Hypertherm HSD130 HySpeed Plasma - Manual (Page 181)

MAINTENANCE
HySpeed HSD130 RHF Instruction Manual 5-35
Chopper tests
Test 1 – 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 chopper
and current sensors. The system closes the contactor and turns chopper channel 1 on 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 show in the AMPS display if the current is < 10 amps or there is no
feedback on current sensor 1 (CS1). Error code 103 will show in the AMPS display if the current is > 35 amps.
If Channel 1 passes the test, the system will repeat the test for channel 2 and current sensor 2. Error code 075 will
show in the AMPS display if the current is < 10 amps. Error code 107 will show in the AMPS display if the current is
> 35 amps.
Place the toggle switch in the ERROR position if the system completes the power-up sequence. If the system shows a
status of -03 the test has passed. The chopper and current sensors are OK.
Troubleshooting low-current error codes 75 and 105
1. Verify that the current sensor (CS1 or CS2) and the cables are not damaged.
2. Exchange CS1 and CS2 to see if the error code switches channels. Replace the faulty sensor if the channel
switches.
3. Measure the resistance between J6.2 and J6.3 on PCB6 with a meter. The value should be increasing as the
capacitor charges. Replace PCB6 if a constant value is seen.
4. Check for loose wires or opens from chopper to PCB6.
5. Check for 220 VAC to 1A, 1B, and 1C on the chopper when the contactor closes.
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.