Hypertherm HPR260 Manual Gas Preventive Maintenance Program Rev.5 - Manual (Page 192)

MAINTENANCE
5-48 HPR260 Auto Gas Instruction Manual
5
Automatic chopper and current sensor tests during power-up
Turn ON the system. When the preflow starts, the contactor will close and the system will automatically test the
choppers and current sensors. The system closes the contactor and turns on chopper 1 at 90% duty cycle. The
chopper will charge the surge capacitor on the I/O board (PCB 6). The current that charges the capacitor should be
between 10 amps and 35 amps. Error code 105 will display on the CNC screen if the current is < 10 amps or there is
no feedback on current sensor 1 (CS1). Error code 103 will display on the CNC screen if the current is > 35 amps.
If chopper 1 passes the test, the system will repeat the test for chopper 2 and current sensor 2 (CS2). Error code 106
will display on the CNC screen if the current is < 10 amps. Error code 104 will display on the CNC screen if the
current is > 35 amps.
Look at the error codes displayed on the CNC screen. If the error code shown is 003, the choppers and current sensors
passed the test and no further tests are required.
If error code number 103, 104, 105, or 106 are displayed, continue with the tests below.
Troubleshooting low-current error code 105 and 106
1. Verify that the current sensors (CS1 and CS2) and
cables are not damaged.
2. Exchange CS1 and CS2. Replace the faulty sensor if
the error code is not displayed again.
3. Use a meter to measure the resistance between wire
38 and wire 39 on PCB6. The value should increase as
the capacitor charges. Replace PCB6 if a constant
value is seen.
4. Check for loose wires or shorts from the chopper to
PCB6.
5. Check for 220 VAC to 1A, 1B, and 1C on the chopper
when the contactor closes.
6. Verify that the fuses (F3 and F4) are in good working
condition.
CS1
CS3
F3
I/O board
(PCB6)
CS2
F4
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.