (Spare)
Ramp-down valve (SV16)
Spare out 2 (Spare)
Gas 2 no mix (SV14)
Gas 2 mix (SV13)
N2 mix (SV12)
N2 inlet 2 (SV11)
Air inlet 3 (SV10)
N2 inlet (SV9)
O2 air inlet (SV8)
CH4 inlet (SV7)
Sample:
>1021111111111111111111167<
>1021C4<


114 READ_INPUTS Manual gas system This command will return the status of inputs to the PC board.
None
Return value:
1 = on, 0 = off
Power Supply
Serial program
Plasma start
Hold ignition
Phase OK
Arc detect
Pierce complete
Corner current
Redundant start
Serial ID0
Serial ID1
Serial ID2
Dipswitch #1
Dipswitch #5
Dipswitch #6
Dipswitch #7
Dipswitch #8
Chopper A overcurrent
Chopper B overcurrent
Sample:
>11496<
>114000000000000000000F6<
117 READ_GAS_INPUTS_FROM_PS Manual gas system This command will allow the CNC to query the gas console I/O
Auto gas system by sending the command to the serial port on the power supply
control board.
Data:
None
Return value:
1 = on, 0 = off
Manual Gas Console
Error select
Status select
Test preflow
Test cutflow
Serial ID bit 0
Serial ID bit 1
Serial ID bit 2
Auto Gas Console
Metering dipswitch 2
Select dipswitch 1
Select dipswitch 2
Select dipswitch 3
Select dipswitch 4
Sample:
>11799<
>1170000000E9<


121 LEAK_CHECK_MODE Manual gas system This command will put the system into leak mode. There are
Auto gas system 3 modes, mode #1 is the inlet leak check mode. This is used to
see if the inlet solenoids are allowing gas to pass through the valve
even when they are closed.
Mode #2 is the system leak check mode which will test for leaks
to atmosphere within the system. Mode #3 is the Burkert valve
flow test. For automatic gas consoles only.
For the inlet leak test, the system should have 0 psi on all gas
channels, and hold at this pressure.
For the system leak test, the system should charge all gas lines,
then hold the pressure.
The Burkert flow test checks for an expected PWM value for a set
pressure and does a gas ramp-down test.
NOTE: This test is preformed using 130 amp O2 / Air
consumables and setting the 30 amp O2 / O2 process
Each test takes about 40 seconds to complete.
This command will only be accepted when the power supply is in
the state IDLE2 (03).
After leak checking is complete the system must be set to mode 0.
An error code will reflect the state of the test. Using the GET_
LAST_ERROR command, you can get the result of the test.
12 = Test in progress
13 = Test passed
14 = Cut gas channel #1 failed
15 = Cut gas channel #2 failed
16 = Plasma ramp-down test failed (Burkert test only)
17 = Shield ramp-down test failed (Burkert test only)
Data:
Mode 0 = run
1 = Inlet leak check
2 = System leak check
3 = Burkert flow check
Return value:
Time for the test to run in seconds, 0 = not accepted
Sample:
>1211C5<
>12140F8< “40 second test”


122 READ_GAS_SWITCH Manual gas system This command will return data that shows the actual position of
the rotary switches used to set the inlet gas type.
The difference between this command and 098 is that this
command returns the values set by the position of the switch.
The 098 command returns values that the software decides are
acceptable gas combinations. For example, H35 plasma and O2
shield is not acceptable and is overridden by the software to be
H35 plasma and N2 shield regardless of the position of the shield
gas knob. In this case, the 098 command would return H35 N2.
This command will return H35 O2.
Data:
None
Return value:
space-delimited
Sample:
>12295<
>1220001 00063C<
124 INDEX_MOTORVALVES Auto gas system Move the motor valve by a fixed number of ADC counts
Data:
Motor Valve number (1 or 2)
Open/Clos (0 = Close, 1 = Open)
Multiplier (move by x10 counts, 3 = move 30 counts)
Return value:
1 = accepted
Sample:
Open Motor valve 1 by 30 counts
>1241 1 36C<
>1241C8<
125 GET_TIMER_COUNTER Manual gas system Read Timer/Counter data from the power supply
None
Return value:
Arc-on time (seconds)
System on time (minutes)
Total starts (# of arc transfers)
Total starting errors (failed to transfer)
Total ramp-down errors (failed to ramp-down current)
Write counter (# of writes to the present memory block – for
diagnostics only)
Memory block (current memory location for timer counter data –
for diagnostics only)
All fields are a fixed width of 7 numbers followed by a space.
Sample:
>12598<
>1250000000 0000000 0000000 0000000 0000000 0000000
0000000 58<


126 GET_INFO2 Auto gas control See 079
board only
127 GET_INFO3 Auto gas control See 079

board only
131 CLEAR WARNINGS Manual gas system This command will clear error codes less than #43.
Auto gas system Sample:
>13195<
>1311C6<
132 READ COOLANT PRESSURE HPR260 ONLY This command returns the raw A/D value for coolant pressure.
83 counts = 225 psi
73 counts = 200 psi
Sample:
>13296<
>13280FE<
133 GET CONTROL DATA3 HPR400XD ONLY This command provides data for the 3rd and 4th choppers used in
the HPR400 system.
Chopper C temp (raw A/D)
Chopper D temp (raw A/D)
Chopper C current (amps)
Chopper D current (amps)
Data:
None
Return value:
Above info space-delimited.
Sample:
>13397<
>133CCT0482 CDT0021 CCC0000 CDC000050<
134 READ ERROR LOG ALL HPR SYSTEMS This command will return the last 4 error codes the system
encountered. The log will only record errors (error code values
greater than 0). It ignores error code 0, which indicates no error
or that an error has been cleared.
The error codes are listed space-delimited, most recent error first.
Data:
None
Return value:
Error – most recent (see table IV Error Codes)
Error #2
Error #3
Error – oldest error
Sample:
>13498<
>134020 020 024 0534A<

136 SERIAL_RESPONSE_DELAY All HPR systems Used when a CNC serial port can only support a half-duplex
connection. The HPR power supply will reduce its response
speed.
Data:
None
Return value:
1 if successful
Sample:
Send >1369A<, response >1361CB<
158 GET_SECONDARY_VERSION HPR800XD ONLY Get the software version of the secondary power supply
Data:
None
Return value:
The Secondary Power Supply software version
ex.”D.0”. “0.0” is returned if no secondary power supply is

connected and the power is on.
sample:
>1589E<
>158D.040<

Error responses
If there is a problem with the serial command, the module will return an error.
Bad checksum
Return ID: 500
Description: T
he serial command received does not have the correct checksum.
Sample: >00091< – checksum should be 90, not 91
>50095< – bad checksum
Bad command
Return ID: 501
Description: If the module does not recognize the command ID, it will return ID 501.
Sample >999AB< – unknown ID
>50196< – bad command
Calculating checksums
Checksum is calculated on the command ID and command data only.
HELLO Command: >00090<

0 = 0x30 (ASCII value for number 0)
0 = 0x30
0 = 0x30
—————
Checksum = 0x30 + 0x30 + 0x30 = 90
READ INPUTS power supply response: >107000058<

1 = 0x31
0 = 0x30
7 = 0x37
0 = 0x30
0 = 0x30
0 = 0x30
0 = 0x30
—————
Checksum = 0x31 + 0x30 + 0x37 + 0x30 + 0x30 + 0x30 + 0x30 = 0x158
We only use the 2 least significant digits so the checksum = 58

Error codes
ID Name Description
000 NO ERROR System is ready to run.
When the pump is restarted after a pump timeout (30 minutes
009 FLOW SWITCH TEST without a start signal) the system will test the flow switch to make
sure there is sufficient flow before firing the torch.
011 NO_ACTIVE_PROCESS The power supply receives an invalid current setting from a CNC.
012 TEST IN PROGRESS One of the gas test modes is running.
013 TEST PASSED The test completed successfully.
014 CUT GAS CHANNEL #1 FAIL The gas pressure is dropping on channel #1, indicating a leak.
015 CUT GAS CHANNEL #2 FAIL The gas pressure is dropping on channel #2, indicating a leak.
016 PLASMA RAMP-DOWN FAIL Pump output has exceeded 200 psi.
017 SHIELD RAMP-DOWN FAIL Shield pressure did not decrease in the allotted time.
018 PUMP OVER PRESSURE Pump output has exceeded 13.79 bar (200 psi.)
No current detected from chopper at ignition and before
020 NO PILOT ARC
1-second timeout.
021 NO ARC TRANSFER No transfer signal detected before 500-msec timeout.
024 Primary
LOST CURRENT CH1 After transfer, lost the chopper current signal.
224 Secondary
025 Primary
225 Secondary
026 Primary
LOST TRANSFER After transfer, lost the transfer signal.
226 Secondary
027 Primary
LOST PHASE When main contactor is engaged, no “phase OK” input.
227 Secondary
028 Primary
228 Secondary
030 GAS SYSTEM ERROR A failure has occurred in the gas system.
031 Primary
START LOST Start signal was removed before steady-state operation.
231 Secondary
032 HOLD TIMEOUT Hold signal was applied for longer than 60 seconds.
Gas console was not able to charge the gas lines to the correct
033 PRE CHARGE TIMEOUT
pressure.
034 Primary Gas console was not able to charge the gas lines to the correct
PRE CHARGE TIMEOUT
234 Secondary pressure.
Nitrogen gas pressure under lower limit of 2.07 bar (30 psi) –
042 LOW NITROGEN PRESSURE
cutting, 0.34 bar (5 psi) – marking
Gas pressure under lower limit of 0.34 bar (5 psi) – pre-flow
044 LOW PLASMA GAS PRESSURE 3.45 bar (50 psi) – cutflow (cutting) 0.34 bar (5 psi) – cutflow
(marking).
045 HIGH PLASMA GAS PRESSURE Gas pressure over upper limit of 7.58 bar (110 psi).
046 LOW LINE VOLTAGE Line voltage is under lower limit of 102 VAC (120 VAC -15%).
047 HIGH LINE VOLTAGE Line voltage is over upper limit of 138 VAC (120 VAC +15%).
048 Primary
CAN ERROR An error occurred with the CAN communication system.
248 Secondary
050 Primary
START ON AT INIT Start signal input is active during power-up.
250 Secondary
053 LOW SHIELD GAS PRESSURE Gas pressure is under lower limit of 0.14 bar (2 psi).

ID Name Description
054 HIGH SHIELD GAS PRESSURE Gas pressure is over upper limit of 7.58 bar (110 psi).
Motor valve 1 inlet pressure is less than 3.45 bar (50 psi) or
055 MV 1 INLET PRESSURE
greater than 9.65 bar (140 psi).
Motor valve 2 inlet pressure is less than 3.45 bar (50 psi) or
056 MV 2 INLET PRESSURE
greater than 9.65 bar (140 psi).
In the selection console, cut gas 1 outlet pressure is less than
057 CUT GAS 1 PRESSURE
3.45 bar (50 psi) or greater than 9.65 bar (140 psi).
In the selection console, if cut gas 2 outlet pressure is less than
3.45 bar (50 psi) for non-mixing, or less than 1.38 bar (20 psi)
058 CUT GAS 2 PRESSURE
when mixing or greater than 9.65 bar (140 psi) for non-mixing
and mixing.
060 LOW COOLANT FLOW Coolant flow is less than the required 2.3 lpm (0.6 gpm).
061 NO PLASMA GAS TYPE Plasma gas has not been selected.
062 NO SHIELD GAS TYPE Shield gas has not been selected, or system is in test mode.
065 Primary
CHOPPER1 OVERTEMP Chopper #1 overheated.
265 Secondary
066 Primary
CHOPPER2 OVERTEMP Chopper #2 overheated.
266 Secondary
067 Primary
MAGNETICS OVERTEMP Transformer has overheated.
267 Secondary
071 COOLANT OVERTEMP Torch coolant has overheated.
AUTOMATIC GAS CONTROL
072 Control board has exceeded 90° C (194° F).
BOARD OVERTEMP
073 Primary
CHOPPER3 OVERTEMP Chopper #3 overheated
273 Secondary
074 Primary
CHOPPER4 OVERTEMP Chopper #4 overheated
274 Secondary
075 Primary CURRENT TOO LOW ON LEM A current less than 10 amps has been detected by current
275 Secondary #3 sensor 3.
093 NO COOLANT FLOW Coolant flow is less than 0.6 gpm.
CURRENT TOO HIGH ON LEM
095 Current has exceeded 35 amps during the chopper test
#4
099 Primary
CHOPPER1 OVERTEMP AT INIT Chopper #1 is indicating overtemp during power-up.
299 Secondary
100 Primary
CHOPPER2 OVERTEMP AT INIT Chopper #2 is indicating overtemp during power-up.
300 Secondary
101 Primary MAGNETICS OVERTEMP AT
Transformer is indicating overtemp during power-up.
301 Secondary INIT
102 Primary
OUTPUT CURRENT AT INIT Chopper current signal is active on power-up.
302 Secondary
103 Primary CURRENT TOO HIGH ON LEM A current greater than 35 amps has been detected by current

ID Name Description
106 Primary CURRENT TOO LOW ON LEM A current less than 10 amps has been detected by current sensor
306 Secondary #2 2.
108 Primary The system has detected current on the work lead during
TRANSFER AT INIT
308 Secondary power-up.
Coolant flow is greater than 1.14 lpm (0.3 gpm) when pump is
109 COOLANT FLOW AT INIT
off.
111 COOLANT OVERTEMP AT INIT Coolant is indicating overtemp during power-up.
116 Primary
WATCHDOG INTERLOCK CAN communication error.
316 Secondary
123 MV 1 ERROR Motor valve 1 did not move into position within 60 seconds.
124 MV 2 ERROR Motor valve 2 did not move into position within 60 seconds.
The power supply control board does not recognize the gas
UNKNOWN GAS CONSOLE
133 console installed or has not received a CAN message identifying
TYPE
the type of console installed.
134 Primary
CHOPPER 1 OVERCURRENT Chopper 1 current feedback has exceeded 160 amps.
334 Secondary
138 Primary
CHOPPER 2 OVERCURRENT Chopper 2 current feedback has exceeded 160 amps.
338 Secondary
139 PURGE TIMEOUT ERROR The purge cycle did not complete within 3 minutes.
AUTO GAS PRESSURE
140 Faulty transducer or auto gas control PCB
TRANSDUCER #1 ERROR
AUTO GAS PRESSURE
TRANSDUCER #2 ERROR
AUTO GAS PRESSURE
TRANSDUCER #3 ERROR
AUTO GAS PRESSURE
TRANSDUCER #4 ERROR
MANUAL GAS CONSOLE
144 INTERNAL FLASH MEMORY Replace manual gas console control PCB
ERROR
AUTOMATIC GAS CONSOLE
145 INTERNAL FLASH MEMORY Replace auto gas console control PCB
ERROR
146 Primary CHOPPER #3 OVERTEMP AT
Chopper #3 is indicating over temp during power-up
346 Secondary INIT
147 Primary CHOPPER #4 OVERTEMP AT
Chopper #4 is indicating over temp during power-up
347 Secondary INIT
151 Primary
SOFTWARE FAIL Software has detected an incorrect state or condition.
351 Secondary
152 INTERNAL FLASH ERROR DSP memory is not working properly.
153 PS EEPROM ERROR EEPROM memory on power supply board not working.
154 Primary
CHOPPER 3 OVER CURRENT Chopper 3 current feedback has exceeded 160 amps
354 Secondary
155 Primary
CHOPPER 4 OVER CURRENT Chopper 4 current feedback has exceeded 160 amps
355 Secondary

ID Name Description
156 Primary
CHOPPER 2 CURRENT AT INIT Chopper 2 current signal is active on power-up
356 Secondary
157 Primary
357 Secondary
158 Primary
358 Secondary
Motor drive board power module is indicating an alarm – this
159 Primary
MOTOR DRIVE FAULT can be comparable to “blowing a fuse” – does not necessarily
359 Secondary
indicate a problem with the board.
Communications between the control board and the pump/motor
160 HPR COOLER CAN FAULT
drive board was interrupted for greater than 1 second.
MAXIMUM COOLANT FLOW Communications between the control board and the pump/motor
161
EXCEEDED drive board was interrupted for greater than 1 second.
SELECTION CONSOLE CAN Power supply has not received a CAN message from the
180
TIMEOUT selection console within 1 second
METERING CONSOLE CAN Power supply has not received a CAN message from the
181
TIMEOUT metering console within 1 second
SECONDARY POWER SUPPLY The secondary power supply fails before transmitting the error to
182
TIMEOUT the primary power supply.
The secondary power supply is ready to provide current output
SECONDARY POWER SUPPLY
383 but does not receive the control signal from the primary power
TIMEOUT
supply.

Status codes
ID Name
00 IDLE
02 PURGE
03 IDLE2
04 PREFLOW
05 PILOT ARC
06 TRANSFER
07 RAMP-UP
08 STEADY STATE
09 RAMP-DOWN
10 FINAL RAMP-DOWN
11 AUTO OFF
12 TEST CUTFLOW
14 SHUTDOWN
15 RESET
16 MAINTENANCE
20 TEST PREFLOW
22 MANUAL PUMP CONTROL
23 INLET LEAK CHECK
24 SYSTEM LEAK CHECK
25 Burkert flow check
Gas type codes
ID Gas type
0 No gas
1 Oxygen
2 Methane (CH4) not supported
3 H35 (argon – hydrogen)
4 H5 (not supported)
5 Air
6 Nitrogen
7 Argon
8 F5 (N95)

CNC requirements
Auto gas console
Below is a list of functionality that CNCs must offer for the automatic gas console version of the HPR system. In this
system configuration there is no local control of the plasma system. All settings and diagnostic information will be under
CNC control.
1. Display and adjust the current setpoint – cutting current, see command ID No. 95
2. Display and adjust the plasma preflow setpoint – pressure setting, see command ID No. 95
3. Display and adjust the plasma cutflow setpoint – pressure setting, see command ID No. 95
4. Display and adjust the shield preflow setpoint – pressure setting, see command ID No. 95
5. Display and adjust the shield cutflow setpoint – pressure setting, see command ID No. 95
6. Display and adjust the plasma gas type – inlet gas selection, see command ID No. 95
7. Display and adjust the shield gas type – inlet gas selection, see command ID No. 95
8. Display and adjust the gas mixing setpoint – pressure setpoint, see command ID No. 95
9. Display the system error code – error code numbers, see command ID No. 3
10. Display the system status code – status code numbers, see command ID No. 2
11. Manual pump control – manually turn on/off the pump, see command ID No. 71
12. Display the firmware version – version of power supply and gas console firmware, see command ID No. 1
13. Test preflow gases – put the system in test gas mode, see command ID No. 64, 65
14. Test cutflow gases – put the system in test gas mode, see command ID No. 66, 67
15. Power on/off – turn on/off the plasma system, not a serial command (active low, dry contact, opto-isolated)
16. Display line voltage – see command ID No. 100
17. Display chopper current(s) – see command ID No. 100
18. Display work lead current – see command ID No. 100
19. Display chopper temperature(s) – see command ID No. 100
20. Display transformer temperature – see command ID No. 100
21. Display gas pressures – see command ID No. 79
22. Display coolant flow rate – see command ID No. 100

Serial interface guidelines

Checksum
The protocol used for the serial interface between the Hypertherm system and the CNC contains a checksum on the
message being sent. The checksum should be validated for each message to ensure the information is not corrupted.
Message retries
We recommend retrying a message if the original message was not acknowledged by the system. This is especially
important when the high-frequency ignition is active. The high-frequency ignition can be active for up to 1 second and
can corrupt serial communications. It is important to space the retries so that the system can handle an interruption in
serial communications for up to 1 second.
Another alternative to handling the high frequency ignition is to poll for the power supply state, using the GET_STATE
command. If the state is (5 – Pilot arc) then stop serial communications until the state is no longer (5 – Pilot arc).
Cable shielding
We have chosen to use metal shell DB style machine/serial interface cables on some on the newer systems. One of the
reasons this type of cable was selected is for their EMI shielding capabilities. It is important that integrity of the shielding
of this cable be maintained. The shielding provides protection from the high-frequency ignition system, if the cable
shields are not properly terminated then the protection is not as effective. This is best achieved by ensuring the shield
has a 360° termination provided on both end of the cables. Using a drain wire will not achieve the proper shielding.
The cable should also be as short as possible with no coils.


Appendix C
robotic applications
In this section:
Components for robotic applications.....................................................................................................................................................c-2
Torch leads........................................................................................................................................................................................c-2
Ohmic contact extension................................................................................................................................................................c-2
Rotational mounting sleeve (optional) – 220864...................................................................................................................c-3
Leather overwrap – 024866........................................................................................................................................................c-3
Robotic teaching torch (laser pointer) – 228394..................................................................................................................c-3
Torch and rotational mounting sleeve dimensions...................................................................................................................c-3
HPR400XD Auto Gas – 806160 Revision 3 c-1

Appendix C – robotic applications
Components for robotic applications

Torch leads
The torch leads listed below have been designed to withstand the added stresses found in robotic, or bevel,
applications. They are available with 2 m (6 ft), or 2.5 m (8 ft) gas leads.
Note: Consumable life will be reduced if the 2.5 m (8 ft) gas leads are used.
Overall length 1.8 M (6 feet) gas lead 2.4 M (8 feet) gas lead
2 m (6 ft) 228514 228516
2.5 m (8 ft) 228515 228517
3 m (10 ft) 228475 228482
3.5 m (12 ft) 228476 228483
4.5 m (15 ft) 228477 228484
6 m (20 ft) 228478 228485
7.5 m (25 ft) 228479 228486
10 m (35 ft) 228480 228487
15 m (50 ft) 228481 228488
Ohmic contact extension

A 2.5 m (8 ft) Ohmic contact wire is part of the lead set. Extensions can be found in the table below.
Part number Length Part number Length

223059 1.5 m (5 ft) 223064 12 m (40 ft)
223060 3 m (10 ft) 223065 15 m (50 ft)
223061 4.5 m (15 ft) 223066 22.5 m (75 ft)
223062 6 m (20 ft) 223067 30 m (100 ft)
223063 9 m (30 ft) 223068 45 m (150 ft)
c-2 HPR400XD Auto Gas – 806160 Revision 3

Rotational mounting sleeve (optional) – 220864

The rotational sleeve is designed for use in applications where the torch
leads are twisted repeatedly. It is an optional component, and does not
need to be used to use the torch leads listed above. The length of the
rotational sleeve is 114.3 mm (4.5 in).
Rotational mounting sleeve clamp – 220900

The rotational sleeve has a larger diameter than standard sleeves (57 mm/2.25 in).
Leather overwrap – 024866

The leather overwrap is 3 m (10 ft) long, and is designed to be installed
over the leads from where they attach to the torch. This adds protection in
applications where molten metal will splash back on the leads.
Robotic teaching torch (laser pointer) – 228394

• Mount the laser pointer in the torch sleeve to provide accurate positioning
and alignment of the torch.
• Use for online programming/teaching and robotic alignment systems.
Torch and rotational mounting sleeve dimensions

84.84 mm
(3.34")
152.65 mm
65.79 mm 37.08 mm (6.01")
(2.59") (1.46") 46.74 mm
33.02 mm (1.84")
(1.30")
50.80 mm
(2.00")
2X 56.01 mm 10.16 mm
(2.205") 50.67 mm (0.40")
(1.995") 56.64 mm
(2.23") 47°
3X 57.02 mm
(2.245")
2 X 12.95 mm
(0.51")
HPR400XD Auto Gas – 806160 Revision 3 c-3

c-4 HPR400XD Auto Gas – 806160 Revision 3

HPR400XD auto gas instruction manual revision changes (806160)
Changed
Description of changes for revision 3 (date of revision - 9/2011)
Page
Global Inch marks (“) have been replaced by the abbreviation (in).
Updated the format and information for both the Electromagnetic compatibility and Warranty sections.
EMC-1 through Added Certification test marks, Differences in national standards, Higher-level systems, laser and
W-2 Automation products, and Proper disposal of Hypertherm products information to the
Warranty section.
Updated the format and content of the safety information. Added Dry dust collection and Laser
Safety sections
radiation information.
Removed the note under the gas quality and pressure requirements table that said “Oxygen, nitrogen,
2-4 and air are required for all systems. Nitrogen is used as a purge gas.” The statement was inaccurate.
Corrected the kPa pressure values from 827 kPa to 793 kPa.
2-5 Added power supply part numbers with Hypernet. Changed kW to kVA in the last column, “power”.
2-11 Corrected the second bullet point to say “minimum” bend radius not maximum.
2-12 Added IEC symbol graphics and descriptions.
Updated information about noise levels. A generic statement pointing customers to information on the
3-3
Hypertherm web site will be added to all Mechanized manuals over time.
Added a paragraph before the bullet points with some details about moving the power supply with
3-11 a fork lift. Added “HPR400XD power supplies with serial number HPR400-000560 or later can be
upgraded to a HPR800XD primary or secondary power supply.” below the bullet points.
3-17 and 3-18 Added mounting hole call out.

3-23, 29, 37,
Added caution box about not using teflon tape.
53 and 55
3-26 Corrected the 2 cable signal list tables to say selection console instead of gas console.
Removed changing consumables note under torch alignment. Added a page and moved Torch lifter
3-42 and 3-43
requirement to next page and added Hypernet information.
Removed the note “Oxygen, nitrogen, and air are required for all systems. Nitrogen is used as a
3-51 purge gas.” from under the first paragraph. The statement was inaccurate. Removed the reference to
methane because it is not used.
Added “See Supply gas hoses at the end of this section for recommendations” to the first paragraph.
Removed the note “Oxygen, nitrogen, and air are required for all systems. Nitrogen is used as a
3-53
purge gas.” from under the first paragraph. The statement was inaccurate. Removed the reference to
methane because it is not used.
4-6 through 4-9 Updated CNC screen examples.
Added “When using the argon marking processes, mark and cut individual parts. Marking the entire
4-10 nest prior to cutting may lead to reduced consumable life. For better results intersperse cuts and
marks.” under Marking.
4-14 Added Mild steel, thick piercing, bevel cutting consumables.
4-17 and 4-18 Expanded “Inspect consumables” from one page to 2. Increased size of graphics for clarity.
HPR400XD Auto Gas – 806160 Revision 3 1

Changed Page Description of change for revision 2 (date of revision - 9/2011)
4-20 Added Torch quick disconnect receptacle graphic.

Added “(for example: 30 amp O2/O2 and 50 amp O2/O2 processes). The pierce complete signal
must be turned off for processes with shield gas preflow pressures that are lower than the cutflow
pressures (for example: 600 amp and 800 amp processes).” to the second paragraph. Added
4-25
third bullet point. Added “moving pierce”, (800 amp SST piercing can be extended to
100 mm (4 in), and “an edge start is recommended unless the operator is experienced with this
technique.” to the last bullet point.
Updated kerf width compensation data. Added mixed gas processes to the table. Added 5 and
4-28 and 4-29 8 mm thicknesses. Populated empty boxes with N/A for not available. Added any new values that
were available.
Updated kerf width compensation table data. Added mixed gas processes to the table. Added
4-30 5/16 in thickness. Populated empty boxes with N/A for not available. Added any new values that
were available.
4-33 through 4-37
Added 5 mm, 8 mm, and 5/16 in thicknesses to the cut charts.
and 4-45,
Added “on the shield” to the note - They are only recommended for use if you have a problem with
4-39 and 4-40 excessive slag on the shield, or problems with the torch misfiring, when using the standard bevel
consumables.
4-45 Corrected the N2 cutflow, flow rate.
4-38, 4-39, 4-46
through 4-60, Added 8 mm, and 5/16 in thicknesses to the cut charts.
4-68 through 4-75
5-4 Changed heading from Control and signal cables to Power and signal cables.
Corrected the last line under number 2 to read “contactor remains closed” instead of
5-5
contactor opens.
5-9, 27, 33 34, and
Updated the diagnostic screen and the Test Pump button (now the Coolant Override button)
38
Added error code number 11. Added XD after HPR130, 260, and 400 in the Name column (all
5-10 instances). Added error code numbers for HPR800XD secondary power supply. Removed error
code number 18. It is for the original HPR260 not the HPR260XD.
Removed the “Perform chopper test” step from error code numbers 020, 024/224, 025/225,
5-11, 5-12
026/226, 028/228, 034/234
5-13, 5-14, and Added HPR400XD references to error code numbers 46, 47 steps 1, 4, and 6. Added
5-17 HPR400XD references to code number 071 steps 1 and 2..
5-18 Added error code number 98 (Phase loss at initialization).
Added a note to the description of error code number 159/359. Added “on PCB7” after D30,
5-24
D31, and D32 in the corrective action steps.
5-25 Added error code number 161
5-26 Added error code numbers 182 and 383
5-31 Added “Main power in” with an arrow. Rewrote the note about checking line to ground, for clarity.
2 HPR400XD Auto Gas – 806160 Revision 3

Changed Page Description of change for revision 2 (date of revision - 9/2011)
5-36 Added a second note about following the troubleshooting steps in order.
5-43 Updated the Gas Leak Test screen shot
Updated the Service Parts Replacement Schedule table. Corrected the part number for the annual
5-67 and 5-68 preventive maintenance kit (it was 228015 and was changed to 228605). Corrected the part
number for the torch main body (it was 220162 and was changed to 220706).
Added part numbers for power supplies with Hypernet and a note about Hypernet. Added the 415
6-2
volt power supply. Added Hypernet upgrade kit
6-5 Updated the part numbers for the control transformers.
Added part numbers to Consumables for mirror image cutting for 80 amp, 130 amp and 260 amp
6-17
mild steel bevel cutting.
Schematics All sheets updated from revision C to revision E.
Appendix A Updated to the latest information and formatting for the Hypertherm torch coolant data (MSDS)
Added the secondary error code ID numbers after the primary error code ID number, for all
Appendix B
applicable error codes.
b-6 Added information to the description of the “HELLO” command.
b-19 Added command numbers 136 and 158 to th ecommand table.
b-21 Added error code number 11.
b-24 Added error code numbers 161, 182, and 383.
Appendix C Updated TOC to include new items.
C-2 Added metric conversions for gas lead lengths. Added graphic of the ohmic contact extension.
Added graphics for the rotational mounting sleeve, the rotational mounting sleeve clamp, the
C-3 leather over wrap, and the robotic teaching torch. Also added a dimensional drawing for the torch
and rotational mounting sleeve.
HPR400XD Auto Gas – 806160 Revision 3 3

4 HPR400XD Auto Gas – 806160 Revision 3

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For your records

Serial number: _____________________________________________

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Revision 3 – November, 2011

© 2011 Hypertherm, Inc.

Hypertherm Plasmatechnik GmbH Hypertherm Brasil Ltda.

Hypertherm (Shanghai) Trading Co., Ltd. Hypertherm Korea Branch

Introduction a. Other supply cables, control cables, signaling and

Compliance Information EMC-1

Consideration should be given to shielding the supply Earthing of the workpiece

The operator should be insulated from all such bonded

Emc-2 Compliance Information

Attention Hypertherm provides repair, replacement or adjustment

This warranty shall not apply to any Powermax brand

Compliance Information W-1

Patent indemnity Insurance

National and local codes

w-2 Compliance Information

Electromagnetic compatibility (EMC)..........................................................................................................EMC-1

HPR400XD Auto Gas – 806160 Revision 3 i

ii HPR400XD Auto Gas – 806160 Revision 3

HPR400XD Auto Gas – 806160 Revision 3 iii

Torch lifter requirement.......................................................................................................................................................................... 3-43

iv HPR400XD Auto Gas – 806160 Revision 3

Stainless steel bevel cutting....................................................................................................................................................... 4-15

HPR400XD Auto Gas – 806160 Revision 3 v

Error code troubleshooting – error codes 160 to 180...................................................................................................... 5-25

vi HPR400XD Auto Gas – 806160 Revision 3

Phase-loss detection test...................................................................................................................................................................... 5-60

HPR400XD Auto Gas – 806160 Revision 3 vii

HPR400XD auto gas instruction manual revision changes (806160).................................................... 1

viii HPR400XD Auto Gas – 806160 Revision 3

Recognize safety danger warning caution

• DANGER safety messages precede related

Electric shock can kill

Cutting can cause fire or explosion

Fire prevention WARNING

Toxic fumes can cause injury or death

The air quality level in any relevant workplace depends

Static electricity can damage circuit boards

Compressed gas equipment

A plasma arc can cause injury and burns

Arc rays can burn eyes and skin

Minimum protective Suggested shade

Pacemaker and hearing aid operation

Noise can damage hearing

A plasma arc can damage frozen pipes

Dry dust collection information

Additional laser safety instructions:

Symbols and marks

Additional safety information

Read and follow these instructions, employer safety

Warning Labels 1. Cutting sparks can cause explosion

Sommaire de cette section:

• DANGER safety messages precede related

Warning Labels 1. Cutting sparks can cause explosion

• Éviter à tout prix le contact électrique entre l’arc plasma

• Ne jamais exposer des bouteilles à une chaleur excessive,

• Ne jamais utiliser des marteaux, des clés ou d’autres

Étiquette de sécurité 1. Les étincelles de coupage peuvent

Cumplimiento • Los mensajes de seguridad de PELIGRO aparecen en

• Nunca exponga los cilindros al calor excesivo,

• Nunca use un martillo, llave ni otra herramienta para

Etiquetas de advertencia 1. Las chispas de corte pueden producir

• The ignition console may be mounted horizontally or vertically.