Troubleshooting Error Code 020 Hypertherm HPR260XD
For maintenance personnel
What is Error Code 020?
The torch descends, touches the plate, rises to pierce height and then
retracts without making a pilot arc.
No current is detected from the chopper during arc initiation.
No pit is made
in the plate
What is arc initiation?
In a working machine arc initiation happens in three stages:
High frequency arc Pilot arc Transferred (cutting) arc
How are the arcs powered?
The high frequency arc is powered by the high frequency generator.
The pilot and cutting arcs are powered by the choppers.
High frequency arc Pilot arc Transferred (cutting) arc
What can the problem be?
Error Code 020 is described in the Maintenance section of the HPRXD
Instruction Manual and corrective actions are listed.
Consumable inspection
Improper or worn consumables can prevent a pilot arc from forming.
Please refer to the Tech Service Training “Consumable Inspection”
Inlet gas pressures
Confirm that you have proper inlet gas pressure.
Gas must be flowing for proper measurement.
For automatic gas delivery systems navigate to
the HPR diagnostics screen. Check inlet gas
pressure in “Test Preflow” and in “Test Cutflow”
For either type of gas
For manual gas systems check system, confirm that ALL
inlet gas pressure with Switch 7 inlet gas pressures are 115
in Preflow and in Cutflow PSI (8.3 Bar) [± 15%}
Gas tests
Perform the three gas system tests described in the Maintenance
section of the Instruction Manual
Manual Gas systems Automatic Gas systems
High frequency at the torch
Position the torch as far from the plate as possible
Set up the cutting system to fire the torch without doing an initial height
sense. (fire the torch in the air)
Observe the nozzle orifice
Use an inspection mirror if necessary
Further testing
If, after following the suggestions listed here, you still have an Error
Code 020 contact:
• Your maintenance department
• The cutting system manufacturer
• A Hypertherm Help Desk
Warning!!
The other tests described in the Instruction Manual and in
this presentation are to be performed by qualified service
personnel ONLY.
There are dangerous voltages, currents and pressures in
an HPRXD power supply.
Do not remove any console covers when power is
connected to the machine unless you have the required
training and certification.
High frequency
If you do not see the high frequency arc in the torch confirm
that it is being made in the high frequency console.
Remove power
Locate the console Turn the HPRXD off
Usually mounted on the back of the power Lock the handle of the
supply or on the cutting system gantry electrical supply box in
the OFF position
High frequency
The high frequency console
Remove the cover Locate the spark gaps
High frequency
Give the power supply a Start
Turn the plasma Press Start
power supply ON
Turn the electrical supply box ON
High frequency
Observe from a safe distance
Appears as a series of flashes
Maximum duration is .5 seconds
Inactive Active
High frequency
If the spark gaps are inactive check the high voltage
transformer.
Remove power
Turn the HPRXD off
Lock the handle of the
electrical supply box in
the OFF position
High voltage transformer
Determine if the primary coil is shorted or open
Disconnect the primary coil wires from the
rear side of the filter
If the coil has very low resistance (less
than 1 Ohm) it is shorted. Replace it.
If there is very high (more than a megohm)
the coil is open. Replace it
High voltage transformer
Measure the resistance of the secondary coil
Disconnect the secondary wires from the
circuit board
If the coil has very low resistance (less than 1
Ohm) it is shorted. Replace it.
If there is very high (more than a megohm) the
coil is open. Replace it
High voltage transformer
Confirm 120 VAC at the transformer after a start.
Beware of leakage (phantom) voltages
120 VAC is sent to the
transformer through a solid-
state device. Without a load
(connected through the filter
to the transformer) you will
see 120 VAC on this line
when the power supply is
on.
High voltage transformer
Confirm 120 VAC at the transformer after a start.
Connect the meter as shown.
Leave the primary coil
wires connected to the
filter and attach the
meter’s clip leads to the
filter connectors.
For maximum protection of
your meter disconnect the
secondary coil wires from
the circuit board
High frequency
Give the power supply a Start
Turn the plasma Press Start
power supply ON
Turn the electrical supply box ON
High voltage transformer
There should be very little voltage before a start
There should be 120 VAC for a maximum of .5 seconds
High voltage transformer
Set it to record the
maximum voltage
You may need to
set up your meter
to capture the Set the range
to Manual
highest voltage.
It may not record
the full 120 VAC
because of the
short time in has to
take the reading
Pilot arc circuit
The nozzle is connected to chopper positive temporarily
during arc initiation by the pilot arc relay
Negative lead
Negative
Pilot arc lead
Pilot arc relay
Positive
Chopper
Start circuit
Work (positive)
lead
Pilot arc relay
Be safe.
Remove power
Turn the HPRXD off
Lock the handle of the
electrical supply box in
the OFF position
Pilot arc relay
Remove the left (from front) side panel.
Locate the pilot arc relay cover and remove it.
High frequency
Give the power supply a Start
Turn the plasma Press Start
power supply ON
Turn the electrical supply box ON
Pilot arc relay
Confirm that the pilot arc relay closes after a Start is
received
The closure lasts a maximum of .5 seconds
Relay contacts open
Relay contacts closed
Pilot arc relay
Be safe.
Remove power
Turn the HPRXD off
Lock the handle of the
electrical supply box in
the OFF position
Pilot arc relay
If the relay doesn’t close check the resistance across to
relay’s coil
Disconnect wires 21 and 22 before measuring.
Pilot arc relay
Confirm that the coil is not open or shorted
If there is very high resistance (≥1M Ohm) replace the relay
If the coil resistance is very low (≤ 1 Ohm) replace the relay
Pilot arc relay
If the coil is not shorted or open check for the 120 VAC
activation voltage
Reconnect wires 21 and 22, attach your clip leads to the
connection with the relay coil.
High frequency
Give the power supply a Start
Turn the plasma Press Start
power supply ON
Turn the electrical supply box ON
Pilot arc relay
Set up your meter to capture the peak voltage
Maximum duration is .5 seconds
Leads test
If you have high frequency at the spark gaps but not at the
torch and the pilot arc relay closes check the continuity of
the lead set.
Leads test
Measure continuity through the pilot arc circuit.
Remove power
Turn the HPRXD off
Lock the handle of the
electrical supply box in
the OFF position
Leads test
Simulate the pilot arc relay being closed by placing jumpers
across both poles.
Leads test
Eliminate the Start Circuit by using a jumper or by
connecting both H8 and H9 to one of the studs.
OR
Leads test
Measure resistance between the nozzle and the table.
There should be less than 10 Ohms of resistance.
Start circuit
If you have continuity through the pilot arc circuit there still
could be a problem with the start circuit
Use the Start circuit test from the maintenance section of
the Instruction Manual to troubleshoot the assembly.
Start circuit
You can also eliminate the Start Circuit by using a jumper
or by connecting both H8 and H9 to one of the studs.
Reconnect power and try to make a pilot arc
If this solves the problem replace the Start Circuit
OR
Main contactor
Check the condition of the main contactor’s contact pads
Remove power
Turn the HPRXD off
Lock the handle of the
electrical supply box in
the OFF position
Main contactor
Even though the contactor is tested at power up it is
possible that it can’t carry sustained pilot arc current
Remove the top cover of the power supply.
Main contactor
Main contactor
Remove the contactor cover
Loosen only the two Phillips head screws
Main contactor
Use a small screwdriver to hold the spring clip away from
each contact so you can pull it out.
Inspect for excessive wear. These parts show very little wear
Main contactor
Typical contact wear
If the silver colored pads have eroded away replace the
contactor
New End of life
Contact pad
Main contactor
Reassemble the contactor
Make sure the ridges on the spring clips go between the two
ridges on the contacts.
The end
