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 –
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 cooler.

    Make sure that no objects cause a blockage to the cooler fan inlets. Objects that are very near the cooler can get pulled into the fan inlets.

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

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

    If the temperature around the cooler 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 from the cooler.
  7. Make sure that each heat-exchanger fan has no visible obstruction, dust, or debris.
    • Use compressed air to clean this area, if necessary. 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.
    • Also make sure to fully install the panels on the cooler. When there are no side panels, there is no air flow across the heat exchanger, which prevents the system from becoming cool.
  8. Measure the resistance for the thermistor:
    1. To measure the resistance for a chopper thermistor, disconnect the connector for that chopper in the plasma power supply.
    2. To measure the resistance for the coolant thermistor, remove the coolant thermistor wires from the connector in the cooler.

      Doing these steps makes it easier to measure only the resistance for the thermistors.

    3. 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
      560, 667, 678 Chopper 1 (cold plate) PCB 2 (plasma power supply) J9 pin 1 J9 pin 2
      561, 668, 679 Chopper 2 (cold plate) (XPR300 and XPR460 only) PCB 3 (plasma power supply) J9 pin 1 J9 pin 2
      562, 669, 680 Chopper 3 (cold plate) (XPR460 only) PCB 8 (plasma power supply) J9 pin 1 J9 pin 2
      587, 670, 681 Heat exchanger PCB 2 (cooler) J2.4 pin 1 J2.4 pin 2
    4. 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).

      85 750 1250
      95 600 1000
      105 400 800
      115 300 600
      125 200 500
      135 150 400
      145 150 250
      155 125 225
      165 100 175
    5. 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. To make a decision on if thermistor replacement 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 ≤ 75°C (167°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 ≤ 75°C (167°F).
      • Replace chopper 1 (PCB 2) for diagnostic code 560.
      • Replace chopper 2 (PCB 3) for diagnostic code 561.
      • Replace chopper 3 (PCB 8) for diagnostic code 562.
      • 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. To make a decision on if 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.