Hypertherm HPR400XD Plasma Cutters Instruction Manual

Hypertherm HPR400XD Plasma Cutters

Hypertherm, Inc.
Etna Road, P.O. Box 5010
Hanover, NH 03755 USA
603-643-3441 Tel (Main Office)
603-643-5352 Fax (All Departments)
info@hypertherm.com (Main Office Email)
800-643-9878 Tel (Technical Service)
technical.service@hypertherm.com (Technical Service Email) 800-737-2978 Tel (Customer Service)
customer.service@hypertherm.com (Customer Service Email) 866-643-7711 Tel (Return Materials Authorization)
877-371-2876 Fax (Return Materials Authorization)
return.materials@hypertherm.com (RMA email)

© 2013 Hypertherm, Inc. All rights reserved.
HPR400XD, HPR800XD, HPRXD, and Hypertherm are trademarks of Hypertherm, Inc. and may be registered in the United States and/or other countries. All other trademarks are the property of their respective holders.
Environmental stewardship is one of Hypertherm’s core values. www.hypertherm.com/environment
100% Associate-owned

WARNING! Before operating any Hypertherm equipment, read the safety instructions in your product’s manual, the Safety and Compliance Manual
(80669C), Waterjet Safety and Compliance Manual (80943C), and
Radio Frequency Warning Manual (80945C). Failure to follow safety instructions can result in personal injury or in damage to equipment.
Copies of the manuals can come with the product in electronic and printed formats. Electronic copies are also on our website. Many manuals are available in multiple languages at www.hypertherm.com/docs.

WARNING

ELECTRIC SHOCK CAN KILL
Disconnect electric power before doing installation or maintenance. You can get a serious electric shock if electric power is not disconnected. Electric shock can seriously injure or kill you.
All work that requires removal of the plasma power supply outer cover or panels must be done by a qualified technician.
Refer to the Safety and Compliance Manual (80669C) for more safety information.

Introduction

Purpose
This Field Service Bulletin describes how to install the contents of the inrush-circuit installation kit (428064) in a HPR400XD or HPR800XD power supply.

Required tools and materials

• 2 3/8-inch wrenches
• Screwdriver
• Number 2 Phillips® screwdriver
• 6 mm hex wrench
• Drill with a 5/16-inch drill bit (additional smaller drill bits can be helpful but are optional)
• 7/16-inch wrench for washer-nut removal/installation
• 3/8-inch nut driver
• Needle-nose pliers

Kit 428064 contents

Inrush Installation Kit

NOTICE

FAILURE TO CORRECTLY INSTALL OR REMOVE NUTS AND BOLTS CAN DAMAGE EQUIPMENT
Always use 2 wrenches to correctly install or remove hex nuts and bolts. Equipment damage can occur when hex nuts and bolts are incorrectly installed or removed.

Overview

The inrush-circuit installation kit (428064) includes an inrush printed circuit board (PCB), a small contactor, 3 resistors, and a jumper wire to connect the components from this kit to the main contactor in the power supply, as shown in Figure 1.
The inrush PCB (141558) turns ON and turns OFF the inrush and main contactors in the power supply in a pre-defined sequence that causes the following results:

• Reduces the effects of high inrush current that occur when the main contactor first turns ON.
• Disconnects inrush resistors when they are not in use. This prevents power loss to inrush resistors that can occur during cutting.

Inrush Installation Kit

This document includes 2 installation procedures:

1. How to install the inrush-circuit assembly and the inrush PCB in the box at the rear of the power supply.
2. How to connect the inrush circuit and inrush PCB to the main contactor that is in the box at the rear of the power supply.

The installation steps are the same for both the HPR400XD and the HPR800XD.

WARNING

FAILURE TO CORRECTLY INSTALL WIRES AND CONNECTIONS CAN CAUSE ELECTRIC SHOCKS AND FIRES
Do not cross the L1, L2, and L3 wires. Use the color-coded and numbered labels on the wires for guidance about how to correctly install them. Make sure to follow the steps in this manual. Incorrect wire installation or bad connections between the inrush PCB and main contactor can cause electric shocks and fires.

Install the inrush circuit assembly and inrush PCB

1. Remove the power from the cutting system:
   a. Set the line-disconnect switch to the OFF position.
   b. Make sure that the power-indicator LED on the power supply is not illuminated.

2. Remove the supply-gas pressure from the cutting system.

3. Remove the cover from the box at the rear of the power supply (Figure 2). Examine the interior panels of the box. Look for 2 sets of pre-installed studs on the top-center and right-side panels.
   a. If you find the 2 sets of studs, skip to step 6 on page 11.
   b. If there are no studs, complete step 4 and step 5 before continuing with step 6 on page 11.
   NOTICE
   THE DRILL-HOLE LOCATIONS CAN BE BAD IF THE TEMPLATES ARE INCORRECTMake sure to use the correct templates. Templates that are the incorrect type or size will cause incorrect measurements for drilling.
   If you print templates from an electronic copy of this document, make sure to use the “Actual Size” printer setting. Do not scale or re-size templates when you print them from an electronic copy.

4. Complete the following steps to drill 2 holes in the right-side panel of the box:
   a. Remove Template A from this document. Fold or cut the template where indicated.
   b. Put the template over the right-side panel of the box. Make sure that the template is aligned with the bottom-right corner of the panel. For information about how to use the template, refer to Template A instructions (right-side panel) on page 21.
   c. Use the location of the drill holes on the templateto find the correct location for the drill holes on the panel.
   d. Use a 5/16-inch drill bit to drill2 holes in the panel where indicated on the template.

5. Complete the following steps to drill 2 holes in the top-center panel of the box:
   a. Remove Template B from this document. Fold or cut the template where indicated.
   b. Put the template over the top-center panel of the box. Make sure that the template is aligned with the right corner of the panel. For information about how to use the template, refer to Template B instructions (top-center panel) on page 25.
   c. Use the location of the drill holes on the template to find the correct location for the drill holes on the panel.
   d. Use a 5/16-inch drill bit to drill 2 holes in the panel where indicated on the template.
   To make the drilling cleaner and easier, use a smaller drill bit before using the 5/16-inch drill bit.

6. Obtain the inrush circuit assembly (229579) from this kit.

7. If there are no pre-installed studs (refer to step 3 on page 10), complete the following steps to install the inrush circuit assembly (229579), as shown in Figure 3:
   a. Obtain the 4 sheet-metal screws (075241) and the 4 hex nuts (075161) from this kit.
   b. Align the inrush circuit assembly (229579) with the holes you drilled in step 4 and step 5.
   c. Use a screwdriver and 3/8-inch wrench to tighten the sheet-metal screws and hex nuts and install the bracket.

8. If pre-installed studs are found (refer to step 3 on page 10), complete the following steps to install the inrush PCB bracket (101507), as shown in Figure 3:
   a. Obtain the 4 hex nuts (075161) from this kit. The 075241 sheet-metal screws are not necessary for installation with pre-installed studs.
   b. Find the slots that are on the inrush assembly bracket. Move the bracket into position over the studs that are on the panels inside the box.
   c. Use a 3/8-inch wrench to tighten the 4 hex nuts and install the bracket.
   

9. Use a 7/16-inch wrench to remove the washer nut that holds the mounting bracket for the main contactor, as shown in Figure 4. Save this washer nut for re-use with the new inrush PCB.
   

10. Put the inrush PCB mounting bracket (101507) with pre-installed inrush PCB (141558) on top of the washer-nut stud 2 , as shown in Figure 5.
    

11. Use a 7/16-inch wrench to install the washer nut and temporarily hold the main contactor mounting bracket and pre-installed inrush PCB in the power supply.

12. Use the PCB wire harness (229971) from this kit to connect the J8.2 connector 3 on the wire harness to the J2 connector on the newly-installed inrush PCB, as shown in Figure 6.

Connect the inrush circuit and inrush PCB to the main contactor

1. Complete the following steps to connect the red, blue, and green wires from the top of the small contactor to the right side of the main contactor:
   a. If the connections on the main contactor are exposed, as shown in Figure 7, use 2 3/8-inch wrenches to remove the bolt (closest to the rear-box cover that was removed in step step 3 on page 10).
   b. If the connections on the main contactor are not exposed, as shown in Figure 8, use a 6 mm hex wrench to remove the screw (closest to the rear-box cover that was removed in step step 3 on page 10).
   c. Connect the red wire (L1) from the small contactor to the main contactor where the bolt or screw was just removed.
   d. Re-connect all L1 wires that were previously connected to the main contactor.
   Figure 7 – The small contactor connected to the main contactor (connections exposed)
   
   

2. Complete the following steps to connect the blue and green wires from the top of the small contactor:
   a. Connect the blue wire (L2) from the small contactor to the middle connection on the main contactor.
   b. Re-connect all L2 wires that were previously connected to the main contactor.
   c. Connect the green wire (L3) from the small contactor to the connection on the main contactor that is closest to the rear panel of the power supply.
   d. Re-connect all L3 wires that were previously connected to the main contactor.

3. Make sure that the red, blue, and green wires from the bottom of the small contactor are connected to the corresponding-colored wires on the right sides of the resistors, as shown in Figure 9:

   • The red wire (L1) is attached to the top resistor.
   • The blue wire (L2) is attached to the middle resistor.
   • The green wire (L3) is attached to the bottom resistor.
     

4. Examine the wire connections on the resistors. Look for loose connections. Use a number 2 Phillips screwdriver and a 3/8-inch wrench to tighten loose connections if found.

5. Complete the following steps to connect the red, blue, and green wires from the left sides of the resistors to the left side of the main contactor, as shown in Figure 10:
   a. If the connections on the main contactor are exposed, use 2 3/8-inch wrenches to remove the bolt (closest to the rear-box cover that was removed in step step 3 on page 10).
   b. If the connections on the main contactor are not exposed, use a 6 mm hex wrench to remove the screw (closest to the rear-box cover that was removed in step step 3 on page 10).
   c. Connect the red wire (L1) from the top resistor to the main contactor where the bolt or screw was just removed.
   d. Re-connect the L1 wires that were previously-connected to the main contactor.

6. Complete the following steps to connect the wires from the middle and bottom resistors:
   a. Connect the blue wire (L2) from the middle resistor to the middle connection on the main contactor.
   b. Re-connect all L2 wires that were previously-connected to the main contactor.
   c. Connect the green wire (L3) from the bottom resistor to the connection on the main contactor that is near the rear panel of the power supply.
   d. Re-connect all L3 wires that were previously-connected to the main contactor.

7. Examine the wire connections on the resistors. Look for loose connections. Use a number 2 Phillips screwdriver and a 3/8-inch wrench to tighten loose connections if found.
   

8. Use a number 2 Phillips screwdriver to disconnect the 2 red and red/black coil wires from the left side of the main contactor, as shown in Figure 11. The red/black wire is labeled A1. The red wire is labeled A2.

9. Examine the rear panel of the power supply. Look for the cable ties used to bundle or shorten the A1 and A2 wires . Cut the cable ties to release the A1 and A2 wires before continuing with the next step.
   

10. Use a number 2 Phillips screwdriver to connect the A1 and A2 wires from the J8.2 PCB wire harness to the coil terminals on the small contactor to the bottom of the small contactor, as shown in Figure 12.
    

11. Look for the red and red/black coil wires labeled B1 and B2 from the J8.2 PCB wire harness.

12. Use a number 2 Phillips screwdriver to connect the A1 and A2 fork-terminal connectors (refer to step 9 on page 9) to the terminal block on the inrush PCB, as shown in Figure 13.
    

13. Use the cable ties (343003) from this kit to hold the red and red/black B1 and B2 wires, and any other loose wires,in position near the rear panel of the power supply. Connect the cable ties from this kit to the rear panel. Make sure that all wires are tightly held in position.
    WARNING
    FAILURE TO CORRECTLY INSTALL WIRES AND CONNECTIONS CAN CAUSE ELECTRIC SHOCKS AND FIRES
    Make sure to follow the steps in this manual about how to correctly install wires and connections. Make sure that connections are tight. Make sure that all wires are tightly held in position. Failure to correctly install wires and connections can cause electric shocks and fires.

14. Make sure that the L1, L2, and L3 wires are correctly installed:

    • The wires do not cross on either side of the main contactor.
    • The wires are connected exactly as shown in Figure 14.
    • The wires are tightly held in position near the rear panel of the power supply.
      

15. Use a 7/16-inch wrench to remove the washer nut used to temporarily hold the PCB mounting bracket (refer to step 11 on page 12).

16. Put the inrush PCB cover (101506) from this kit on top of the inrush PCB-mounting bracket assembly, as shown in Figure 15. Make sure that the cover does not pinch any wires.
    

17. Use a 7/16-inch wrench to install the washer nut and permanently hold the inrush PCB cover, mounting bracket, and inrush PCB in position.

18. Collect the 3 wires from the newly-installed inrush PCB-bracket assembly. Move the wires on top of the cover. Use the cable holder, pre-installed on the inrush PCB cover, to hold the wires, as shown in Figure 16.
    

19. Use a 3/8-inch nut driver to install the cover on the box on the rear of the power supply, as shown in Figure 17. Make sure the cover does not pinch any wires.

20. Restore the supply-gas pressure to the cutting system.

21. Restore power to the cutting system:
    a. Set the line-disconnect switch to the ON position.
    b. Make sure that the power indicator LED on the power supply is illuminated.

Addendum – measurements for drilling

NOTICE
THE DRILL-HOLE LOCATIONS CAN BE BAD IF THE TEMPLATES ARE INCORRECT
Make sure to use the correct templates. Templates that are the incorrect type or size will cause incorrect measurements for drilling.
If you print templates from an electronic copy of this document, make sure to use the “Actual Size” printer setting. Do not scale or re-size templates when you print them from an electronic copy.

If you are unable to use the Template A and Template B sheets included in this document, you can use the following measurements (Figure 18) to find the correct locations to drill the holes.

Template A instructions (right-side panel)

1. Remove the Template A sheet from this document. Fold or cut the template where indicated.
2. Put the template over the right-side panel of the box, as shown in Figure 19. Make sure that the template is aligned with the bottom-right corner of the panel.
3. Use the location of the drill holes on the template to find the correct location for the drill holes on the panel.
4. Use a 5/16-inch drill bit to drill 2 holes, based on their location on the template.

NOTICE
THE DRILL-HOLE LOCATIONS CAN BE BAD IF THE TEMPLATES ARE INCORRECT
Make sure to use the correct templates. Templates that are the incorrect type or size will cause incorrect measurements for drilling.
If you print templates from an electronic copy of this document, make sure to use the
“Actual Size” printer setting. Do not scale or re-size templates when you print them from an electronic copy.

Template A

Template B instructions (top-center panel)

1. Remove the Template B from this document. Fold or cut the template where indicated.
2. Put the template over the top-center panel of the box, as shown in Figure 20. Make sure that the template is aligned with the right corner of the panel. This is the corner that is near the rear-box cover.
3. Use the location of the drill holes on the template to find the correct location for the drill holes on the panel.
4. Use a 5/16-inch drill bit to drill 2 holes in the panel, based on their location on the template.

NOTICE
THE DRILL-HOLE LOCATIONS CAN BE BAD IF THE TEMPLATES ARE INCORRECT
Make sure to use the correct templates. Templates that are the incorrect type or size will cause incorrect measurements for drilling.

If you print templates from an electronic copy of this document, make sure to use the “Actual Size” printer setting. Do not scale or re-size templates when you print them from an electronic copy.

Template B

Documents / Resources

| Hypertherm HPR400XD Plasma Cutters [pdf] Instruction Manual
HPR400XD, HPR800XD, Plasma Cutters
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References

• Plasma, waterjet and laser cutting systems from Hypertherm
• Plasma, waterjet and laser cutting systems from Hypertherm
• Hypertherm Associates
• Plasma, waterjet and laser cutting systems from Hypertherm
• Hypertherm Associates

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