HPR 260 Manual Instrution

MAINTENANCE

Power supply coolant system servicing

Draining the coolant system

1Turn OFF the power, and remove the return coolant hose (red tape) from the pump and put it in a 20 liter (5 gallon) container.

2Turn ON the pump manually using the manual pump control button on your CNC screen.

3Turn OFF the pump when the coolant stops flowing.

Caution: The coolant pump can be damaged if it is run without coolant. Turn

OFF the pump immediately when the coolant stops flowing.

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

Coolant system filter

Filter replacement

1.Turn OFF all power to the system.

2.Remove housing.

3.Remove and discard filter element.

4.Install new filter element 027664.

5.Re-install housing.

2

3

4

5

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Coolant flow test procedure

The control board (PCB3) receives a voltage signal from the flow switch that is dependent on the flow rate (lpm/gpm) of the coolant. A voltage of 0.67 VDC from the flow switch equals 2.3 lpm (0.6 gpm). PCB3 will allow the system to operate if the voltage signal is 0.67 VDC or greater. If the selection console shows a coolant flow error (093) the system will need to be turned OFF and then ON again and the following test needs to be performed to determine if the problem is coolant flow or the flow switch.

1.Turn ON the power. Turn ON the pump manually using the manual pump control button on your CNC screen. Allow the coolant to flow for 60 seconds.

2. Read the coolant flow rate on the CNC screen. Proper coolant flow is greater than (>) 2.65 lpm (0.7 gpm).

3. If the flow is less than (<) 2.65 lpm (0.7 gpm), verify the voltage signal from the flow switch.

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Testing the flow switch

4.Reconnect the return hose to the pump and turn ON the power.

5.Measure the VDC between TP210 and TP206.

TP206 is common on PCB3. TP210 provides a filtered, 67% scaled, voltage from the flow switch. 0.45 VDC (0.67 VDC at the flow switch) equals 2.3 lpm (0.6 gpm). If the TP210 voltage reading is below 0.45 VDC and the flow is equal to or above 3.0 lpm (1 gpm), replace the flow switch.

TP 206

TP 210

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Gas leak test procedure

Leak test 1

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.

Leak test 2

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.

Metering console flow test

1.You must have 130-amp consumables in the torch and an O2/O2process selected to perform this test.

2.Perform Metering Valve Flow Check.

3.Turn OFF power and then turn ON power. This will purge gases from the system.

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Power supply control board PCB3

Control PC board LED list

LED	Signal	Notes
D100	+5 VDC
D101	+3.3 VDC
D113	CAN TX	Constant blinking
D114	CAN RX	Constant blinking

Control PCB3 firmware list

Item Part number

U104 081094 EVEN

U105 081094 ODD

Control PC Board LEDN300 List					Control PC Board LEDN301 List
LEDN	Output	Input	Notes		LEDN	Output	Input	Notes
LEDN1	Machine motion				LEDN1	HV transformer
LEDN2	Error				LEDN2	Pump motor enable
LEDN3	Ramp-down error				LEDN3	Contactor
LEDN4	Not ready				LEDN4	Pilot arc relay
LEDN5	Soft start enable		Not used		LEDN5	Spare
LEDN6	Pilot arc enable				LEDN6	Surge select
LEDN7		Corner current			LEDN7			Not connected
LEDN8		Pierce			LEDN8			Not connected
LEDN9		Hold			LEDN9			Not connected
LEDN10		Plasma start			LEDN10		Phase loss

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Power supply power distribution board PCB2

D1

D2

D5

D7

D25

D31 D32

D33

D26

D35

D3

D23

D12

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
D12	24 VAC (switched)	Green
D23	240 VAC (switched)	Green
D25	+ 24 VDC	Red
D26	Pump motor	Green
D31	+ 5 VDC	Red
D32	- 15 VDC	Red
D33	+ 15 VDC	Red
D35	24 VAC	Green

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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

Start circuit troubleshooting

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.

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D2 should always be illuminated.

D1 illuminates as soon as the torch fires and will extinguish as soon as the arc transfers to the workpiece. If arc transfer is immediate, the LED will not illuminate.

If there is no arc at the torch or if the arc will not transfer:

1. Turn OFF all power to the system.

2.Remove wires from H8 (WORK) and H9 (NOZZLE) studs on the board.

3.Verify a resistance of 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 15 kΩ between C1 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 1 Ω across the R3 resistor.

15kΩ

5.5kΩ

041811

R1

1Ω

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Pilot arc current levels

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

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