Hypertherm HyPerformance Plasma HPR800XD User manual

HPR800XD™ Auto Gas
Preventive Maintenance Program
Instruction Manual
808680 | Revision 2 | English

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HPR800XD Auto Gas
Preventive Maintenance Program
Instruction Manual
808680
Revision 2
English
November 2018
Hypertherm, Inc.
Hanover, NH 03755 USA

Hypertherm, Inc.
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91-11-40521201/ 2/ 3 Tel
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[e-mail] (Main Office Email)
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(Technical Service Email)

ENGLISH
Copies of the manuals may accompany the product in electronic and printed
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for each manual, from the “Documents library” at www.hypertherm.com.
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sú k dispozícii aj v sekcii z „knižnice Dokumenty“ na www.hypertherm.com.

HPR800XD Auto Gas Instruction Manual 808680 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 ........................................................................................................ 11
Examine and lubricate O-rings .................................................................................................................................... 12
Examine the water tube and torch ............................................................................................................................. 12
Weekly ...................................................................................................................................................................................... 13
Examine hoses and torch leads .................................................................................................................................. 13
Do tests for gas leaks ................................................................................................................................................... 13
Do a check of the coolant flow ................................................................................................................................... 13
Do a check of the coolant level .................................................................................................................................. 13
Monthly ..................................................................................................................................................................................... 14
Clean inside the power supply ................................................................................................................................... 14
Clean the chiller air filter ............................................................................................................................................... 14
Clean inside the chiller ................................................................................................................................................. 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

8HPR800XD Auto Gas Instruction Manual 808680
Contents
Cutting area and operation effects .....................................................................................................................................21
External cutting area .......................................................................................................................................................21
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 HPR800XD Auto Gas cables and leads ..................................................................................................26
Primary power supply to secondary power supply cables ............................................................................................26
Interface cable .................................................................................................................................................................26
Communication cable ....................................................................................................................................................26
Power supply to ignition console leads .............................................................................................................................26
Pilot arc lead ....................................................................................................................................................................26
Negative lead ...................................................................................................................................................................26
Ignition console power cable .......................................................................................................................................27
Coolant hoses .........................................................................................................................................................................27
Chiller-interface console to ignition console ............................................................................................................27
Chiller to chiller-interface console ..............................................................................................................................27
Power supply to chiller cables .............................................................................................................................................27
Control cable ...................................................................................................................................................................27
Power cable .....................................................................................................................................................................27
Power supply to selection console cables .......................................................................................................................28
Control cable ...................................................................................................................................................................28
Power cable .....................................................................................................................................................................28
Cable and gas hose assembly (selection console to metering console) ..................................................................28
Power supply to CNC interface cable ...............................................................................................................................28
Torch lead .................................................................................................................................................................................29
Work lead .................................................................................................................................................................................29
Ohmic contact wire ................................................................................................................................................................29
Supply gas hoses ...................................................................................................................................................................30
Air hose .............................................................................................................................................................................30
Argon-hydrogen (H35) or nitrogen-hydrogen (F5) hose .......................................................................................30
Nitrogen or argon hose .................................................................................................................................................30
Oxygen hose ....................................................................................................................................................................30
System information .........................................................................................................................................................................31
Model number ..........................................................................................................................................................................31
Serial number ...........................................................................................................................................................................31
System voltage ........................................................................................................................................................................31
Coolant requirements ............................................................................................................................................................31
Notes .................................................................................................................................................................................................32
Maintenance log for HPR800XD Auto Gas plasma systems ..............................................................................................33

HPR800XD Auto Gas Instruction Manual 808680 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 at
www.hypertherm.com/docs.
HPR800XD Auto Gas Instruction Manual: 806500

10 HPR800XD Auto Gas Instruction Manual 808680
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.
Tab le 1
*See the chiller manufacturer manual for guidance on chiller maintenance. Chiller manufacturer specifications override Hypertherm’s
recommendations for chiller maintenance.
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
Clean the chiller air filter* X
Clean inside the chiller* 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

HPR800XD Auto Gas Instruction Manual 808680 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 all of the air filters for contamination.
If you find moisture or oil, replace the air filter.
If you find a moderate quantity of solid contamination, such as
dust, blow air through it or use suction to clean the filter.
If you find a large quantity of solid contamination, replace the air
filter.
See Air filter element replacement in your system’s instruction
manual for replacement instructions.
Do a check of the coolant level and condition
Make sure that the coolant tank in the chiller is full:
1. Remove the panel from the left rear side of the chiller.
2. Look at the coolant tank.
3. If the level is more that 5.1 cm (2 inches) from the top of the tank, add coolant (028872) to this level.
4. Record the number of gallons your system requires in Coolant requirements on page 31.
Examine the coolant tank for contamination. If you find any contamination, drain the tank and replace the coolant. See
Draining the coolant system in your system’s instruction manual for instructions.
Examine the inline coolant strainers in the chiller. See the DuraChill 5 HP Air-Cooled Chiller For Hypertherm Instruction
Manual (806600) for details.
1
34

12 HPR800XD Auto Gas Instruction Manual 808680
Preventive Maintenance Program
Examine and lubricate O-rings
1. Examine all of the O-rings on the torch and consumables for
damage.
2. If you find damage, replace the O-ring.
Receptacle O-rings and torch O-rings for the torch main body
are available as part of kit 428252. Other O-rings are included
with the consumables.
3. Apply a thin film of silicone lubricant (027055) to all O-rings.
The O-rings should look shiny. Too much lubricant can prevent
gas flow.
4. Install all O-rings so they fit snugly.
5. Examine all threaded consumables, and remove any dirt from the
threads.
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

HPR800XD Auto Gas Instruction Manual 808680 13
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 HPR800XD Auto 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 the following gas system tests:
Inlet Leak test
System Leak test
Proportional valve test – Make sure that you use the 130 A O2/Air consumables and that you select the 30 A O2/O2
plasma process.
Do a check of the coolant flow
Find the flow rate shown on the CNC’s diagnostic screen. Record the coolant flow.
If the information on the CNC indicates a problem with the coolant flow, do the tests described in Coolant flow tests 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 coolant tank in the chiller is full:
1. Remove the panel from the rear left side of the chiller.
2. Look at the coolant tank.
3. If the level is more that 5.1 cm (2 inches) from the top of the tank, add coolant (028872) to this level.
4. Record the number of gallons your system requires in Coolant requirements on page 31.

14 HPR800XD Auto Gas Instruction Manual 808680
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.
Clean the chiller air filter
These instructions are only for the PolyScience chiller. If you do not use a PolyScience chiller, refer to the chiller
manufacturer manual for air filter replacement and more information on how to clean the air filter.
Chillers have 3 reusable air filters. Chillers in dusty environments need their filters cleaned more frequently.
Do not let the air filters become clogged with dust. This reduces air flow and can decrease cooling efficiency. It can also
lead to filter breakthrough, allowing dust to get into the condenser coils.
To remove and clean the chiller’s air filters:
1. Hold the strap at the bottom center of the filter and carefully lift it up and away from the chiller housing.
2. Use a water or high pressure air stream directed through the back of the air filter (the downstream side) to remove
dust from the filter. Let the filter dry, as required.
3. Position the top edge of filter in the upper channel of the chiller housing.
4. Carefully lift on the bottom strap while pushing the bottom edge of the filter toward the housing.
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.

HPR800XD Auto Gas Instruction Manual 808680 15
Preventive Maintenance Program
Clean inside the chiller
1. Turn OFF the power to the chiller.
2. Remove the top and side panels.
3. Blow out or vacuum any accumulation of dust and particulates from:
The top and side panels
The inside of the chiller
The fans
4. Remove dust and particulates 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
All of the connections in the chiller

16 HPR800XD Auto Gas Instruction Manual 808680
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
Do the coolant flow test and record the coolant flow rate. You can find the coolant flow rate on the diagnostic screen
on the CNC. For more information, see Do a check of the coolant flow on page 13.
If the flow rate is below 2.9 L/min (0.75 g/min), do the coolant flow test in Coolant flow tests in the Maintenance
section of your system’s instruction manual. You may need to service the coolant system or replace the coolant pump
or motor.
The flow alarm turns on when the flow rate is below 2.3 L/min (0.6 g/min). For more information, see Testing the flow
sensor in the Maintenance section of your system’s instruction manual.
Examine the coolant tank for contamination. If you find any contamination, flush the tank. See Do a check of the
coolant level and condition on page 11 for instructions.
Make sure that you use the correct Hypertherm coolant (028872) or use water that meets the requirements in Water
purity requirements in the Installation section of your system’s instruction manual.
1
2

HPR800XD Auto Gas Instruction Manual 808680 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 HPR800XD Auto 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 HPR800XD Auto 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 HPR800XD Auto Gas Instruction Manual 808680
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 HPR800XD Auto Gas cables and leads on page 26
System information on page 31
Notes on page 32
Average shifts per day Estimated arc hours per year
1500
2 1,000
31,500

HPR800XD Auto Gas Instruction Manual 808680 19
Preventive Maintenance Program
Tab l 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
428263 1 Torch rebuild and filter kit without coolant* X X X X X X X X X X X X
428264 1 Torch rebuild and filter kit with coolant* X X X X X X X X X X X X
028872 4–6Coolant(ingallons)** XXXXXXXXXXXX
Kit: Electronics***
428270
428272
2 200 V – 240 V
380 V – 600 V
XXXXXX
003249 2 Inrush contactor XXXX X
220705 1 Quick-disconnect torch receptacle X X X
1Torchlead
†XXX
006113 1 Coolant check valve X X
006077 2 Gas check valve X X
027079 6 10-inch fan X X
127039 16 6-inch fan XX
229235 1 Coolant flow switch X X
229345 1 Coolant solenoid valve X X
1Gaslead
†XX
1 Pilot arc lead†XX
041802 1 Power board (PCB2) X
041817 1 Ignition board (PCB IGN) X
006109 3 Gas solenoid valve‡X
228984 2 X
129854 1 High-frequency transformer (T1) X
005263 8 Gas pressure sensor X
229213 2 I/O board X
Chiller coolant pump
040296
040297
1 200 V – 460 V
575 V – 600 V
X
129792 8 Chopper X

20 HPR800XD Auto Gas Instruction Manual 808680
Preventive Maintenance Program
* This kit includes the air filter (011110), 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 31.
*** Kit 428270 includes a pilot arc relay (003149), contactor (003218), and torch main body (220706). Kit 428272 includes a pilot arc
relay (003149), contactor (003233), and torch main body (220706). See your system’s instruction manual for the correct voltage,
then record this number in System voltage on page 31.
†Record the part numbers for cables and leads in Part numbers for HPR800XD Auto 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.