Troubleshooting for process-gas inlet pressure faults in the TorchConnect console for OptiMix systems

Diagnostic codes 702, 705, 769, and 770

The 702, 705, 769, and 770 diagnostic codes identify a problem with the process-gas inlet pressure. Process-gas inlet pressure has an effect on cut quality, cut speed, and consumable life.

The nitrogen (N2) and Argon (Ar) gas regulators inside the OptiMix™ gas connect console are set at Hypertherm® before the regulators are installed in the gas connect console. The regulators are set in a dynamic condition, when gas is flowing, with 7.9 bar – 8.6 bar (115 psi – 125 psi) on the inlet and 6.9 bar (100 psi) on the outlet. A downstream 1.6 mm (0.063 inch) orifice is part of both regulator setting configurations.

It can be necessary to adjust the regulators if the following conditions occur:
  • The N2 shield inlet (P4) pressure is more than 7.5 bar (110 psi) or less than 6.2 bar (90 psi).
  • The Ar shield inlet (P4) pressure is more than 7.5 bar (110 psi) or less than 6.2 bar (90 psi).

Symptoms

Code Symptoms XPR® models XPR action Code cancels with...
702 For a minimum of 200 milliseconds, the nitrogen (N2) inlet pressure (P4) in the TorchConnect™ console is less than 5.52 bar (80 psi) or more than 8.61 bar (125 psi). All models None
  • Set process
  • Remote on-off
705 For a minimum of 200 milliseconds, the argon (Ar) inlet pressure (P4) in the TorchConnect console is less than 5.52 bar (80 psi) or more than 8.61 bar (125 psi).
769 Line B Argon inlet pressure (P1) is less than 5.52 bar (80 psi) or more than 8.62 bar (125 psi).
770 Line B N2 inlet pressure (P1) is less than 5.52 bar (80 psi) or more than 8.62 bar (125 psi).

Corrective action to adjust the N2 regulator

  1. Install one of the following sets of consumables:
    • 460 A O2/Air
    • 460 A Mix/N2
    • 300 A O2/Air
    • 300 A N2/N2
    • 300 A Mix/N2
    • 170 A O2/Air
    • 170 A N2/N2
    • 170 A Mix/N2
  2. Use the XPR web interface to select one of the following processes:
    • 2100 for 300 A N2/N2 aluminum or stainless steel
    • 2057 for 170 A N2/N2 aluminum or stainless steel
  3. Remove the cover from the OptiMix gas connect console.
  4. Pull up the N2 regulator knob until the orange indicator is visible.
    Diagram showing the N2 and Ar regulator knobs in the gas connect console.
    1 Nitrogen (N2) regulator knob
    2 Argon (Ar) regulator knob
  5. Go to Gas System in the XPR web interface.
  6. Select TEST PREFLOW.
  7. While the gas flows, adjust the regulator until the shield inlet sensor (P4) on the web interface is 6.9 bar (100 psi).

    Oscillations in the flow rates in the mixer N2 line can occur when the N2 regulator in the gas connect console is set to too high of a pressure to the N2 shield line. Decrease the pressure output of this regulator to decrease the pressure oscillations.

Corrective action to adjust the Ar regulator

  1. Install one of the following sets of consumables:
    • 460 A O2/Air
    • 300 A O2/Air
    • 170 A O2/Air
  2. Use the XPR web interface to select one of the following processes:
    • 2074 for Mix/N2 (Ar pierce assist) stainless steel and aluminum
    • 1205 for O2/N2 mild steel
    • 1157 for O2/Air (Ar pierce assist) mild steel
  3. Remove the cover for the OptiMix gas connect console.
  4. Pull up the Ar regulator knob until the orange indicator is visible.
  5. Go to Gas System in the XPR web interface.
  6. Select TEST PIERCEFLOW.
  7. While the gas flows, adjust the regulator until the shield inlet sensor (P4) on the web interface is 6.9 bar (100 psi).