Hypertherm HPR130 User manual

HPR130®Manual Gas
Preventive Maintenance Program
Instruction Manual
808590 | Revision 1 | English

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© 2015 Hypertherm Inc.

HPR130 Manual Gas
Preventive Maintenance Program
Instruction Manual
808590
Revision 1
English
February 2015
Hypertherm Inc.
Hanover, NH 03755 USA

Hypertherm Inc.
Etna Road, P.O. Box 5010
Hanover, NH 03755 USA
603-643-3441 Tel (Main Office)
603-643-5352 Fax (All Departments)
[email protected] (Main Office Email)
800-643-9878 Tel (Technical Service)
[email protected] (Technical Service Email)
800-737-2978 Tel (Customer Service)
[e-mail] (Customer Service Email)
866-643-7711 Tel (Return Materials Authorization)
877-371-2876 Fax (Return Materials Authorization)
[email protected] (RMA email)
Hypertherm Plasmatechnik GmbH
Technologiepark Hanau
Rodenbacher Chaussee 6
D-63457 Hanau-Wolfgang, Deutschland
49 6181 58 2100 Tel
49 6181 58 2134 Fax
49 6181 58 2123 (Technical Service)
Hypertherm (S) Pte Ltd.
82 Genting Lane
Media Centre
Annexe Block #A01-01
Singapore 349567, Republic of Singapore
65 6841 2489 Tel
65 6841 2490 Fax
65 6841 2489 (Technical Service)
Hypertherm (Shanghai) Trading Co., Ltd.
Unit 301, South Building
495 ShangZhong Road
Shanghai, 200231
PR China
86-21-60740003 Tel
86-21-60740393 Fax
Hypertherm Europe B.V.
Vaartveld 9
4704 SE
Roosendaal, Nederland
31 165 596907 Tel
31 165 596901 Fax
31 165 596908 Tel (Marketing)
31 165 596900 Tel (Technical Service)
00 800 4973 7843 Tel (Technical Service)
Hypertherm Japan Ltd.
Level 9, Edobori Center Building
2-1-1 Edobori, Nishi-ku
Osaka 550-0002 Japan
81 6 6225 1183 Tel
81 6 6225 1184 Fax
Hypertherm Brasil Ltda.
Rua Bras Cubas, 231 – Jardim Maia
Guarulhos, SP - Brasil
CEP 07115-030
55 11 2409 2636 Tel
55 11 2408 0462 Fax
Hypertherm México, S.A. de C.V.
Avenida Toluca No. 444, Anexo 1,
Colonia Olivar de los Padres
Delegación Álvaro Obregón
México, D.F. C.P. 01780
52 55 5681 8109 Tel
52 55 5683 2127 Fax
Hypertherm Korea Branch
#3904 Centum Leaders Mark B/D,
1514 Woo-dong, Haeundae-gu, Busan
Korea, 612-889
82 51 747 0358 Tel
82 51 701 0358 Fax

WARNING!
READ THE SAFETY INFORMATION
Before operating or maintaining any Hypertherm equipment, read the
Safety and Compliance Manual (80669C) for important safety information.
You can find the Safety and Compliance Manual in the “Downloads library”
at www.hypertherm.com.

HPR130 Manual Gas Instruction Manual 808590 7
Contents
Preventive Maintenance Program ........................................................................................... 9
Overview ............................................................................................................................................................................................ 9
Cleaning and inspection schedule ........................................................................................................................................... 10
Daily ......................................................................................................................................................................................... 11
Do a test of the inlet pressures .................................................................................................................................. 11
Examine all of the air filters ......................................................................................................................................... 11
Do a check of the coolant level and condition ....................................................................................................... 12
Examine and lubricate O-rings ................................................................................................................................... 13
Examine the water tube and torch ............................................................................................................................ 13
Weekly ..................................................................................................................................................................................... 14
Examine hoses and torch leads ................................................................................................................................. 14
Do tests for gas leaks .................................................................................................................................................. 14
Do a check of the coolant flow .................................................................................................................................. 14
Do a check of the coolant level ................................................................................................................................. 14
Monthly .................................................................................................................................................................................... 15
Clean inside the power supply .................................................................................................................................. 15
Examine the coolant system ....................................................................................................................................... 15
Examine the main contactor ....................................................................................................................................... 16
Examine the pilot arc relay .......................................................................................................................................... 16
Do the coolant flow test .............................................................................................................................................. 16
Examine the gas line connections ............................................................................................................................. 17
Examine the hoses ........................................................................................................................................................ 17
Examine the cables ....................................................................................................................................................... 17
Examine the ground connections .............................................................................................................................. 17
Examine the table-to-workpiece connection .......................................................................................................... 17
Component replacement schedule .......................................................................................................................................... 18
Cutting area and operation effects ................................................................................................................................... 21
External cutting area ..................................................................................................................................................... 21

8HPR130 Manual Gas Instruction Manual 808590
Contents
Incoming air supply quality .......................................................................................................................................... 22
Metal dust inside the power supply cabinet ........................................................................................................... 22
Consumable use ........................................................................................................................................................... 23
Cut-cycle time ............................................................................................................................................................... 24
Find arc hour data on a Hypertherm CNC ............................................................................................................................. 25
Part numbers for HPR130 Manual Gas cables and leads ................................................................................................. 26
Power supply to ignition console leads ........................................................................................................................... 26
Pilot arc lead ................................................................................................................................................................. 26
Negative lead ................................................................................................................................................................. 26
Ignition console power cable ..................................................................................................................................... 26
Ignition console coolant hose .................................................................................................................................... 27
Power supply to gas console cables ............................................................................................................................... 27
Control cable ................................................................................................................................................................. 27
Power cable ................................................................................................................................................................... 27
Cable and gas hose assembly (gas console to off-valve) ........................................................................................... 27
Power supply to CNC interface cable ............................................................................................................................. 28
Torch lead ............................................................................................................................................................................... 28
Work lead ............................................................................................................................................................................... 28
Supply gas hoses ................................................................................................................................................................. 29
Air hose ........................................................................................................................................................................... 29
Argon-hydrogen (H35) or nitrogen-hydrogen (F5) hose ..................................................................................... 29
Nitrogen or argon hose ............................................................................................................................................... 29
Oxygen hose .................................................................................................................................................................. 29
System information ....................................................................................................................................................................... 30
Model number ........................................................................................................................................................................ 30
Serial number ......................................................................................................................................................................... 30
System voltage ...................................................................................................................................................................... 30
Coolant requirements .......................................................................................................................................................... 30
Notes ............................................................................................................................................................................................... 31
Maintenance log for HPR130 Manual Gas plasma systems .............................................................................................. 32

HPR130 Manual Gas Instruction Manual 808590 9
Preventive Maintenance Program
Overview
Congratulations on the purchase of your Hypertherm plasma system.
Hypertherm plasma systems can operate in harsh conditions for many years. To maintain system performance, minimize
operating costs, and lengthen system life, follow the maintenance procedures given in this Preventative Maintenance
Program (PMP).
Hypertherm made this PMP specifically for your plasma system. The PMP has two parts: a cleaning and inspection
schedule and a component replacement schedule.
If you have questions about how to maintain your plasma system, contact your OEM or regional Hypertherm Technical
Service team. You can find contact information for each regional office at www.hypertherm.com on the “Contact us”
page.
This document refers to your system’s instruction manual. If you do not have your instruction manual, you can find it in the
Hypertherm downloads library:
1. Go to www.hypertherm.com.
2. Click Downloads library.
3. Enter your instruction manual’s part number in the Part number field.
HyPerformance HPR130 Manual Gas Instruction Manual: 804570

10 HPR130 Manual Gas Instruction Manual 808590
Preventive Maintenance Program
Cleaning and inspection schedule
This is a daily, weekly, and monthly schedule for cleaning and inspections. The PMP has instructions for each task. These
instructions help your personnel understand what to do and what to look for during each task. In general, an operator can
do the daily and weekly tasks, while maintenance personnel usually do the monthly tasks.
A monthly maintenance log is in the back of this manual. You can make photocopies of the maintenance log to record
tasks.
Tabl e 1
Maintenance task or activity Daily Weekly Monthly
Do a test of the inlet pressures X
Examine all of the air filters X
Do a check of the coolant level and condition X
Examine and lubricate O-rings X
Examine the water tube and torch X
Examine hoses and torch leads X
Do tests for gas leaks X
Do a check of the coolant flow X
Do a check of the coolant level X
Clean inside the power supply X
Examine the coolant system X
Examine the main contactor X
Examine the pilot arc relay X
Do the coolant flow test X
Examine the gas line connections X
Examine the hoses X
Examine the cables X
Examine the ground connections X
Examine the table-to-workpiece connection X

HPR130 Manual Gas Instruction Manual 808590 11
Preventive Maintenance Program
Daily
Do a test of the inlet pressures
1. With the gas flowing in test preflow mode, make sure that the pressure at the
regulator is set to 8 bar (115 psi).
2. Repeat the test in cutflow mode, and make sure that the regulator is set to 8 bar
(115 psi).
For instructions about setting supply regulators, see Setting the supply
regulators in your system’s instruction manual.
Examine all of the air filters
Examine the compressed air filter system.
1

12 HPR130 Manual Gas Instruction Manual 808590
Preventive Maintenance Program
Do a check of the coolant level and condition
Make sure that the tank is full to the neck with coolant:
1. Open the cover of the coolant tank on the outside of the enclosure.
2. If the level of the coolant is below the top of the tank, add coolant (028872) to the neck of the
tank.
3. Record the number of gallons your system requires in Coolant requirements on page 30.
Examine the coolant tank for contamination. If you find any contamination, then:
1. Turn OFF the power to the system.
2. Remove the red coolant hose from the top of the coolant tank and
put it in a 20 liter (5 gallon) container.
3. Turn ON the power to the system.
4. Run the system until the coolant tank is empty.
You can get coolant flow errors. These errors can cause the
system to shut down. If the system shuts down, you need to
repeat the steps to drain the tank.
5. Turn OFF the power to the system.
6. Attach the coolant hose to the top of the coolant tank.
Empty the container.
7. Fill the tank with clean coolant or water, and drain the tank again. (Repeat step 2 –step 6.)
8. Fill the tank to the neck with clean coolant.
9. Turn ON the power to the system.
10. Run the system to fill the hoses and leads with coolant.
11 . If necessary, add more coolant to the tank to fill it to the neck.
1
4

HPR130 Manual Gas Instruction Manual 808590 13
Preventive Maintenance Program
Examine and lubricate O-rings
Examine all of the 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 can prevent gas flow.
Examine the water tube and torch
1. Examine the water tube for bends and pitting.
2. Examine the nozzle and electrode mating surfaces on the torch main body for
damage or pitting.
3. Use a clean cloth to clean the internal and external surfaces of the torch. Use a
cotton swab to clean internal surfaces that are not easy to get to.
Make sure that you do not leave any cotton fibers on the inner surfaces of the
torch main body.
4. Use compressed air to remove any remaining particles from the torch main body.
1
2
3

14 HPR130 Manual Gas Instruction Manual 808590
Preventive Maintenance Program
Weekly
Examine hoses and torch leads
1. Examine all air hoses, coolant hoses, and torch leads for:
Scrapes, cuts, or holes
Chemical spills or burns
Kinks or bends
2. Replace any hoses or leads that have damage.
See Part numbers for HPR130 Manual Gas cables and leads on page 26 for lengths and part numbers.
Do tests for gas leaks
For more information, see Gas leak tests in the Maintenance section of your system’s instruction manual.
Do a check of the coolant flow
Find the flow rate shown on the gas console. Record the coolant flow.
For more information, see Test 6 – bucket test at the pump in the Maintenance section of your system’s instruction
manual.
If the flow rate is below 2.9 L/min (0.75 g/min), contact your maintenance department to service the coolant system.
Do a check of the coolant level
Make sure that the tank is full to the neck with coolant:
1. Open the cover of the coolant tank on the outside of the enclosure.
2. If the level of the coolant is below the top of the tank, add coolant (028872) to the neck of the
tank.
3. Record the number of gallons your system requires in Coolant requirements on page 30.

HPR130 Manual Gas Instruction Manual 808590 15
Preventive Maintenance Program
Monthly
Clean inside the power supply
1. Turn OFF the power to the power supply.
2. Remove the top and side panels of the power supply.
3. Use low pressure air or a vacuum to remove any accumulation of dust and particles from:
The top and side panels
The inside of the power supply
The fans
4. Remove dust and particles from circuit boards.
Be careful not to damage the circuit boards.
5. Install the top and side panels before you turn ON the power.
Examine the coolant system
Examine the coolant system for coolant leaks at all connections. Make sure you examine:
The ignition console
The torch main body
The internal connection in the power supply
WARNING!
ELECTRIC SHOCK CAN KILL
Disconnect electric power before performing any maintenance.
All work requiring removal of the power supply cover must be performed by
a qualified technician.
Read the Safety and Compliance Manual (80669C) for important safety
information.

16 HPR130 Manual Gas Instruction Manual 808590
Preventive Maintenance Program
Examine the main contactor
1. Examine the contacts in the main contactor for black or rough surfaces.
2. If you find too much of this condition, replace the main contactor.
Examine the pilot arc relay
1. Remove the cover of the pilot
arc relay.
2. Examine the contacts inside the
relay for black or rough
surfaces.
3. If you find too much of this
condition, replace the pilot arc
relay.
4. Install the cover of the pilot arc
relay.
Be careful that you do not pinch the wires between the cover and the center panel.
Do the coolant flow test
For more information, see Coolant flow tests in the Maintenance section of your system’s instruction manual.
1
2

HPR130 Manual Gas Instruction Manual 808590 17
Preventive Maintenance Program
Examine the gas line connections
Spray all of the gas line connections with soapy water. If bubbles appear on a gas line, tighten or replace it as necessary.
See Part numbers for HPR130 Manual Gas cables and leads on page 26 for lengths and part numbers.
Examine the hoses
Examine each hose for kinks or sharp bends that can restrict gas flow or cause damage to the hose.
If the cutting table uses a power track system to support the leads that go from the power supply to the gas console or
torch, look at the position of the leads in the track. Make sure the leads do not twist or kink. This can cause a restriction.
Examine the cables
Examine all cables for scratches or unusual wear. If the outside insulation is cut or has any other damage, replace the
cable. See Part numbers for HPR130 Manual Gas cables and leads on page 26 for lengths and part numbers.
Examine the ground connections
Make sure that all components of the system are individually grounded to a driven earth ground. See the Installation and
Grounding section of your system’s instruction manual.
Examine the table-to-workpiece connection
Examine the work lead (+) connection where the work lead (+) connects to the cutting table.
Make sure that there is no paint, oil, dirt, or rust on the workpiece. This type of contamination prevents a clean
metal-to-metal contact between the work lead and the cutting table or workpiece. It can also cause arc-transfer
problems.
CAUTION!
Do not clean brass connections with ammonia-based cleaners. Ammonia causes brass to crack and
become brittle.

18 HPR130 Manual Gas Instruction Manual 808590
Preventive Maintenance Program
Component replacement schedule
This is a list of components and their recommended replacement schedules. The schedule uses total arc hours to
estimate when to replace a component. The use of cumulative arc hours is the most accurate method to estimate when
you need to replace a component.
If you have a Hypertherm CNC, you can find the total number of arc hours on the CNC. See Find arc hour data on a
Hypertherm CNC on page 25. You can also find cumulative arc hours on a serial communication link between your CNC
and power supply.
If you do not have a Hypertherm CNC and your CNC cannot track arc hours, use the guide below to estimate arc hours
per year. This guide uses the average number of 8-hour shifts that the system operates on an average work day. For more
information about calculating arc hours, contact your table manufacturer.
Your cutting area and operations can have an effect on this schedule. See Cutting area and operation effects on page 21.
Record information about your system and its replacement requirements in the following places:
Part numbers for HPR130 Manual Gas cables and leads on page 26
System information on page 30
Notes on page 31
Average shifts per day Estimated arc hours per year
1500
2 1,000
31,500

HPR130 Manual Gas Instruction Manual 808590 19
Preventive Maintenance Program
Tabl e 2
Item
Number Quantity Component Cumulative number of arc hours
500 1,000 1,500 2,000 2,500 3,000 3,500 4,000 4,500 5,000 5,500 6,000
428309 1 Kit:Torchrebuildandfilterwithoutcoolant* XXXXXXXXXXXX
428310 1 Kit: Torch rebuild and filter with coolant*
028872 3–4Coolant(ingallons)** XXXXXXXXXXXX
428265 1 Kit: Electronics*** XXXXXX
220163 1 Quick-disconnect torch receptacle X X X
228170 1 Kit: Coolant pump with clamp X X X
1Torchlead
†XXX
006075 1 Coolant check valve X X
027079 1 10-inch fan X X
027185 2 Heat-exchange fan X X
127039 2 6-inch fan XX
228022 1 Kit: Coolant flow switch X X
228538 1 Kit: Coolant pump motor with clamp X X
228993 1 Kit: Coolant solenoid valve X X
1 Gas lead†XX
1 Pilot arc lead†XX
041802 1 Power board (PCB2) X
041817 1 Ignition board (PCB IGN) X
006109 6 Gas solenoid valve‡X
129854 1 High-frequency transformer (T1) X
005263 4 Gas pressure sensor X
041837 1 I/O board X
129792 1 Chopper X

20 HPR130 Manual Gas Instruction Manual 808590
Preventive Maintenance Program
* This kit includes the coolant filter (027664) and torch rebuild kit (428252).
** The number of gallons you need depends on the length of the leads. See your system’s instruction manual for more information then
record this number in Coolant requirements on page 30.
*** Kit 428265 includes a pilot arc relay (003149), contactor (003249), and torch main body (220162). See your system’s instruction
manual for the correct voltage, then record this number in System voltage on page 30.
†Record the part numbers for cables and leads in Part numbers for HPR130 Manual Gas cables and leads on page 26 so you can
refer to this information when you replace these components.
‡The gas solenoid valves that are connected to the air lines must be maintained. The quantity of gas solenoid valves given is the
quantity of valves connected to the air lines not the total quantity of valves in the system.