Troubleshooting for over-temperature faults for choppers and coolant

Diagnostic codes 560 – 562, 587

Diagnostic codes 560 – 562 and 587 identify an over-temperature condition with choppers or coolant. The result can be:
  • Potential damage to system components
  • Decreased cut quality
  • Safety risks because of the system operating outside of its safe temperature range

Symptoms

Code Symptoms XPR® models XPR action Code cancels with...
560 The Insulated-gate Bipolar Transistor (IGBT) temperature for Chopper 1 is more than 75°C (167°F). All models Ramp down Temperature is in range
561 The IGBT temperature for Chopper 2 is more than 75°C (167°F). XPR300®, XPR460®
562 The IGBT temperature for Chopper 3 is more than 75°C (167°F). XPR460
587

XPR170® and XPR300: The coolant temperature in the plasma power supply is more than 85°C (185°F).

XPR460: The coolant temperature in the cooler is more than 75°C (167°F).

 All models

Corrective action

  1. Make sure that there is sufficient clearance around the plasma power supply.

    For sufficient ventilation, Hypertherm® recommends a minimum separation distance of 1 meter (3.3 feet) between the plasma power supply and other objects or equipment.

  2. Make sure that the ambient temperature at the location of the plasma power supply is in the permitted temperature range for cutting system operation.

    If the temperature around the plasma power supply is more than the temperature limit, you can get reduced performance and over-temperature diagnostic codes.

  3. While all of the fans continue to operate, let the temperature of the cutting system decrease.
  4. From the XPR web interface, make sure that the heat-exchanger fan speed is in the permitted range.
    Fan type Permitted range of speed
    Large fans (254 mm / 10 inch) 2,800 RPM – 3,400 RPM
    Small fans (120 mm / 4.7 inch) 5,600 RPM – 6,400 RPM
  5. If the fan speed is in the permitted range, remove the power from the cutting system.
  6. Remove the pump-side panel and the front panel from the plasma power supply.
  7. Make sure that each heat-exchanger fan has no visible obstruction, dust, or debris.
    • The heat-exchanger area can collect large amounts of dust or debris. Multiple uses of compressed air is often necessary to clean this area. Use personal protective equipment for protection from airborne particulates and debris.
    • Make sure to keep fan rotation to a minimum during compressed air use. You can use a gloved hand to hold a fan in position, if necessary.
  8. Measure the resistance for the thermistors:
    1. Disconnect the connector for each chopper, or remove the chopper thermistor wires from the connector.

      Doing this step makes it easier to measure only the resistance for the thermistors.

    2. Use a digital multimeter to measure the resistance from each thermistor wire, using these diagnostic codes and connector-pin locations:
      Diagnostic code Thermistor location Location of thermistor wires / connector Pins
      587, 670, 681 Heat exchanger, top PCB 1 J1.2 pin 7 J1.2 pin 8
      560, 667, 678 Chopper 1 (cold plate) PCB 2 J9 pin 1 J9 pin 2
      561, 668, 679 Chopper 2 (cold plate) (XPR300 and XPR460 only) PCB 3 J9 pin 1 J9 pin 2
    3. Look for a resistance value that is outside of the minimum or maximum values in Ohmic resistance values for thermistors.

      At approximately 25°C (77°F), look for a resistance of approximately 10,000 ohms (Ω).

    4. For each resistance value that you measure, do the following:
      If you see this condition...Do these steps...
      The resistance value is outside of the minimum or maximum value in Ohmic resistance values for thermistors. Look for a wiring fault. Possible replacement of a thermistor is necessary. Speak to your cutting machine supplier or regional Hypertherm Technical Service team.
      The resistance value is approximately 0 ohms (Ω).
      1. Examine the wiring between each thermistor and its connector pins.
      2. Look for shorts between wires or to the ground.
      The resistance value is more than 100 ohms (Ω) and less than the minimum resistance value.
      1. Remove the power from the cutting system.
      2. Let the coolant get to a temperature that is ≤ 85°C (185°F).
      3. Supply power to the cutting system.
      4. Go back to the beginning of step 8.
      The resistance continues to be less than the minimum ohmic value or does not change after the coolant is ≤ 85°C (185°F).
      • Replace chopper 1 (PCB 2) for diagnostic code 560.
      • Replace chopper 2 (PCB 3) for diagnostic code 561.
      • Replace the copper pipe thermistor assembly for error code 587.
      The thermistor resistance is in the permitted range when the thermistor is disconnected from the control Printed Circuit Board (PCB), and the code continues when the thermistor is reconnected to the control PCB. Possible replacement of the control PCB is necessary. Speak to your cutting machine supplier or regional Hypertherm Technical Service team.
      The resistance is in the permitted range. You can continue to operate the plasma cutting system.
  9. If you cannot find or correct the problem, speak to your cutting machine supplier or regional Hypertherm Technical Service team.