Hypertherm hsd130 interface

Yeah, somehow i managed to miss this.
When in doubt, more C4 !!!
Use relays as you have in the drawing for ARCOK, do not wire anything to Mesa, do a test cut and check if the relay closes while cutting. Do the same thing for TorchON but reversed, meaning contacts go to plasma and coil on the Mesa side but do not wire to Mesa just use whatever can give 15-24V and trigger the relay with it see if the torch fires. After this, you can wire stuff to Mesa, one at a time, test, wire, test....
As for the Arc Voltage, find the big rectifiers, usually with big aluminium heatsinks and find the positive and negative, wire two short wires to each, wire 2 of 1MOhm/2W resistors to each of those wires, on the other side of the resistors wire two thinner wires prefferably shielded and send those to Mesa THCAD, mind the polarity, although nothing will happen if you do mix the polarity but you will have no voltage reading on screen.
Make positively and ultimately sure you have the power cord and plug under your foot while adding this, i do that always to prevent someone somehow getting the idea that it belongs plugged to the wall...while i have both hands inside!

You rock. Thank you.

For the arc volts, from the torch-, it splits to two wires that go to 2 transformers? and then to the rectifier.
In the attached pic, I circled the torch- wire route in red and the work+ in white.
Should I just attach to one torch- wire at the rectifier or ?

Also, do you mean one 1Mohm/2w on each wire for a total of 2 resistors or two 1Mohm/2w on each wire for a total 4 resistors?

 

bentiggin wrote:

Also, do you mean one 1Mohm/2w on each wire for a total of 2 resistors or two 1Mohm/2w on each wire for a total 4 resistors?
 

1 resistor on each wire, two in total.
So my advice on wiring on the rectifier wont work as this seems to be an SCR controlled rectifier, but there is hope, wire resistors to the big terminals on the picture on the left side, use a DVM to find the torch and clamp connections, clamp will be positive and torch will be negative but you have to remove the torch cap to check as the outer torch nozzle is not connected to any of those.
Are the high voltage/high frequency parts on the other side of that metal wall?

I believe the high frequency parts are on the other side of the wall to the left. Pic attached of what i think is the high frequency parts.

The torch- and work+ have been identified so that shouldn't be a problem.

 

Yes, those are the "very very dangerous - you will most certainly die if you touch them while powered on and someone fires the torch" parts
Except, you do not necessarily have to touch them, even 1-3cm away can irrevocably cause death, depending on ambient moisture.
Again for clarity, do not wire anything on this side.

I finally got around to getting everything wired up enough to test.
At first, I couldn't get it to start using a relay and a power supply on a switch. I realized the manual says "or dry contact closer", so I wired the relay directly to start- pin 15 and start+ pin 34, which worked.

Now I can't get my arc ok signal. I followed the example wiring in the manual. I connected ark ok+ pin 23 to the relay. Then 24vdc+ pin 37 to the relay. Then ark ok- pin 4 to power ground pin 36.
Wired up like this, the arc will not start and the plasma cutter gives an error. If I disconnect the ground to ark ok- pin 4, the plasma will start without errors. I am getting 24 volts between power and ground, and the 2 ark ok pins will close the circuit when the arc starts.

I am attaching the examples from the manual plus diagram of how I wired the arc ok relay.
I may have wired it up like example 4(which it says don't use) a long time ago before I decided to remove the old interface connection on it, so maybe that messed it up.

Does my ark ok wiring seem right? Should I try wiring it differently or should I consider using a reed relay instead?