Troubleshooting for over-temperature faults for inductors and transformers

Diagnostic codes 580 – 586, 589, 793

These over-temperature diagnostic codes identify when the temperature of the inductors or transformers in the plasma system is more than the permitted range.

Symptoms

Code Symptoms XPR® models XPR action Code cancels with...
580
The temperature of one of the following inductors is more than 160°C (320°F):
  • Inductor 1 (1A)
  • Inductor 2 (1B)
  • Inductor 3 (2A)
  • Inductor 4 (2B)
  • Inductor 5 (3A)
  • Inductor 6 (3B)

When conditions are normal, approximately 10 minutes are necessary for the plasma cutting system to become cool. Over-temperature diagnostic codes can occur when more than 10 minutes are necessary for the temperature of the plasma system to decrease.

A high ambient temperature can have an effect on cooling time.

 All models Ramp down Temperature is in range
581
582 XPR300®, XPR460®
583
584 XPR460
585
586 For a minimum of 5 seconds, the temperature of a transformer is more than 160°C (320°F). All models
589 XPR460
793 For a minimum of 5 seconds, the temperature of the control transformer is more than 160°C (320°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 your plasma power supply is more than the temperature limit, you can get reduced performance and over-temperature diagnostic codes. Refer to Plasma power supply general specifications.

  3. While all of the fans continue to operate, let the temperature of the cutting system decrease.
  4. Make sure that the magnetics are at a temperature of ≤160°C (320°F) before you continue with the next step.
  5. Without removing the external side panel on the plasma power supply, look through the ventilation trusses on the plasma power supply to examine the magnetics fans inside.

    Look through the ventilation trusses on the front of the plasma power supply to see the magnetics fans (254 mm / 10 inches) inside. It is not necessary to remove the external panels to see these fans. The magnetics fans are near the front and bottom.

  6. From the XPR web interface, make sure that the speed for each magnetics fan is in the permitted range.

    During normal operation, it can be difficult to see individual blades because of the fast speed of the fan rotation. If you can easily see individual blades without the use of a strobe lamp, the rotation speed is possibly too slow.

    Fan type Permitted range of speed
    Large fans (254 mm / 10 inches) 2,800 RPM – 3,400 RPM
    Small fans (120 mm / 4.7 inches) 5,600 RPM – 6,400 RPM
  7. If the speed of the fans is less than the permitted range, remove the electric power from the cutting system.
  8. Remove the front panel from the plasma power supply.
  9. If you find obstructions, debris, or dust, use compressed air to remove the obstruction, debris, or dust from the fans and from the magnetics area.

    The magnetics 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.

  10. If the magnetics fans have no visible obstruction, dust, or debris:
    1. Disconnect the connector from the control Printed Circuit Board (PCB) (for the magnetics).
    2. Use a digital multimeter and the following connector-pin locations to measure the resistance from each thermistor wire:

      Thermistors are on the magnetics.

      Diagnostic codes Thermistor location Location of thermistor wires/connector 1st connector pin 2nd connector pin
      580, 660, 671 Inductor 1A PCB 1 (plasma power supply) J1.4 pin 3 J1.4 pin 4
      581, 661, 672 Inductor 1B PCB 1 (plasma power supply) J1.4 pin 5 J1.4 pin 6
      582, 662, 673 Inductor 2A PCB 1 (plasma power supply) J1.4 pin 7 J1.4 pin 8
      583, 663, 674 Inductor 2B PCB 1 (plasma power supply) J1.2 pin 1 J1.2 pin 2
      584, 664, 675 Inductor 3A PCB 1 (plasma power supply) J1.2 pin 3 J1.2 pin 4
      585, 665, 676 Inductor 3B PCB 1 (plasma power supply) J1.2 pin 5 J1.2 pin 6
      586, 666, 677 Transformer 1 PCB 1 (plasma power supply) J1.4 pin 1 J1.4 pin 2
      589, 682 , 683 Transformer 2 PCB 1 (plasma power supply) J1.25 pin 1 J1.25 pin 2
      791, 792, 793 Control transformer PCB 1 (plasma power supply) J1.25 pin 3 J1.25 pin 4
    3. Look for a resistance value from each thermistor wire that is outside of the minimum or maximum value 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 ohmic resistance is outside of the minimum or maximum value in Ohmic resistance values for thermistors. Look for a wiring fault. Possible replacement of a thermistor can be 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 thermistor resistance is in the permitted range when the thermistor is disconnected from the control PCB, and the code continues when the thermistor is reconnected to the control PCB. Possible replacement of the control PCB can be necessary. Speak to your cutting machine supplier or regional Hypertherm Technical Service team. Refer to Plasma power supply control PCB (141545) diagram.
  11. If you cannot find or correct the problem, speak to your cutting machine supplier or regional Hypertherm Technical Service team.