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Hypertherm XPR170, Instruction Manual

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Hypertherm XPR170 Instruction Manual Download Page 151

Connect for Communication

4

XPR300

Instruction Manual

809480

151

How to connect to the plasma power supply with serial RS-422

For an example of a system diagram, refer to 

Serial RS-422 and discrete multi-system 

interface (Sheet 17 of 22)

 on page 433.

For serial RS-422 multi-drop (multi-system) addressing, refer to 

XPR serial RS-422 

multi-drop (multi-system) addressing

 in the 

CNC Communication Protocol for the XPR 

Cutting System

 (809810).

For information on signals and protocols, refer to 

XPR serial RS-422 communications

 and 

Serial RS-422 and EtherCAT commands

 in the 

CNC Communication Protocol for the XPR 

Cutting System

 (809810).

To use arc voltage control (AVC) with a serial RS-422 cutting system, you 
must install an additional PCB inside the plasma power supply. For 
information about how to install this board, refer to 

VDC3 board 

installation (for AVC with RS-422 and discrete-only)

 on page 158.

1.

Remove the rear panel of the plasma power supply. Refer to 

Remove the external panels from 

the system components

 on page 92.

2.

Put End A (

Figure 40

) of the serial RS-422 cable through the hole in the bottom of the rear 

compartment in the plasma power supply. Refer to 

Figure 41

 on page 153.

3.

Connect End A of the serial RS-422 cable to the correct connector on the control board in the 
plasma power supply:

For systems with multiple plasma power supplies, use the top connector (J12) for the 
CNC. Use the bottom connector (J13) to connect to the next plasma power supply.

For systems with only one plasma power supply, you can use either connector to 
connect to the CNC.

4.

Connect the End B (

Figure 40

) of the cable to the CNC.

5.

If you are only monitoring with RS-422 serial, you are done. If you want to operate the cutting 
system, go to 

step 6

.

6.

You must connect to the plasma power supply with discrete. Refer to 

How to connect to the 

plasma power supply with discrete

 on page 154.

Summary of Contents for XPR170

Page 1: ...XPR300 Instruction Manual 809480 REVISION 6 ENGLISH ...

Page 2: ...as proof of purchase in case of an insurance loss Go to www hypertherm com registration for easy and fast registration If you experience any problems with the product registration process please contact registration hypertherm com For your records Serial number __________________________________________________________________________ Purchase date _________________________________________________...

Page 3: ...XPR300 Instruction Manual 809480 REVISION 6 ENGLISH Original instructions November 2020 Hypertherm Inc Hanover NH 03755 USA www hypertherm com ...

Page 4: ...pertherm Inc Etna Road P O Box 5010 Hanover NH 03755 USA 603 643 3441 Tel Main Office 603 643 5352 Fax All Departments info hypertherm com Main Office Email 800 643 9878 Tel Technical Service technical service hypertherm com Technical Service Email 800 737 2978 Tel Customer Service customer service hypertherm com Customer Service Email 866 643 7711 Tel Return Materials Authorization 877 371 2876 F...

Page 5: ...ponibles para cada manual de la Biblioteca de documentos en www hypertherm com ET EESTI ESTONIAN HOIATUS Enne Hyperthermi mis tahes seadme kasutamist lugege läbi toote kasutusjuhendis olevad ohutusjuhised ning Ohutus ja vastavusjuhend 80669C Veejoa ohutuse ja vastavuse juhend 80943C ja Raadiosageduse hoiatusjuhend 80945C Ohutusjuhiste eiramine võib põhjustada vigastusi ja kahjustada seadmeid Juhis...

Page 6: ...ERTIZARE Înainte de utilizarea oricărui echipament Hypertherm citiți instrucțiunile de siguranță din manualul produsului manualul de siguranță și conformitate 80669C manualul de siguranță și conformitate Waterjet 80943C și din manualul de avertizare privind radiofrecvența 80945C Produsul poate fi însoțit de copii ale manualului în format tipărit și electronic De asemenea dumneavoastră puteţi obţin...

Page 7: ...lanan kılavuzların kopyalarını www hypertherm com adresindeki Documents library Dosyalar kitaplığı başlığından da elde edebilirsiniz VI TIẾNG VIỆT VIETNAMESE CẢNH BÁO Trước khi vận hành bất kỳ thiết bị Hypertherm nào hãy đọc các hướng dẫn an toàn trong hướng dẫn sử dụng sản phẩm của bạn Sổ tay An toàn và Tuân thủ 80669C Sổ tay An toàn và Tuân thủ Tia nước 80943C và Hướng dẫn Cảnh báo Tần số Vô tuy...

Page 8: ......

Page 9: ... reducing emissions SC 23 Mains supply SC 23 Maintenance of cutting equipment SC 23 Cutting cables SC 23 Equipotential bonding SC 23 Earthing of the workpiece SC 24 Screening and shielding SC 24 Warranty SC 25 Attention SC 25 General SC 25 Patent indemnity SC 25 Limitation of liability SC 25 National and local codes SC 25 Liability cap SC 26 Insurance SC 26 Transfer of rights SC 26 ...

Page 10: ... marks 36 Safety and EMC symbols and marks 36 IEC symbols 37 2 Qualifications and Requirements 39 Document requirements 39 Operator qualifications 40 Qualifications of service personnel 41 System electrical requirements 42 Code conformity 42 Input power requirements 42 General input power requirements 42 Plasma power supply 43 Line disconnect switch requirements 43 Circuit breaker and fuse require...

Page 11: ...nded configuration with the VWI or OptiMix gas connect console 59 Site requirements 60 Length requirements for hoses cables and leads 60 Bend radius requirements for hoses cables and leads 61 Maximum diameters for console to console lead sets 61 Distance requirements between high frequency leads and control cables 62 Distance requirements for ventilation and access 62 Distance requirements for com...

Page 12: ...re 97 Pilot arc coolant hose set and shield water assembly only for VWI and OptiMix 97 Power CAN and 5 gas assembly only for VWI and OptiMix 97 Oxygen hose blue 98 Nitrogen hose black 98 Air hose black 98 Hydrogen OptiMix only red 98 Argon VWI or OptiMix only black 98 F5 VWI or OptiMix only red 98 Shield water VWI or OptiMix only blue 98 Connect the plasma power supply and gas connect console Core...

Page 13: ...rations 138 Mild steel 30 A O2 O2 138 Mild steel 50 A O2 Air 138 Mild steel 80 A 130 A 170 A 220 A and 300 A O2 Air 139 Non ferrous stainless steel and aluminum example configurations 140 Non ferrous 40 A N2 N2 and Air Air 140 Non ferrous 60 A F5 N2 N2 N2 N2 H2O and Air Air 141 Non ferrous 80 A F5 N2 N2 N2 N2 H2O Air Air 142 Non ferrous 130 A N2 N2 H2 Ar N2 N2 N2 H2O 143 Non ferrous 170 A N2 N2 H2...

Page 14: ...iew 193 Internal ohmic contact sense 193 External ohmic contact sense 194 How to install a remote on off switch 196 Examples of output circuits 197 Examples of input circuits 198 5 Coolant Installation 199 Overview 199 How to fill the cutting system with coolant 200 6 Operation 203 Overview 203 Controls and indicators 204 Controls 204 CNC 204 Wireless device 204 Indicators 205 Power indicator LEDs...

Page 15: ...ous mild steel processes 219 Non ferrous stainless steel and aluminum processes 220 Stainless steel 221 Aluminum 222 Processes for special applications 223 Underwater cutting 223 Mirror cutting 224 Process selection 225 How to use process IDs to access optimal settings 225 Process ID offsets overrides 226 How to use cut charts 227 Process core thickness PCT 227 Process categories 227 How to select...

Page 16: ...o measure the pit depth of an electrode 252 How to do coolant maintenance 253 Estimate the total coolant volume for your cutting system 254 Replace all of the coolant 254 Remove old coolant from the coolant system 255 8 Diagnostics and Troubleshooting 259 Overview 259 Safety considerations 260 Initial inspection steps 261 Remove the power from the cutting system 261 Examine the PCBs 263 Measure th...

Page 17: ...terface 340 Do a container test 340 How to test continuity between the nozzle and workpiece 342 How to measure resistance from thermistors 345 How to do an ohmic contact test 347 PCB information 350 Plasma power supply power distribution PCB 141425 350 Plasma power supply control PCB 141322 351 DIP switch positions 353 Plasma power supply chopper PCB 141319 354 Plasma power supply start circuit PC...

Page 18: ...w 2 384 Front adapters and valves 385 Torch assembly 386 Torch bracket 387 Consumable starter kits 388 Mild steel consumable starter kit 428616 388 Stainless steel and aluminum consumable starter kit 428617 389 Mild steel consumable starter kit with torch 428618 390 Stainless steel and aluminum consumable starter kit with torch 428619 391 Other consumable and torch parts 392 Plasma power supply to...

Page 19: ...ons of warning label icons 405 10 Wiring Diagrams 407 Wiring diagram symbols 408 Valve states during operation 410 Valve states by process ID 410 Overview Sheet 1 of 22 417 Plasma power supply 1 Sheet 2 of 22 418 Plasma power supply 2 Sheet 3 of 22 419 Plasma power supply 3 Sheet 4 of 22 420 Plasma power supply 4 Sheet 5 of 22 421 Plasma power supply 5 Sheet 6 of 22 422 Plasma power supply 6 Sheet...

Page 20: ... system interface Sheet 18 of 22 434 EtherCAT connection to EDGE Connect TC Sheet 19 of 22 435 Discrete and serial RS 422 CNC connections Sheet 20 of 22 436 Discrete CNC connections Sheet 21 of 22 437 Wireless subsystem block diagram Sheet 22 of 22 438 ...

Page 21: ...s 52 Table 12 Purity measurement methods for coolant water 56 Table 13 Recommendations for where to position system components 60 Table 14 Length ranges for interconnect hoses cables and leads 60 Table 15 Maximum distance between the plasma power supply and controlling device 63 Table 16 Equipment to lift or move the plasma power supply 84 Table 17 Definitions of symbols on the label inside the pl...

Page 22: ...ts for ferrous mild steel processes 228 Table 31 Process category options and expected quality speed results for non ferrous processes 229 Table 32 Inspection preventive maintenance and cleaning tasks 238 Table 33 Inspection tasks for consumables 243 Table 34 PCB names and locations 264 Table 35 Diagnostic codes in the web interface 268 Table 36 Diagnostic codes 269 Table 37 Minimum and maximum oh...

Page 23: ...t User shall ensure that other equipment being used in the environment is compatible This may require additional protection measures h Time of day that cutting or other activities are to be carried out The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place The surrounding area may extend beyond the boundaries of the...

Page 24: ...onnection is not permitted the bonding should be achieved by suitable capacitances selected according to national regulations Note The cutting circuit may or may not be earthed for safety reasons Changing the earthing arrangements should only be authorized by a person who is competent to assess whether the changes will increase the risk of injury for example by allowing parallel cutting current re...

Page 25: ...erly packed to Hypertherm s place of business in Hanover New Hampshire or to an authorized Hypertherm repair facility all costs insurance and freight pre paid by the customer Hypertherm shall not be liable for any repairs replacement or adjustments of Products covered by this warranty except those made pursuant to this paragraph and with Hypertherm s prior written consent The warranty set forth ab...

Page 26: ...ein shall be null and void and you will have no further recourse against Hypertherm under the Warranty or otherwise Waterjet product warranty coverage Consumable parts are not covered by this warranty Consumable parts include but are not limited to high pressure water seals check valves cylinders bleed down valves low pressure seals high pressure tubing low and high pressure water filters and abra...

Page 27: ... system CNC torch lifter cutting table and other components Wet process Any process that uses water as a shield fluid Dry process Any process that does not use water as a shield fluid Ferrous Mild steel Non ferrous Stainless steel and aluminum Gases Hydrogen H2 argon Ar nitrogen N2 oxygen O2 water H2O F5 95 nitrogen 5 hydrogen Mixed fuel gas A mixture of H2 Ar N2 created in the OptiMix gas connect...

Page 28: ...ater injection and OptiMix Each type provides a different set of gas connection capabilities which provide selecting and metering functions for the gas control system The gas connect console has 2 printed circuit boards PCBs a control PCB and an ignition PCB If your XPR cutting system is equipped with an OptiMix gas connect console there is also a gas mixer that has its own control board A green p...

Page 29: ...wer supply part number varies The part number and specifications can differ for your plasma power supply Refer to Table 1 on page 30 and Table 2 on page 31 for part numbers and specifications 81 70 cm 32 17 in 127 28 cm 50 11 in 124 76 cm 49 12 in 590 kg 1 300 lb ...

Page 30: ... that use water as a shield fluid 10 C 40 C 14 F 104 F Applies only to cutting systems that do not use water as a shield fluid Note Only VWI and OptiMix equipped cutting systems can use water as a shield fluid Idle state power consumption CE models 87 85 W Power source efficiency at rated maximum output power CE models 91 8 Power factor cosθ 0 98 at 66 5 kW Cooling Forced air Class F Insulation Cl...

Page 31: ...nt at 66 5 kW output A I1 Regulatory approval Safety EMC Power kVA 10 U1 X I1 X1 73 078620 200 3 50 60 218 cCSAus 75 4 078621 208 60 209 cCSAus 078622 220 50 60 198 cCSAus 078623 240 60 181 cCSAus 078624 380 50 60 115 CCC 078625 400 50 60 109 CE RCM EAC UKr and AAA 078626 415 50 105 CE RCM EAC UKr and AAA 078627 440 60 99 cCSAus 078628 480 60 91 cCSAus 078629 600 60 73 cCSAus ...

Page 32: ...t console part numbers and dimensions For mounting dimensions refer to Gas connect console on page 85 1 2 3 Varies Refer to Table 3 1 2 3 1 2 3 Core VWI OptiMix 4 4 4 Gas connect console Part number Dimension Dimension Dimension Dimension with fittings Weight Core 078631 374 65 mm 14 75 in 383 80 mm 15 11 in 205 99 mm 8 12 in 431 80 mm 17 00 in 16 24 kg 35 80 lb VWI 078632 522 22 mm 20 56 in 19 12...

Page 33: ...s is on the bottom of the torch connect console However you can move the mounting brackets to either side Console placement with the torch lead connection on the bottom can minimize the risk of leaked water or coolant collecting inside of the console Water or coolant collection inside of the TorchConnect console can damage internal electrical components For mounting dimensions refer to TorchConnec...

Page 34: ...surface length Overall sleeve length Combined weight torch head receptacle consumables Combined weight with sleeve Short 111 7 mm 4 4 in 155 mm 6 1 in 1 4 kg 3 lb 1 5 kg 3 3 lb Standard 189 6 mm 4 5 in 233 mm 9 2 in 1 6 kg 3 6 lb Extended 268 1 mm 10 6 in 311 mm 12 3 in 1 7 kg 3 9 lb Varies Clamp surface length Overall sleeve length 160 8 mm 6 33 in Rated arc striking voltage 15 3 kV Maximum gas p...

Page 35: ...Borate All printed circuit boards torch torch mounting sleeve Magnesium Heatsinks cold plates Natural graphite Pump motor resistors Phosphorus Sheet metal panels Rare earth elements heavy and light Torch breakaway pump motor Silicon metal Heatsinks cold plates transformers inductors IGBT modules Tantalum Capacitors Tungsten Power resistors ...

Page 36: ...Low Voltage Directive the European Electromagnetic Compatibility EMC Directive the Radio Equipment Directive RED and the Restriction of Hazardous Substances RoHS Directive See the European CE Declaration of Conformity for details Eurasian Customs Union CU mark CE versions of products that include an EAC mark of conformity meet the product safety and EMC requirements for export to Russia Belarus an...

Page 37: ...e control labels and switches Direct current DC Alternating current AC Plasma torch cutting Gouging AC input power connection The terminal for the external protective earth PE conductor I Power is ON O Power is OFF A 1 phase or 3 phase inverter based power source Volt amperage curve drooping characteristic f1 f2 1 ...

Page 38: ...Specifications 1 38 809480 Instruction Manual XPR300 ...

Page 39: ...e Maintenance Program PMP Instruction Manual 809490 XPR Firmware Updates Field Service Bulletin 809820 You can find these documents on the USB memory stick that came with your plasma power supply If you do not have these documents technical documentation is available at www hypertherm com docs Technical documentation is current as of the date of its release Subsequent revisions are possible Refer ...

Page 40: ...al 80669C and on the labels that are on the cutting system Get adequate operator training from a knowledgeable source before operation Adequate training topics include but are not limited to the following How to start and stop the cutting system during routine operation and in an emergency Conditions and actions that can cause injuries to people or damage cutting system equipment How to operate al...

Page 41: ... any service or maintenance on the cutting system or equipment The entity responsible for workplace safety where your XPR300 cutting system is used must do a risk assessment and establish the criteria for service personnel training and qualifications Do not do any service or maintenance on the cutting system or equipment if you cannot follow all of the safety instructions or if you cannot satisfy ...

Page 42: ...stem installation and operation at the installation site The switches fuses and cords that you supply must satisfy all applicable national and local electrical codes and requirements and be installed by a licensed electrician General input power requirements appear in Table 6 For specific requirements for switches fuses and cords refer to Line disconnect switch requirements on page 43 Circuit brea...

Page 43: ...efer to Line disconnect switch requirements on page 43 Always follow the local and national electrical safety requirements for your location including requirements for correct electrical system design and installation Contact a licensed electrician for more information about the codes in your location Line disconnect switch requirements As an installer or user you must supply a separate line disco...

Page 44: ...nstallation Contact a licensed electrician for more information about the codes in your location If time delay high inrush fuses are not permitted at your site because of national or local codes use a motor start circuit breaker or equivalent Main power cord requirements As an installer or user you must supply the main power cord for your cutting system Refer to Table 6 on page 43 for recommended ...

Page 45: ...efer to How to install a remote on off switch on page 196 WARNING ELECTRIC SHOCK CAN KILL The plasma power supply contains dangerous electric voltages that can seriously injure or kill you Even if the plasma power supply is turned OFF you can still get a serious electric shock if the plasma power supply remains connected to an electric power source When the remote on off switch is in the OFF posit...

Page 46: ...O2 oxygen 99 5 pure clean dry oil free Core VWI 7 5 bar 0 4 110 psi 5 OptiMix 7 9 bar 0 4 115 psi 5 71 slpm 150 scfh N2 nitrogen 99 99 pure clean dry oil free Core VWI 7 5 bar 0 4 110 psi 5 OptiMix 8 3 bar 0 4 120 psi 5 181 slpm 380 scfh Air Clean dry oil free consistent with 8573 1 2010 Class 1 4 2 Core VWI 7 5 bar 0 4 110 psi 5 OptiMix 7 9 bar 0 4 115 psi 5 118 slpm 250 scfh H2 hydrogen 99 995 p...

Page 47: ...occur if oxygen is not removed Flashback arrestors are REQUIRED to stop the spread of fire to the supply gases unless a flashback arrestor is not available for a specific gas or pressure As an installer or user you must supply the exhaust ventilation and flashback arrestors for your cutting system You can get them from your cutting machine supplier HYDROGEN GAS CAN CAUSE AN EXPLOSION OR FIRE Hydro...

Page 48: ...iameter of at least 10 mm 0 375 inch for supply gas hoses that are 76 m 250 feet or less Table 8 on page 48 describes the recommended sizes for gas fittings Table 8 Recommended sizes for gas fittings The location of regulators and the number of elbow fittings can have an effect on inlet pressure If the inlet pressure for your cutting system is not within recommended specifications contact your cut...

Page 49: ...ose connections or hose fittings can crack or leak The wrong fittings can cause malfunctions with the internal valves because contaminants can enter the valves through damaged or loose fittings NOTICE DIRTY OILY AIR CAN CAUSE DAMAGE TO THE AIR FILTER BOWL Some air compressors use synthetic lubricants that contain esters Esters can damage the polycarbonates in the air filter bowl Add additional gas...

Page 50: ...ence the recommended inlet gas fittings for your gas connect console Refer to Table 8 Recommended sizes for gas fittings on page 48 Single stage gas regulation Reduces source gas pressure to the necessary delivery pressure in 1 step Delivery pressure is not tightly controlled with this type of gas regulation Good choice for generic applications and where fluctuations in source gas pressure are sma...

Page 51: ...al dissolved solids can be tested with a TDS meter Hypertherm Waterjet part number 1 13897 available from Hypertherm Water that does not meet minimum purity specifications can cause excessive deposits on the torch nozzle and shield These deposits can alter the water flow and produce an unstable arc Refer to Shield water requirements VWI and OptiMix on page 51 Quality Minimum and maximum pressure F...

Page 52: ...g system make sure to tighten all connections to the recommended torque specifications in Table 11 on page 52 Hoses are available from Hypertherm Refer to Water optional shield fluid blue on page 401 of the Parts List Additional regulator requirement for shield water optional Water pressure regulators are built into the VWI and OptiMix gas connect consoles Additional water pressure regulators are ...

Page 53: ...source of compressed air that is clean and dry Use a regulator to adjust the compressed air to 5 52 bar 80 psi 3 Connect the compressed air hose to the water inlet on the gas connect console The air hose needs to adapt to a JIC 6 male fitting on the gas connect console 4 Use the XPR web interface or CNC to select a process ID for a water process such as 2028 5 Select Preflow from the Plasma Proces...

Page 54: ... data and information about how to handle and store coolant propylene glycol and benzotriazole You can find the MSDS and SDS online Technical documentation is available at www hypertherm com docs NOTICE LOW COOLANT LEVELS CAN DAMAGE THE CUTTING SYSTEM AND COOLANT PUMP Never operate the cutting system if you get a low coolant level notice There is a risk of serious damage to the cutting system and ...

Page 55: ...Hypertherm coolant 028872 according to the calculation below The maximum percentage of propylene glycol should never exceed 50 Refer to Estimate the total coolant volume for your cutting system on page 254 Coolant requirements for operation in temperatures above 40 C 104 F For operating temperatures above 40 C 104 F and that can never go at or below 0 C 32 F use treated water with no propylene gly...

Page 56: ...s for coolant water Always use water that meets the specifications in Table 12 on page 56 when using a custom coolant mix Water that is too pure can also cause problems Deionized water can cause corrosion in the coolant system After deionization add benzotriazole 128020 Use water purified by any method deionization reverse osmosis sand filters water softeners etc as long as the water purity meets ...

Page 57: ...onsole and torch use the following limitations and requirements Site requirements on page 60 Length requirements for hoses cables and leads on page 60 Bend radius requirements for hoses cables and leads on page 61 Distance requirements between high frequency leads and control cables on page 62 Distance requirements for ventilation and access on page 62 Distance requirements for communications on p...

Page 58: ...c control CNC lead 2 Work lead 3 Controller area network CAN cable 4 Power cable 120 VAC 5 Coolant hoses 1 supply 1 return 6 Pilot arc lead 7 Negative lead 8 Pilot arc and coolant hose set assembly a Pilot arc lead b Coolant hose set 1 supply 1 return 9 Power CAN 3 gas assembly c Power cable 120 VAC d CAN cable e 3 gas hoses Core 10 Torch lead 11 Regulators Position a gas regulator within 3 meters...

Page 59: ...ler area network CAN cable 4 Power cable 120 VAC 5 Coolant hoses 1 supply 1 return 6 Pilot arc lead 7 Negative lead 8 Pilot arc coolant hose set shield water assembly a Pilot arc lead b Coolant hose set 1 supply 1 return c Shield water hose VWI or OptiMix 9 Power CAN 5 gas assembly d Power cable 120 VAC e CAN cable f 5 gas hoses VWI or OptiMix 10 Torch lead 11 Regulators Position a gas regulator w...

Page 60: ... cables and leads that are the correct length Hoses cables or leads that are too short can cause restriction of mechanical movement Cables and leads that are too long can cause electromagnetic interference EMI EMI can have a negative effect on cut quality Contact your cutting machine supplier for recommendations about the best lead lengths for your cutting system Plasma power supply Level surface ...

Page 61: ...y hoses Maximum diameters for console to console lead sets The connectors for the console to console lead sets have the following maximum diameters 5 6 cm 2 2 in for the pilot arc coolant hose lead set 5 8 cm 2 3 in for the gas hose set For lengths refer to Gas connect console to torch connect console connections in Parts List on page 361 15 25 cm 6 in Minimum bend radius measured inside diameter ...

Page 62: ...C from the following CAN cable Power cable 120 VAC CNC lead EtherCAT serial RS 422 or discrete lead Distance requirements for ventilation and access Ventilation Do not block the ventilation louvers on the corners or bottom panels of the front and back of the plasma power supply A separation distance of least 1 m 3 3 feet is required for ventilation Do not block the ventilation louvers on the gas c...

Page 63: ...ess device manufacturers for wireless devices integrated into Hypertherm products can be found in the Downloads library at www hypertherm com The user of Hypertherm products that have integrated wireless devices is responsible for ensuring that each wireless device has been certified for the country of use and configured with the correct selection of frequency and channel for the country of use Wi...

Page 64: ...ng Does not interfere with the torch lifter The XPR torch mounting sleeve is larger than the torch mounting sleeve for HPR torches Modification or replacement of previous mounting hardware is necessary for XPR torches Mounting brackets are available from Hypertherm Refer to Torch bracket on page 387 of the Parts List Torch lifter requirements Choose a lifter that has a weight capacity of at least ...

Page 65: ... mixing setpoints Display settings The CNC must show the following data Plasma gas type Shield gas type Process ID selected System diagnostic codes Gas connect console firmware version Plasma power supply firmware version The CNC must show the following data in real time to troubleshoot and diagnose system operation Chopper current Work lead current System status codes Chopper temperature Transfor...

Page 66: ...ng The CNC must be able to execute the following commands to diagnose and troubleshoot system operation Test preflow gases Test pierceflow gases Test cutflow gases Test for gas system leaks For more information on CNC commands refer to the CNC Communication Protocol for the XPR Cutting System 809810 ...

Page 67: ...applies to the incoming line voltage It prevents a shock hazard to any personnel from any of the equipment or the cutting table It includes the service ground coming into the plasma system and other systems such as the CNC and the motor drives as well as the supplemental ground rod connected to the cutting table In the plasma circuits the ground is carried from the plasma system chassis to the cha...

Page 68: ... the PE ground must be connected to the cutting table ground bus bar using a minimum 21 2 mm2 4 AWG grounding cable 047031 Consult an electrician in your location to make sure that your grounding meets all local and national electric codes 5 For the most effective shielding use the Hypertherm CNC interface cables for I O signals serial communication signals between plasma systems in multi drop con...

Page 69: ...the table and do not need to connect to the table ground bus bar 14 If you are installing a voltage divider board mount it as closely as possible to where the arc voltage is sampled One recommended location is inside the plasma system enclosure If a Hypertherm voltage divider board is used the output signal is isolated from all other circuits The processed signal should be run in twisted shielded ...

Page 70: ...round bus It is bolted to the gantry close to the motor All of the individual ground cables from the components mounted on the gantry connect to the bus A single heavy cable then connects the gantry ground bus to the table ground bus 1 Cable to the cutting table ground bus 2 Ground cables from components on the gantry 1 2 ...

Page 71: ...re that the grounding and shielding practices that you use satisfy the requirements for your location Chassis and EMI ground Service ground 1 2 3 4 5 6 7 8 9 10 11 PE earth ground 1 Cutting table 2 Gantry 3 Plasma system 4 Table ground bus bar 5 Gantry ground bus bar 6 Torch height control lifter 7 Torch connect console 8 CNC controller 9 Torch height control module 10 Gas connect console Connect ...

Page 72: ...Qualifications and Requirements 2 72 809480 Instruction Manual XPR300 ...

Page 73: ...s and leads on page 60 Bend radius requirements for hoses cables and leads on page 61 Distance requirements between high frequency leads and control cables on page 62 Distance requirements for ventilation and access on page 62 Distance requirements for communications on page 63 Review the Installation checklist on page 74 This plasma system can make more than the permitted acoustical noise levels ...

Page 74: ...emote on off switch on page 45 As an installer or user you must supply the remote on off switch for your cutting system Process gas and plumbing Refer to Process gas requirements Core VWI and OptiMix gas connect consoles on page 46 You must supply the process gases and supply gas plumbing for your cutting system Make sure that the gas quality meets requirements Make sure that the gas pressure meet...

Page 75: ... water pressure is above 7 92 bar 115 psi Refer to Additional regulator requirement for shield water optional on page 52 Configuration Refer to Requirements to position system components on page 57 Make sure that the configuration of system components is correct Refer to Configuration with Core gas connect console on page 82 and Configuration with VWI or OptiMix gas connect console on page 83 Make...

Page 76: ...ly to gas connect console connections on page 393 Gas connect console to torch connect console connections on page 395 Plasma power supply to CNC connections on page 397 Plasma power supply to cutting table connection on page 398 Torch connect console to torch receptacle connection on page 399 Make sure that the hoses cables and leads are the correct type Refer to Prepare the hoses cables and lead...

Page 77: ...bly Core on page 109 Power CAN and 3 gas assembly Core only Refer to Connect the power CAN and 3 gas assembly Core on page 112 VWI OptiMix Refer to Connect the gas connect console VWI or OptiMix to the TorchConnect console on page 113 Pilot arc coolant hose set and water assembly Refer to Connect the pilot arc coolant hose set and shield water assembly VWI or OptiMix on page 113 Power CAN and 5 ga...

Page 78: ...rectly installed into the torch receptacle Refer to Install the torch into the torch receptacle on page 135 Make sure that the torch is correctly installed into the lifter Refer to Torch lifter requirements on page 64 As an installer or user you must supply the motorized torch lifter for your cutting system Electrical power Make sure that electrical power is supplied to the cutting system Refer to...

Page 79: ...Manual 80669C for more safety information WARNING ELECTRIC SHOCK CAN KILL The line disconnect switch must be in the OFF position before you connect the power cord to the cutting system It must REMAIN in the OFF position until all installation steps are complete If the line disconnect switch is not in the OFF position you can get a serious electric shock Electric shock can seriously injure or kill ...

Page 80: ...of fire to the supply gases unless a flashback arrestor is not available for a specific gas or pressure As an installer or user you must supply the exhaust ventilation and flashback arrestors for your cutting system You can get them from your cutting machine supplier HYDROGEN GAS CAN CAUSE AN EXPLOSION OR FIRE Hydrogen is a flammable gas that can cause an explosion or fire Keep flames away from cy...

Page 81: ...STEM Incorrect coolantcan damage the cutting system Refer to Coolant requirements on page 54 NOTICE PTFE TAPE CAN CAUSE CLOGGED VALVES REGULATORS AND TORCHES Never use PTFE tape on any joint preparation Use only a liquid or paste thread sealant on male thread ends NOTICE DIRTY OILY AIR CAN CAUSE DAMAGE TO THE AIR FILTER BOWL Some air compressors use synthetic lubricants that contain esters Esters ...

Page 82: ...Coolant hose set 1 supply 1 return 6 Pilot arc lead 7 Negative lead 2 0 or 4 0 8 Pilot arc and coolant hose set assembly a Pilot arc lead b Coolant hose set 1 supply 1 return 9 Power CAN 3 gas assembly c Power cable 120 VAC d CAN cable e 3 gas hoses Core 10 Torch lead 11 Hoses for supply gases Regulator Position a gas regulator within 3 meters 10 feet of the gas connect console or take actions to ...

Page 83: ...ly 1 return 6 Pilot arc lead 7 Negative lead 2 0 or 4 0 8 Pilot arc coolant hose set shield water assembly a Pilot arc lead b Coolant hose set 1 supply 1 return c Shield water hose VWI or OptiMix 9 Power CAN 5 gas assembly d Power cable 120 VAC e CAN cable f 5 gas hoses VWI or OptiMix 10 Torch lead 11 Hoses for supply gases shield water Regulator Position a gas regulator within 3 meters 10 feet of...

Page 84: ...that can get caught on the plasma power supply Only use lift equipment that can safely lift and support the plasma power supply If you use the lift eye to lift the plasma power supply lift only the plasma power supply Do not exceed the maximum lift eye rating See Table 1 on page 30 If you use a lift truck use one with forks that extend along the entire bottom of the plasma power supply The bottom ...

Page 85: ...ve questions about when or how to use the mounting holes contact your cutting machine supplier or regional Hypertherm Technical Service team Figure 1 Mounting dimensions for the Core and VWI gas connect consoles 26 98 cm 10 63 in 1 27 cm 0 50 in Gas inlet side of gas connect console Gas inlet side of gas connect console Core 19 69 cm 7 75 in 6 48 mm 0 26 in Never position the gas connect console a...

Page 86: ...ns for the OptiMix gas connect console 32 05 cm 12 62 in 1 27 cm 0 50 in 19 69 cm 7 75 in Gas inlet side of gas connect console OptiMix 6 48 mm 0 26 in Gas inlet side of gas connect console Never position the gas connect console at an angle Gas outlet side of gas connect console ...

Page 87: ...with the torch lead connection on the bottom can minimize the risk of leaked water or coolant collection inside Water or coolant inside the console can damage internal electrical components If the EasyConnect connection points up it is necessary to support the torch lead so the minimum 15 25 cm 6 in bend radius is maintained If you have questions about console orientation or about when or how to u...

Page 88: ...3 88 809480 Instruction Manual XPR300 Figure 4 Side mount orientation and mounting bracket dimensions for the TorchConnect console 339 85 mm 13 38 in 135 mm 5 31 in 6 35 mm 0 25 in Mounting brackets side orientation ...

Page 89: ...XPR300 Instruction Manual 809480 89 Figure 5 Bottom mount orientation and mounting bracket dimensions for the TorchConnect console 339 85 mm 13 38 in 135 mm 5 31 in 6 35 mm 0 25 in 101 60 mm 4 00 in Mounting brackets ...

Page 90: ...grounding and shielding recommendations Refer to Recommended grounding and shielding on page 67 2 Ground system components after you position them and before you connect the hoses cables and leads Refer to Figure 6 Figure 7 Figure 8 and Figure 9 for grounding details Figure 6 Plasma power supply grounding detail ...

Page 91: ...Installation 3 XPR300 Instruction Manual 809480 91 Figure 7 Gas connect consoles grounding detail Figure 8 TorchConnect console grounding detail Core VWI OptiMix M6 ground stud M6 ground stud ...

Page 92: ...ounting bracket WARNING ELECTRIC SHOCK CAN KILL Disconnect electric power before doing installation or maintenance You can get a serious electric shock if electric power is not disconnected Electric shock can seriously injure or kill you All work that requires removal of the plasma power supply outer cover or panels must be done by a qualified technician Refer to the Safety and Compliance Manual 8...

Page 93: ...jure or kill you Even if the plasma power supply is turned OFF you can still get a serious electric shock if the plasma power supply remains connected to an electric power source Use extreme caution if you do diagnosis or maintenance tasks when the plasma power supply remains connected to an electric power source and the outer cover or panels are removed For installation usually it is necessary to...

Page 94: ...Installation 3 94 809480 Instruction Manual XPR300 Figure 11 Remove panels from the gas connect console Move the panel horizontally to remove it ...

Page 95: ...Installation 3 XPR300 Instruction Manual 809480 95 Figure 12 Remove top and side panels from the TorchConnect console ...

Page 96: ...rrect hoses cables and leads prior to installation For part numbers and specifications refer to the Parts List on page 361 Coolant hose set The coolant hose set includes 1 supply hose with green bands and 1 return hose with red bands Negative lead with strain relief Pilot arc lead with strain relief Power cable CAN cable Work lead ...

Page 97: ...er 59 1 feet assembly is compatible only with the 2 meter 6 6 feet or 2 5 meter 8 2 feet torch lead Pilot arc coolant hose set and shield water assembly only for VWI and OptiMix The coolant hose set includes 1 supply hose with green bands and 1 return hose with red bands Power CAN and 5 gas assembly only for VWI and OptiMix The 18 meter 59 1 feet assembly is compatible only with the 2 meter 6 6 fe...

Page 98: ...I or OptiMix only black F5 VWI or OptiMix only red Shield water VWI or OptiMix only blue Use a hand over hand motion to uncoil the hoses cables and leads As you uncoil them position the flat portion on the floor To avoid equipment damage do not pull from one end of the hose cable or lead to uncoil it Pulling from one end can cause damage ...

Page 99: ...422 Power Pilot Arc CNC Discrete Pilot Arc Work CAN RS422 Negative Power V RS422 Negative Work EtherCAT Out CAN CNC Discrete Coolant Supply Green Coolant Return Red EtherCAT In EtherCAT Table 17 Definitions of symbols on the label inside the plasma power supply CAN Power Negative Work Pilot arc Coolant supply Coolant return CAN V ...

Page 100: ...lant return hose red to the coolant return fitting red b Connect the coolant supply hose green to the coolant supply fitting green If your cutting system previously used the XPR short torch make sure to interchange the coolant hoses prior to standard torch operation Refer to the XPR Short Torch Instruction Manual 810640 for information about how to do this 1 2 1 Coolant return hose red band 2 Cool...

Page 101: ...0 101 2 Connect the coolant hose set to the gas connect console a Connect the coolant return hose red to the coolant return fitting red bottom b Connect the coolant supply hose green to the coolant supply fitting green top Red 1 2 Green 3 4 1 2 3 4 ...

Page 102: ...cable For lengths refer to Power cable on page 394 of the Parts List Figure 15 Connect the power cable To plasma power supply male cable connector To gas connect console female cable connector Plasma power supply Gas connect console Use your fingers to tighten these connectors Do not use tools ...

Page 103: ...cable For lengths refer to CAN cable on page 395 of the Parts List Figure 17 Connect the CAN cable To gas connect console female cable connector To plasma power supply male cable connector Plasma power supply Gas connect console Use your fingers to tighten these connectors Do not use tools ...

Page 104: ...ork lead to the plasma power supply and cutting table Figure 18 Work lead For lengths refer to Work lead on page 398 of the Parts List Figure 19 Connect the work lead to the plasma power supply shown and cutting table not shown To plasma power supply To cutting table ...

Page 105: ...negative lead 2 Put the negative lead and strain relief nut through the hole in the gas connect console or plasma power supply 3 Put the inner nut over the end of the lead 4 Connect the gas connect console end of the lead to the coolant block or connect the plasma power supply end of the lead to the negative connector 5 Tighten the inner nut onto the strain relief nut 3 To plasma power supply To g...

Page 106: ...Installation 3 106 809480 Instruction Manual XPR300 Figure 21 Connect the negative lead with strain relief Plasma power supply Gas connect console ...

Page 107: ...nnect the pilot arc lead with strain relief Figure 22 Pilot arc lead with strain relief For lengths refer to Pilot arc lead with strain relief on page 393 of the Parts List Figure 23 Connect the pilot arc lead with strain relief to the plasma power supply ...

Page 108: ...the gas connect console Core VWI or OptiMix You do not need the strain relief nut Remove the nut from the lead and tighten the strain relief into the panel on the gas connect console For ease of access remove the top insulation panel before you connect the pilot arc lead Move the panel horizontally to remove it ...

Page 109: ...onsole on page 113 Connect the pilot arc and coolant hose set assembly Core Figure 25 Pilot arc and coolant hose set assembly For lengths refer to Pilot arc and coolant hose set assembly Core on page 395 of the Parts List 1 Connect the lead assembly to the gas connect console a Put the hoses and lead through the hole in the gas connect console To gas connect console To torch connect console 4 1 2 ...

Page 110: ...t the pilot arc lead d Connect the coolant return hose red to the coolant return fitting red e Connect the coolant supply hose green to the coolant supply fitting green f Remove the hose clamp from the lead and put it into the groove on the console collar g Push the coupler into the console collar and tighten the clamp e d c b f g ...

Page 111: ... in the TorchConnect console b Connect the coolant return hose red to the coolant return fitting red c Connect the coolant supply hose green to the coolant supply fitting green d Connect the pilot arc lead e Remove the hose clamp from the lead and put it into the groove on the console collar f Push the coupler into the console collar and tighten the clamp a d c b e f ...

Page 112: ...the 2 meter 6 6 feet or 2 5 meter 8 2 feet torch lead For lengths refer to Power CAN and 3 gas assembly Core on page 395 of the Parts List Figure 27 To gas connect console male cable connectors To torch connect console female cable connectors 1 2 3 4 5 1 2 3 4 5 1 Power cable 2 CAN cable 3 Oxygen hose blue 4 Nitrogen hose black 5 Air hose black Core gas connect console TorchConnect console 1 2 3 4...

Page 113: ...coolant hose set and shield water assembly VWI or OptiMix Figure 28 Pilot arc coolant hose set and shield water assembly For lengths refer to Pilot arc coolant hose set and shield water assembly VWI or OptiMix on page 396 of the Parts List 1 Connect the lead assembly to the gas connect console a Put the hoses and lead through the hole in the gas connect console To gas connect console To torch conn...

Page 114: ...he coolant return hose red to the coolant return fitting red e Connect the coolant supply hose green to the coolant supply fitting green f Connect the water hose inside of the VWI or OptiMix console g Remove the hose clamp from the lead and put it into the groove on the console collar h Push the coupler into the console collar and tighten the clamp c e d f b g h ...

Page 115: ...to the connector until it stops approximately 13 mm 0 5 inch c Connect the coolant return hose red to the coolant return fitting red d Connect the coolant supply hose green to the coolant supply fitting green e Connect the pilot arc lead f Remove the hose clamp from the lead and put it into the groove on the console collar g Push the coupler into the console collar and tighten the clamp a e d c b ...

Page 116: ... 2 feet torch lead For lengths refer to Power CAN and 5 gas assembly VWI or OptiMix on page 396 of the Parts List Figure 30 1 2 3 4 5 6 7 1 2 3 4 5 6 7 To gas connect console male cable connectors To torch connect console female cable connectors 1 Power cable 2 CAN cable 3 Oxygen hose blue 4 Air hose black 5 Argon hose black 6 Nitrogen hose black 7 H2 mix or F5 hose red VWI or OptiMix gas connect ...

Page 117: ...ou can get them from your cutting machine supplier HYDROGEN GAS CAN CAUSE AN EXPLOSION OR FIRE Hydrogen is a flammable gas that can cause an explosion or fire Keep flames away from cylinders and hoses that contain hydrogen Keep flames and sparks away from the torch when using hydrogen as a plasma gas Consult your local safety fire and building code requirements for the storage and use of hydrogen ...

Page 118: ...gulator Position a gas regulator within 3 meters 10 feet of the gas connect console or take actions to adjust inlet gas pressures to tolerances specified in the process gas requirements Refer to Process gas requirements Core VWI and OptiMix gas connect consoles on page 46 Pressurize the entire system and look for gas leaks after installation is complete Your system installer or a licensed plumber ...

Page 119: ... must be designed for use with the appropriate gas and pressure rating Incorrect hoses hose connections or hose fittings can crack or leak NEVER connect a supply gas to a hose connection or fitting that is not designed for that gas type or pressure A replacement hose connection or fitting must meet all applicable regulations and codes Non compliant hoses hose connections or hose fittings can crack...

Page 120: ...CE PTFE TAPE CAN CAUSE CLOGGED VALVES REGULATORS AND TORCHES Never use PTFE tape on any joint preparation Use only a liquid or paste thread sealant on male thread ends NOTICE DIRTY OILY AIR CAN CAUSE DAMAGE TO THE AIR FILTER BOWL Some air compressors use synthetic lubricants that contain esters Esters can damage the polycarbonates in the air filter bowl Add additional gas filtration if necessary N...

Page 121: ...have the correct supply gas hoses before you connect them Hypertherm recommends an internal diameter of at least 10 mm 0 375 inch for supply gas hoses that are 76 m 250 feet or less 2 Tighten all fittings to the torque specifications in Table 19 on page 118 3 After installation is complete pressurize the entire system and look for gas leaks A licensed plumber can do this for you Fitting type Size ...

Page 122: ...ING MISSING CHECK VALVES CAN CAUSE AN EXPLOSION OR FIRE Never remove a check valve An explosion or fire can occur if the cutting system is operated without check valves WARNING INCORRECT SUPPLY GAS CONNECTIONS CAN CAUSE AN EXPLOSION OR FIRE An explosion or fire can occur if a supply gas hose is connected to the wrong port on a gas connect console NEVER connect a supply gas to a hose connection or ...

Page 123: ...internal valves because contaminants can enter the valves through damaged or loose fittings CAUTION INCORRECT SUPPLY GAS FITTINGS CAN CAUSE VALVES TO MALFUNCTION Do not change or replace the supply gas fittings on the gas connect console If you alter or replace the fittings it can cause the internal valves to malfunction if particulates get inside CAUTION INCORRECT SUPPLY GAS CONNECTIONS CAN CAUSE...

Page 124: ...flow rates that are outside of recommended ranges can Cause problems with system performance Result in bad cut quality Shorten the life of consumables If the quality of the gas is bad or if the pressure setting is incorrect it can decrease Cut quality Cut speed Cut thickness capabilities NOTICE PTFE TAPE CAN CAUSE CLOGGED VALVES REGULATORS AND TORCHES Never use PTFE tape on any joint preparation U...

Page 125: ...hoses that are 76 m 250 feet or less 2 Tighten all fittings to the torque specifications in Table 19 on page 118 3 After installation is complete pressurize the entire system and look for gas leaks A licensed plumber can do this for you Hydrogen H2 only for OptiMix Shield water H2O Oxygen O2 Air Nitrogen N2 Argon Ar Hydrogen H2 F5 Regulators Shield water H2O only for VWI and OptiMix F5 Argon Ar Ni...

Page 126: ... that the temperature range for cutting system operation with shield water is reduced to above 0 C to 40 C 32 F to 104 F Connect the torch receptacle to the TorchConnect console 1 Uncoil approximately 2 meters 6 5 feet of the torch end of the torch lead assembly 2 Put the torch collar onto the connector end of the torch 3 Put the torch mounting sleeve onto the torch end of the torch lead assembly ...

Page 127: ...3 N m 19 0 N m 144 in lbf 168 in lbf b Insert the plasma valve connector Use your fingers to tighten the connection Do not use tools c Connect the pilot arc lead yellow Use your fingers to tighten the connection Do not use tools d Connect the ohmic lead orange Use your fingers to tighten the connection Do not use tools e Connect the coolant supply hose green Push the hose into the connector until ...

Page 128: ... 5 inch This is a push to connect fitting 6 Install the torch mounting sleeve a Move the the torch mounting sleeve in the direction of the torch b Use your hands totighten the torch mounting sleeve connection A spanner wrench 104879 comes with all 4 of the consumable parts kits 428616 428617 428618 428619 Do not over tighten the torch mounting sleeve if you use the spanner wrench to stabilize the ...

Page 129: ...he clamp Move the collar in the direction of the torch NOTICE FOR THE BEST CUT QUALITY AND CONSUMABLE LIFE USE THE CORRECT LEAD LENGTHS The manufactured lengths of torch and console leads are critical for system performance Never change the lengths of leads Cut quality and the lifespan of consumables will be decreased if you change the lead lengths 7 8 9 1 2 3 4 5 6 2 To torch connect console To t...

Page 130: ...g receptacles in the TorchConnect console 2 Connect the torch lead assembly to the TorchConnect console Use your hands to tighten the coupler on the torch lead assembly Do not use tools Connect the plasma valve cable to its connector Use your fingers to tighten this connection Do not use tools Remove plug to access the ohmic wire if you use a third party ohmic circuit ...

Page 131: ...om the cutting system a Set the line disconnect switch to the OFF position b Make sure that the power indicator LED is not illuminated on the plasma power supply gas connect console and TorchConnect console 2 Install the torch mounting bracket onto the torch lifter Refer to the instruction manual that came with the torch lifter for information about how to install the torch mounting bracket in the...

Page 132: ...r standard position cutting marking and piercing During bevel cutting the torch is at an angle not perpendicular to the workpiece The torch position for XPR torches can range from 0 52 For information on bevel cutting refer to Bevel cutting on page 218 6 Remove the consumables including the water tube from the torch Figure 35 Level the torch 7 Tighten the screws on the torch mounting bracket ...

Page 133: ...s 3 Apply a thin film of silicone lubricant 027055 to each O ring on every consumable The O rings should look shiny Too much lubricant can prevent gas flow Remove excess lubricant if found WARNING ELECTRIC SHOCK CAN KILL Disconnect electrical power before doing installation or maintenance The line disconnect switch must REMAIN in the OFF position until all installation or maintenance steps are com...

Page 134: ...rode Do not use your hands If you fail to correctly install or tighten the electrode torch damage can occur Hypertherm recommends tightening the electrode to between 2 3 N m 2 8 N m 20 in lbf 25 in lbf torque Hypertherm offers 2 tools for tightening XPR torch components 104119 or 429013 The electrode toque tool 429013 is pre calibrated at 2 5 N m 22 1 in lbf d Install the swirl ring into the nozzl...

Page 135: ...ubricant 027055 to each of the 4 O rings inside of the torch body Do not apply silicone to the brass electrical connectors The O rings should look shiny Too much lubricant can prevent gas flow Remove excess lubricant if found 2 Install the torch in the torch receptacle a Turn the torch body with slight upward force until you feel it engage into position in the receptacle Use your hands to tighten ...

Page 136: ...ectrician 1 Make sure that the line disconnect switch is in the OFF position and remains in the OFF position until all installation steps are complete 2 Connect the main power cord to the plasma power supply as shown in Figure 37 a Connect the ground lead PE from the main power cord to the ground terminal of TB1 Incorrect Correct WARNING ELECTRIC SHOCK CAN KILL The line disconnect switch must be i...

Page 137: ... national and local electrical codes to connect the W V and U power leads from the main power cord to the line disconnect switch Table 22 Table 22 Color codes for main power cord wires U V W GND PE TB1 Wire color codes for North America Wire color codes for Europe Asia and most locations outside of North America U Black U Black V White V Blue W Red W Brown PE earth ground Green yellow PE earth gro...

Page 138: ... on page 243 in the Maintenance section of this manual Ferrous mild steel example configurations Mild steel 30 A O2 O2 Consumables for mirror cutting only Mild steel 50 A O2 Air Consumables for mirror cutting only Water tube 420368 Electrode Swirl ring Nozzle 420222 420407 420620 420225 Nozzle retaining cap 420365 Shield 420228 420619 420200 Shield retaining cap Water tube 420368 Electrode Swirl r...

Page 139: ...g only Water tube 420368 Electrode Swirl ring Nozzle 420240 420249 420276 420258 420242 420607 420406 420594 420260 420609 420243 420252 420279 420261 Nozzle retaining cap 420365 Shield 420246 420605 420255 420608 420491 420615 420513 420616 420200 Shield retaining cap 80 A 130 A 170 A 300 A 420242 420607 220 A 420273 420270 420406 ...

Page 140: ...l and aluminum example configurations Non ferrous 40 A N2 N2 and Air Air Consumables for mirror cutting only Water tube 420368 Electrode Swirl ring Nozzle 420303 N2 N2 420314 420598 420288 Nozzle retaining cap 420365 Shield 420291 420624 420200 Shield retaining cap 420294 Air Air ...

Page 141: ...N2 and N2 H2O can only be used with VWI or OptiMix consoles Water tube Electrode Swirl ring Nozzle F5 N2 N2 N2 420303 420323 420604 Nozzle retaining cap Shield F5 N2 N2 N2 420309 420603 Shield retaining cap 420368 420365 420200 N2 H2O 420300 420593 Air Air 420294 Air Air 420309 Air Air 420297 N2 H2O 420303 N2 H2O 420296 F5 N2 N2 N2 420297 ...

Page 142: ... and N2 H2O can only be used with VWI or OptiMix consoles Water tube Electrode Swirl ring Nozzle N2 H2O 420303 420323 420604 N2 H2O 420290 Nozzle retaining cap Shield F5 N2 N2 N2 420309 420603 Shield retaining cap 420368 420365 420200 F5 N2 N2 N2 420306 Air Air 420294 N2 H2O 420300 420593 F5 N2 N2 N2 420303 Air Air 420306 Air Air 420309 ...

Page 143: ...d N2 H2O can be used with OptiMix consoles N2 H2O can be used with VWI or OptiMix consoles Water tube Electrode Swirl ring Nozzle 420356 N2 N2 420314 420598 420315 Nozzle retaining cap Shield N2 N2 420318 420597 Shield retaining cap N2 H2O 420469 420595 H2 Ar N2 N2 420323 420604 H2 Ar N2 N2 420318 420597 N2 H2O 420314 420598 420368 420365 420200 ...

Page 144: ...or OptiMix consoles Water tube Electrode Swirl ring Nozzle N2 N2 420356 H2 Ar N2 N2 420323 420604 Nozzle retaining cap Shield N2 N2 420327 420613 Shield retaining cap Air Air 420258 Air Air 420260 N2 N2 420314 420598 N2 H2O 420314 420598 Air Air 420513 N2 H2O 420472 420611 H2 Ar N2 N2 420327 420613 N2 N2 420324 H2 Ar N2 N2 420356 N2 H2O 420356 420368 420365 420200 H2 Ar N2 N2 420324 N2 H2O 420324 ...

Page 145: ...nd N2 H2O can be used on OptiMix consoles N2 H2O can be used with VWI or OptiMix consoles Water tube Electrode Swirl ring Nozzle Nozzle retaining cap Shield Shield retaining cap 420356 N2 N2 420323 420604 420359 N2 N2 420362 420601 H2 Ar N2 N2 420358 420623 N2 H2O 420323 420604 H2 Ar N2 N2 420362 420601 N2 H2O 420475 420622 420368 420365 420200 ...

Page 146: ...Installation 3 146 809480 Instruction Manual XPR300 ...

Page 147: ... to connect to the plasma power supply with serial RS 422 on page 151 Refer to How to connect to the plasma power supply with discrete on page 154 If you use serial RS 422 you must also use discrete to fully operate the cutting system Refer to Table 23 on page 148 Wireless XPR Web Interface and discrete Use this method with a wireless enabled device and discrete compatible controller Refer to How ...

Page 148: ...therCAT to a cutting system that uses the factory default configuration Contact your cutting machine supplier or Hypertherm Technical Service team with questions Example If you use EtherCAT to set the process the preferred method to monitor is EtherCAT However you can use RS 422 or the XPR web interface to monitor Set process with To fully operate the cutting system Monitor with Discrete EtherCAT ...

Page 149: ...magnetic interference EMI problems with your cutting system Separate the EtherCAT cable from the pilot arc lead negative lead or any power cables that have a voltage higher than 120 VAC Refer to Distance requirements between high frequency leads and control cables on page 62 Do not putthe EtherCAT cable near the gas connect console Wire Construction Stranded tinned wire Diameter 0 75 mm 7 X 0 25 m...

Page 150: ...Connect for Communication 4 150 809480 Instruction Manual XPR300 Figure 39 Connect EtherCAT cables to plasma power supply EtherCAT in from the CNC EtherCAT out to the next plasma power supply ...

Page 151: ...stallation for AVC with RS 422 and discrete only on page 158 1 Remove the rear panel of the plasma power supply Refer to Remove the external panels from the system components on page 92 2 Put End A Figure 40 of the serial RS 422 cable through the hole in the bottom of the rear compartment in the plasma power supply Refer to Figure 41 on page 153 3 Connect End A of the serial RS 422 cable to the co...

Page 152: ...398 in the Parts List Table 24 Pinout for serial RS 422 interface cable 3 2 7 5 4 7 2 3 5 4 End A To the plasma power supply top serial connector J12 End B To the CNC End A Wire color End B Wire type Signal Pin number Pin number Signal TxD 4 Red 7 RxD Pair TxD 2 Black 3 RxD RxD 7 White 4 TxD Pair RxD 3 Black 2 TxD GND 5 Green 5 GND Pair Cut Black Cut ...

Page 153: ...t for Communication 4 XPR300 Instruction Manual 809480 153 Figure 41 Connect the serial RS 422 cable to the plasma power supply Serial RS 422 to the next plasma power supply if any Serial RS 422 from the CNC ...

Page 154: ...ignals and protocols refer to XPR discrete communication in the CNC Communication Protocol for the XPR Cutting System 809810 1 Remove the rear panel of the plasma power supply Refer to Remove the external panels from the system components on page 92 2 Put End A Figure 42 of the discrete cable through the hole in the bottom of the rear compartment in the plasma power supply Refer to Figure 43 on pa...

Page 155: ...Output2 Motion Notifies the CNC that an arc transfer has occurred and to begin machine motion once the CNC s pierce delay time elapses Green 6 Motion Black 7 Input1 3 Hold The CNC delays plasma arc initiation This signal is normally used in combination with the Start signals to synchronize multiple torches Activate this signal at the same time as the Plasma Start signal Deactivate this signal to f...

Page 156: ...rds that have their own ohmic contact circuit Refer to How to use ohmic contact sense on page 193 End A Figure 42 on page 154 J19 pin Input Output Signal Function Wire color 1 Output2 Error Notifies the CNC that an alert error or failure has occurred This signal is not intended to be used to stop table motion Orange 2 Error Black 3 Output2 Ready for start Notifies the CNC that the plasma power sup...

Page 157: ...Connect for Communication 4 XPR300 Instruction Manual 809480 157 Figure 43 Connect the discrete cable to the plasma power supply Discrete cable to the CNC ...

Page 158: ...n seriously injure or kill you All work that requires removal of the plasma power supply outer cover or panels must be done by a qualified technician Refer to the Safety and Compliance Manual 80669C for more safety information CAUTION STATIC ELECTRICITY CAN DAMAGE PRINTED CIRCUIT BOARDS Use precautions when handling printed circuit boards PCBs to protect them from static electricity Correct PCB ha...

Page 159: ...r parts included in the kit The wire harness to connect the VDC3 board is located in a clip inside of the plasma power supply The wiring harness includes the arc voltage wires and the power wires N E G W O R K 1 2 3 4 5 6 1 Plasma power supply 2 Board VDC3 141511 Wire harness in the plasma power supply 3 Wires VDC3 board 120 VAC 4 Wires Arc voltage 5 Male connector to VDC3 board pre installed on t...

Page 160: ...cation 4 160 809480 Instruction Manual XPR300 How to install the VDC3 board 141511 Figure 45 VDC3 board J2 1 2 3 4 5 6 7 8 J3 J1 1 2 J1 120 VAC wires connector J2 VDC3 board cable connector J3 Arc voltage wires connector ...

Page 161: ...Connect for Communication 4 XPR300 Instruction Manual 809480 161 1 Use a 10 mm hex socket wrench or nut driver to remove the rear panel of the plasma power supply Figure 46 ...

Page 162: ...ion 4 162 809480 Instruction Manual XPR300 2 Use a 2 Phillips screwdriver to remove the 4 screws from the studs 3 With J3 on top use the 4 screws to install the board on the studs Tighten the screws to 9 2 kg cm 8 0 in lb J3 ...

Page 163: ...tion Manual 809480 163 How to connect the VDC3 board 141511 1 Remove the wire bundle from the wire clip in the plasma power supply The wire bundle is included in the plasma power supply The bundle includes the arc voltage wires and power wires ...

Page 164: ... shown in Figure 47 3 Connect the other end of the VDC3 120 VAC harness to the 120 VAC connector Figure 47 4 Attach the spade connector of the yellow wire WORK to the J3 WORK terminal as shown in Figure 48 5 Attach the spade connector of the yellow black wire NEG to the J3 ELECTRODE terminal Figure 48 NEG WORK E L E C T R O D E W O R K S H I E L D G N D J3 ...

Page 165: ...c voltage wires on top of the existing wires 8 Use NCS pin 3 NCE pin 4 Aout pin 6 and Aout pin 7 to connect to the CNC Refer to Figure 45 on page 160 for the locations of the pins Refer to Table 27 for the pinout Use the interface requirements of your CNC for additional connection requirements Table 27 Pinout for J2 on the VDC3 board 9 Install the rear panel of the plasma power supply N E G W O R ...

Page 166: ...ma power supplies Web interface support information If you have a problem connecting and you suspect a problem with your device router or local network contact your system administrator If you have a problem connecting and you suspect a problem with the plasma power supply contact your cutting machine supplier or Hypertherm Technical Service CAUTION WEAK NETWORK SECURITY INCREASES THE RISK FOR UNA...

Page 167: ...tor LED is illuminated on the plasma power supply c Make sure that the remote on off switch is set to ON 2 On your device go to the wireless connections menu This menu can be different on different devices 3 Choose the XPR connection The default connection name is xpr the System ID The System ID is the last 4 digits of the Media Access Control MAC address For more information on the System ID and ...

Page 168: ...d in the upperleft of the XPR web interface If the Client ID and the Operator ID are the same on your device you are in control of the plasma power supply and can set a process Refer to Web interface screen information on page 184 for more information on the interface menus 7 To fully operate the cutting system you must also use discrete Refer to How to connect to the plasma power supply with disc...

Page 169: ...less access Before you begin You must set up a router with a local network to access Follow the router s instructions to do this If you have problems setting up your router contact your system administrator You must know the SSID and passphrase for the router 1 Follow the procedure in Use AP mode to connect on page 167 to connect the wireless set up device to the plasma power supply 2 Choose Conne...

Page 170: ...nect for Communication 4 170 809480 Instruction Manual XPR300 3 Choose Client Settings 4 Choose an option to connect to wireless networks Select an existing network on page 171 Set up manually on page 174 ...

Page 171: ...plasma power supply scans for and shows the available access points 1 Choose Select to connect to your router 2 Type the required credentials for the router in Passphrase 3 If needed select the Advanced Options check box and select a method to get the IP address If not go to step 4 a Dynamic Host Configuration Protocol DHCP ...

Page 172: ...mmunication 4 172 809480 Instruction Manual XPR300 b Static IP advanced users only 4 Choose Next to go to the Wireless Configuration Summary screen This page shows information about the SSID Channel and Security type ...

Page 173: ...ork The plasma power supply now resets and connects to the new network To access the web interface after setup refer to Access the XPR web interface after setup in network mode on page 177 7 If you are only monitoring with the XPR web interface you are done If you want to operate the cutting system go to step 8 8 You must connect to the plasma power supply with discrete Refer to How to connect to ...

Page 174: ...this option you manually set up the wireless network 1 Select or type the wireless related settings such as SSID Channel Security and Passphrase 2 If needed select the Advanced Options check box and select a method to get the IP address If not go to step 3 a Dynamic Host Configuration Protocol DHCP ...

Page 175: ...Instruction Manual 809480 175 b Static IP advanced users only 3 Choose Next to go to the Wireless Configuration Summary screen This page shows information about the SSID Channel Security type IP Address Subnet Mask Gateway and DNS Server ...

Page 176: ...ork The plasma power supply now resets and connects to the new network To access the web interface after setup refer to Access the XPR web interface after setup in network mode on page 177 6 If you are only monitoring with the XPR web interface you are done If you want to operate the cutting system go to step 7 7 You must connect to the plasma power supply with discrete Refer to How to connect to ...

Page 177: ...ess through power cycles without having to set up the wireless module with the static IP address 1 Use your router s web interface to find the DHCP client table Refer to Figure 49 for an example Figure 49 Example DHCP client table 2 Find the IP address of the plasma power supply Your plasma power supply name shows as GS_ the last 6 digits of the MAC address 3 Open a web browser 4 Use the assigned ...

Page 178: ... Manual XPR300 Change the limited AP settings You can change the limited AP SSID channel network address and DHCP settings in the Connect screen 1 Choose Other Connect Limited AP Settings 2 On the Limited AP Settings screen select the AP mode settings ...

Page 179: ...4 XPR300 Instruction Manual 809480 179 3 Choose Advance Options then Next 4 Verify that the settings are correct Adjust if necessary otherwise choose Save 5 Choose Apply Settings The change takes effect after you cycle the power ...

Page 180: ...aintenance You can get a serious electric shock if electric power is not disconnected Electric shock can seriously injure or kill you All work that requires removal of the plasma power supply outer cover or panels must be done by a qualified technician Refer to the Safety and Compliance Manual 80669C for more safety information WARNING ELECTRIC SHOCK CAN KILL The plasma power supply contains dange...

Page 181: ...from the cutting system a Set the line disconnect switch to the OFF position b Make sure that the power indicator LED is not illuminated on the plasma power supply 7 Set position 4 on DIP switch S3 located on the main control board to the OFF position This enables the wireless WARNING ELECTRIC SHOCK CAN KILL The plasma power supply contains dangerous electric voltages that can seriously injure or ...

Page 182: ...asma power supply WARNING ELECTRIC SHOCK CAN KILL Disconnect electric power before doing installation or maintenance You can get a serious electric shock if electric power is not disconnected Electric shock can seriously injure or kill you All work that requires removal of the plasma power supply outer cover or panels must be done by a qualified technician Refer to the Safety and Compliance Manual...

Page 183: ...ly 5 Supply power to the cutting system a Set the line disconnect switch to the ON position b Make sure that the power indicator LED is illuminated on the plasma power supply WARNING ELECTRIC SHOCK CAN KILL The plasma power supply contains dangerous electric voltages that can seriously injure or kill you Use extreme caution if you do service or maintenance work on a plasma power supply when it is ...

Page 184: ...ntrol of the plasma power supply The first part of the Operator ID shows the type of connection that sent a process WiFi for wireless Uart 422 for serial RS 422 or EtherCAT for EtherCAT To change which device has control of the plasma power supply refer to How to change the device that has control on page 192 Client ID This is the identifier for a device that communicates with the plasma power sup...

Page 185: ...ply On this screen you can monitor the status of the plasma power supply This screen also lists inputs and outputs When highlighted red or gray that input or output is active The XPR web interface shows different fields for different XPR models The screen shown is for reference only ...

Page 186: ...volumes and energized valves with color coded highlights that illuminate when active Pressure measurements and setpoints near the proportional valves and duty cycle PWM sensors represented by the diagram This screen gives you the option to display either bar or psi units of measure You can do 4 tests from this screen Test Preflow Test Cutflow Test Pierceflow and Gas Leak Test The gas leak test is ...

Page 187: ...XPR300 Instruction Manual 809480 187 Connect for Communication 4 Figure 51 Example text view screen that describes the gas system status ...

Page 188: ...Connect for Communication 4 188 809480 Instruction Manual XPR300 Figure 52 Example diagram view screen that shows the gas system status ...

Page 189: ... Instruction Manual 809480 189 Log On this screen you can monitor active diagnostic codes and view diagnostic code history There are 4 categories of codes information alert error and failure Refer to Table 36 on page 269 for definitions ...

Page 190: ...pply you can select a process ID based on material thickness and process type You can customize some parameters by choosing the to open the menu The plasma power supply keeps this customization until the remote on off switch is set to OFF or the power is removed from the plasma power supply The customization is also reset when you select a new process ...

Page 191: ...re On this screen you can change the connection name limited AP password limited AP IP address or the setup password You cannot use special characters in any of the fields on this screen The connection name must be less than 32 characters long Passwords must be between 8 and 20 characters long Passwords are case sensitive Connect On this screen you can change your client settings and connect to ot...

Page 192: ...nt ID and the Operator ID in the XPR web interface are the same on your device you are in control of the plasma power supply To change the device that has control of the plasma power supply 1 Remove the power from the cutting system a Set the line disconnect switch to the OFF position b Make sure that the power indicator LED is not illuminated on the plasma power supply 2 Supply power to the cutti...

Page 193: ...tact is disabled when the remote on off switch is in the OFF position Internal ohmic contact sense This is the default installation for the torch and torch connect console No action is required Figure 53 Internal ohmic diagram J4 J3 J2 J27 J1 7 8 9 1 2 3 4 5 6 10 11 1 Torch 2 Ohmic wire inside torch and torch lead 3 Torch connect console 4 Ohmic wire torch receptacle to ohmic relay 5 Ohmic relay 6...

Page 194: ...ct switch to the OFF position b Make sure that the power indicator LED is not illuminated on the torch connect console 2 Disconnect the ohmic wire from J3 on the ohmic PCB in the torch connect console 3 Connect the ohmic wire that you removed from J3 to J4 pin1 4 If you have a third party ohmic circuit remove the plug from the sheet metal on the torch connect console to access the ohmic wire insid...

Page 195: ...nside the lifter Figure 55 Example external ohmic diagram 6 9 J27 J4 J3 J2 J1 7 1 2 3 4 5 6 9 8 10 1 Torch 2 Ohmic wire inside torch and torch lead 3 Torch connect console 4 Ohmic wire torch receptacle to ohmic relay 5 Ohmic relay 6 Ohmic wire ohmic relay to J4 7 Ohmic PCB 8 Ohmic wire J4 to lifter or third party ohmic circuit 9 Torch lifter or third party ohmic circuit 10 Pin 1 and pin 2 on J4 ar...

Page 196: ...e or kill you Even if the plasma power supply is turned OFF you can still get a serious electric shock if the plasma power supply remains connected to an electric power source When the remote on off switch is in the OFF position electric power remains active to the following components in the system Control board Control transformer input and output 48 V power supply 24 V power supply 120 VAC and ...

Page 197: ...5 VDC 24 VDC XPR C E CNC PLC 10 kΩ optional High impedance 10 mA 5 VDC 24 VDC 10 kΩ optional CNC PLC XPR C E High impedance 10 mA CNC 24 V 24 V CNC 24 V XPR E C J17 t Wire ground CNC PLC External relay 24 VDC low power coil 10 mA or 2400 Ω All relay coils require a freewheeling diode across the relay coil High current contact closure inputs AC or DC Install a jumper 108056 XPR Any voltage C E Powe...

Page 198: ... The life of the external relay can be extended if you add a metalized polyester capacitor 0 022 μF 100 V or higher in parallel with the relay contacts 24 VDC XPR Power ground External relay AC or DC Output from CNC PLC Transistor output optocoupler 24 VDC XPR Power ground CNC PLC CNC PLC 24 VDC XPR 12 VDC 24 VDC Active high drive Power ground Power ground ...

Page 199: ...your cutting machine supplier to reorder coolant For information about how to calculate the approximate total volume of coolant for your cutting system refer to Estimate the total coolant volume for your cutting system on page 254 The plasma power supply ships with the coolant filter 027005 and coolant pump screen 127559 installed Additional coolant filters and screens are available from Hyperther...

Page 200: ...spout You can see the coolant level from the fill port inlet as you pour the coolant NOTICE LOW COOLANT LEVELS CAN DAMAGE THE CUTTING SYSTEM AND COOLANT PUMP Never operate the cutting system if you get a low coolant level notice There is a risk of serious damage to the cutting system and to the coolant pump if you operate the cutting system with no coolant or with low coolant If your coolant pump ...

Page 201: ... When you send a process the gases start to flow and after a few seconds the coolant pump starts If the pump stops it is necessary to purge the air out of the coolant loop Use the remote on off switch to start and stop the coolant pump until the pump continues to run 8 If necessary add more coolant to fill the reservoir to the base of the fill spout 9 After installation of the coolant use the CNC ...

Page 202: ...Coolant Installation 5 202 809480 Instruction Manual XPR300 ...

Page 203: ...orch positions and process settings you need on page 217 Process selection on page 225 How to use cut charts on page 227 How to select consumables on page 230 Factors of cut quality on page 230 If you have questions about how to operate your cutting system contact your cutting machine supplier or regional Hypertherm Technical Service team You can find contact information for each regional office a...

Page 204: ...Cut chart screen See the instruction manual that came with your CNC for descriptions of CNC screens For information about how to use the Hypertherm CNC to control cutting system operation see The instruction manual that came with your CNC CNC Communication Protocol for the XPR Cutting System 809810 Wireless device A wireless device can be used to setup and monitor the XPR cutting system A wireless...

Page 205: ...ctric power and the remote on off switch is in the ON position The plasma power supply that came with early XPR300 cutting systems has a green only power indicator A power indicator LED upgrade kit 428893 is available from Hypertherm if you want a 2 color LED for your plasma power supply Figure 56 Power indicator LED on the plasma power supply When illuminated the green power indicator LED on the ...

Page 206: ...console left and on the torch connect console right CNC display Except for the power indicator LEDs that show power status all other visual indications of cutting system performance appear on the CNC or XPR web interface For CNC screen descriptions see the instruction manual that came with your CNC ...

Page 207: ...tem to start the Powerup State 1 Power is supplied to the cutting system Cutting system operation STARTS Make sure that signals are OFF for the following Main contactor Coolant pump Cooling fans Establish CAN communication Wait for RS 422 serial EtherCAT or wireless communication between the plasma power supply and CNC or wireless device Determine system configuration number of choppers and number...

Page 208: ...n start Initial checks State 2 again No Measure the following Temperatures main transformers choppers coolant Inlet pressures gas connect console torch connect console Are the measurements within the acceptable range No Diagnose and troubleshoot the problem Refer to Diagnostics and Troubleshooting on page 259 Yes Wait for process selection by the operator Select a process ID Continue to Gas purge ...

Page 209: ...ssary to complete a purge is based on 1 the type of operator selected process that the CNC or wireless device sends to the cutting system 2 if this is the first process sent after the Powerup State 1 starts and 3 the type of previous operator selected process Is a specialty purge necessary Yes Do a specialty purge No Stage 1 Operate preflow gases Turn ON the coolant pump and start coolant flow Sta...

Page 210: ...ed No Yes For new process selection continue to Initial checks State 2 on page 208 OR For a Plasma Start command continue to Preflow charge DC State 7 on page 210 Start preflow gas flow Turn ON the inrush contactor and then the main contactor Turn ON the chopper Turn ON the fans if not already on Turn ON the coolant pump if not already on Measure gas pressure Make sure that Hold Ignition signal is...

Page 211: ...acceptable range No Yes Is the DC bus voltage within the acceptable range No Yes Turn ON the high frequency circuit ignition arc created Is the Chopper 1 current above the minimum current No Yes Does Ignite State 8 complete within 500 milliseconds No Diagnose and troubleshoot the problem Refer to Diagnostics and Troubleshooting on page 259 Yes Continue to Pilot arc State 9 on page 212 ...

Page 212: ...eptable range No Yes Is the DC bus voltage within the acceptable range No Yes Is the current for Chopper 1 within the acceptable range No Yes Is the current for the work lead within the acceptable range Chopper 2 becomes active during this time No Yes Does the Pilot arc State 9 complete within 500 milliseconds No Diagnose and troubleshoot the problem Refer to Diagnostics and Troubleshooting on pag...

Page 213: ...oes the coolant flow rate remain within the acceptable range No Diagnose and troubleshoot the problem Refer to Diagnostics and Troubleshooting on page 259 Yes Do the gas pressures remain within the acceptable range No Yes Do the temperatures remain within the acceptable range No Yes Does the current for Chopper 1 and Chopper 2 remain within the acceptable range If the process is less than or equal...

Page 214: ...e circuit Ohmic sensing for the N2 H2O process is available in cutting systems with firmware that is revision L or later Stall force is required when the N2 H2O process is used underwater During a dry process the cutting system closes the high voltage relay and enables the ohmic sense circuit except during high frequency starts Decrease current to the final setpoint Decrease gas flow to the final ...

Page 215: ... console a plasma gas purge occurs automatically when the cutting system changes from a non mixed fuel gas process to a mixed fuel gas H2 mix or F5 process or from a mixed fuel gas H2 mix or F5 to a non mixed fuel gas process Core XPR cutting systems skip gas change purges The type of plasma gas used for the purge is based on the type of cutting system configuration OptiMix or VWI OptiMix XPR cutt...

Page 216: ... setup purges for all XPR cutting systems If you have a cutting system equipped with an OptiMix or VWI gas connect console a process setup purge automatically follows the gas change purge and includes preflow and cutflow purges If you have a Core XPR cutting system the gas change purge is skipped and only the process setup purge occurs The type of process gas used for a process setup purge is base...

Page 217: ... have an effect Slower torch speeds and higher currents make deeper marks Faster torch speeds and lower currents make shallower marks Make sure to mark and cut individual parts when you use the argon marking processes Marking the entire nest prior to cutting can reduce the life of consumables For better results alternate cuts and marks Poor quality marking or burn through can occur with metal that...

Page 218: ...workpiece 3 Cut height The linear distance from the center of the torch to the workpiece surface along the torch center line For optimal results select a cut height that is based on an effective thickness value in the cut charts If a specific cut height is inconsistent with a clearance requirement select a slightly higher cut height to prevent torch collisions 4 Cone angle All XPR torches have a 7...

Page 219: ...internal feature cutting use O2 O2 The 300 A processes on some thicknesses use O2 N2 Argon assist technology uses argon Ar in the shield to increase pierce capacity Refer to the XPR Cut Charts Instruction Manual 809830 for information about the gases used for plasma gas and shield gas during different processes All mild steel processes use Hypertherm s enhanced LongLife technology that works toget...

Page 220: ...es by gas connect console type and gas type Table 29 Process recommendations for cut quality based on metal thickness and type Gas connect console Available stainless steel processes Available aluminum processes Core N2 N2 N2 N2 Air Air VWI N2 N2 N2 H2O F5 N2 N2 N2 N2 H2O Air Air OptiMix N2 N2 N2 H2O H2 mix N2 F5 N2 N2 N2 N2 H2O H2 mix N2 Air Air Metal thickness Metal type Metric mm English in Sta...

Page 221: ...variety of gas mixtures The cutting system chooses an optimized combination of 3 gases or 2 gases H2 Ar based on the thickness of the metal to be cut HyDefinition vented water injection processes VWI processes use a low flow rate of water through the shield line instead of shield gas A process that uses water as a shield fluid is sometimes known as a wet process Wet processes deliver an overall go...

Page 222: ...e cutting system chooses an optimized combination of 3 gases or 2 gases H2 Ar based on the thickness of the metal to be cut HyDefinition vented water injection processes VWI processes use a low flow rate of water through the shield line instead of shield gas A process that uses water as a shield fluid is sometimes known as a wet process For aluminum wet processes generally produce a smoother edge ...

Page 223: ...to cutting non ferrous alloys to implement a risk assessment and mitigation plan that eliminates the risk of detonation by preventing hydrogen accumulation Do not cut a workpiece that is more than 75 mm 3 inches below the surface of the water It can negatively affect cutting system performance Do not use True Hole processes underwater True Hole processes are not compatible with underwater cutting ...

Page 224: ...ts Refer to the XPR Cut Charts Instruction Manual 809830 Underwater cut chart settings are provided for Ferrous processes 80 A and above Non fuel gas stainless steel processes 80 A and above Mirror cutting Consumable parts for mirror cutting are available for all processes They include a special swirl ring and shield that causes the gases to swirl in the opposite direction The opposite direction g...

Page 225: ...within limits Refer to Process ID offsets overrides on page 226 How to use process IDs to access optimal settings When you select a process ID from the CNC or XPR web interface you automatically get the optimized settings that Hypertherm recommends for that process The pre programmed settings come from Hypertherm s extensive laboratory tests Because of differences in cutting systems metals and con...

Page 226: ... command An offset override command is a type of serial RS 422 or EtherCAT signal that lets you change the default value of a setting within an allowable limit For example if a pre programmed plasma pressure value is 65 and you want to change it to 70 send an offset command of 5 65 5 70 You can also use the web interface to send the desired plasma pressure value 70 Refer to Web interface screen in...

Page 227: ... quality is important In other cases speed is important Often the best choice balances these requirements Process core thickness PCT The cut chart for every cutting process contains a range of possible thicknesses Process engineers work to optimize a range of thicknesses process category 1 for XPR This optimized range is known as the process core thickness PCT Thicknesses greater and less than the...

Page 228: ...of productivity and cut quality The process is optimized for this thickness Expect cut speeds that range from 2 030 mm min 3 810 mm min 80 in min 150 in min Dross free in most cases Very good Very good Category 2 Thicker than PCT Good choice when edge quality is more important than speed Expect cut speeds that are slower than 2 030 mm min 80 in min Expect some low speed dross Very good excellent L...

Page 229: ...ocess is optimized for this thickness Expect cut speeds that range from 1 016 mm min 3 048 mm min 40 in min 120 in min Dross free in most cases Very good excellent Very good Category 2 Thicker than PCT In most situations you can expect square cut edges with sharp top edges Darker edge color is possible with stainless steel Expect cut speeds that are slower than 1 016 mm min 40 in min Expect some d...

Page 230: ...ity Dross Dross is more likely to occur on a hot workpiece The first cut in a series often produces the least dross You can expect more dross with more cuts Changes in shield flow can dramatically influence dross formation on non ferrous metals Worn or damaged consumables can produce intermittent dross How to get the results you want This section of the manual gives general recommendations for how...

Page 231: ...eady which can cause irregular cut patterns Make sure to do routine service and maintenance to the drive system and rails See the instruction manual that came with your cutting machine or table for information on how to do this Do all cutting system maintenance tasks as scheduled Refer to Maintenance on page 237 Recommendations for perpendicular position cutting processes Always start with the def...

Page 232: ...ing piercing processes Refer to the XPR Cut Charts Instruction Manual 809830 If it is difficult to pierce the workpiece because of metal type or thickness Increase the shield pierce flow if this function is available with your CNC For this to work the shield pierce signal must be activated For information about how to activate the shield pierce signal see the instruction manual that came with your...

Page 233: ...le bevel compensation cut charts or process parameter tables that automatically compensate key settings such as torch height and cut speed Pierce control and assist technology Pierce delay settings The operator selects the time in seconds necessary to pierce through the full thickness of the metal The operator enters this setting from the CNC or XPR web interface For recommendations on how to choo...

Page 234: ...ovement into the scrap area of the workpiece If possible use a chain cut so that the path of torch movement leads directly from one cut part into the next This will minimize multiple plasma arc starts and stops for multi part cutting that damage electrodes Arc Response Technology The plasma power supply is equipped with choppers that monitor the current and arc voltage load once every 33 microseco...

Page 235: ...re to complete the cut on the workpiece causes the arc to stretch and then snap out in a rampdown error which can drastically decrease consumable life Common causes for a rampdown error are Incorrect hole lead outs Running off the edge of the workpiece The cutting system can detect a rampdown error before the arc snaps out and can respond quickly to do a controlled stop of the current and gas pres...

Page 236: ...Operation 6 236 809480 Instruction Manual XPR300 ...

Page 237: ...es maintenance steps that you must do daily before system operation For instructions about preventive maintenance such as weekly monthly and yearly tasks refer to the XPR Preventative Maintenance Program PMP Instruction Manual 809490 For recommendations about how to diagnose and troubleshoot performance issues refer to Diagnostics and Troubleshooting on page 259 For printed circuit board PCB drawi...

Page 238: ...amine the water tube and torch X Examine hoses cables and leads X Do tests for gas leaks X Do a check of the coolant flow X Clean inside the plasma power supply X Examine the contactors X Examine the pilot arc relay X Examine the coolant system X Do the coolant flow test X Examine the gas line connections X Examine the hoses X Examine the cables X Examine the ground connections X Examine the table...

Page 239: ...wing at least once daily before system operation Examine the gas regulators on page 241 Examine the shield water regulator if applicable on page 241 Examine the connections and fittings on page 241 Examine the consumable parts torch and torch receptacle on page 242 Examine the torch lead on page 247 ...

Page 240: ...AN KILL The plasma power supply contains dangerous electric voltages that can seriously injure or kill you Even if the plasma power supply is turned OFF you can still get a serious electric shock if the plasma power supply remains connected to an electric power source Use extreme caution if you do diagnosis or maintenance tasks when the plasma power supply remains connected to an electric power so...

Page 241: ...ectricity 3 Make sure that the power indicator LED is not illuminated on the plasma power supply gas connect console or torch connect console Examine the gas regulators Before you start cutting system operation examine the regulator regulators for the supply gases Make sure that the supply gas pressures and flow rates are within the recommended range Refer to Table 7 on page 46 Adjust the regulato...

Page 242: ...ngs inside of the plasma power supply are replaceable For part numbers and specifications refer to the Parts List on page 361 5 Make sure that the hoses cables and leads do not twist or kink during torch movement and system operation Adjust them if needed 6 Before you supply power to the cutting system always complete all inspection and maintenance tasks Examine the consumable parts torch and torc...

Page 243: ...ield cap Erosion or missing material Cracks Melted eroded or missing material Damaged O rings Replace the shield cap Molten material attached If there is no damage to the shield cap you can remove the molten material If there is damage replace the shield cap Dry O rings Apply a thin film of silicone lubricant 027055 to O rings that appear dry Shield A center hole that is not circular Damaged O rin...

Page 244: ...O rings Use a clean lint free cloth to remove excess silicone lubricant Dry O rings Apply a thin film of silicone lubricant 027055 to O rings that appear dry Swirl ring Chips or cracks Blocked gas holes Damaged O rings Replace the swirl ring Dirt or debris Use compressed air to remove dirt or debris Replace the swirl ring if you find damage Over lubricated O rings Use a clean lint free cloth to re...

Page 245: ...the torch receptacle on page 135 Examine the torch 1 Complete the following procedures before continuing a Remove the power from the cutting system on page 240 b Remove the torch and consumable parts on page 242 2 Examine the torch for Damage or excess wear on the external O rings that are on the front of the torch Damage or excess wear on the internal O rings that are on the rear of the torch Dry...

Page 246: ... lubricant if found 7 Before you supply power to the cutting system install the following components Consumables in the torch Refer to Install the consumables on page 133 Torch in the torch receptacle Refer to Install the torch into the torch receptacle on page 135 Examine the torch receptacle 1 Complete the following procedure before continuing a Remove the power from the cutting system on page 2...

Page 247: ...er to Install the consumables on page 133 Torch in the torch receptacle Refer to Install the torch into the torch receptacle on page 135 Examine the torch lead Before cutting system operation examine the torch lead Look for damage or wear Look for kinks cracks cuts or excess wear Replace the torch lead if you find these conditions Make sure that all connections between the torch and torch lead are...

Page 248: ... Torch rebuild kits are available from Hypertherm Refer to Preventive maintenance kits on page 401 of the Parts List b Apply a thin film of silicone lubricant 027055 if the O ring is dry The O ring should look shiny Too much lubricant can restrict water tube motion Remove excess lubricant if found WARNING ELECTRIC SHOCK CAN KILL Disconnect electrical power before doing installation or maintenance ...

Page 249: ...page 135 How to identify emitter wear Emitter wear can indicate when to replace the electrode Emitter wear can be described by the width depth and appearance of the electrode pit The number of starts and the arc on time can have an effect on emitter wear Emitter wear can cause the cut quality to degrade Your cut quality requirements will indicate when to replace the electrode If an electrode needs...

Page 250: ...e of a new electrode note hafnium emitter and electrode pit If the electrode pit diameter extends beyond the hafnium Figure 61 replace the electrode and nozzle Figure 61 Wide electrode pit that extends beyond the hafnium Electrode face Electrode pit Hafnium emitter ...

Page 251: ...he electrode and nozzle Figure 62 Non symmetrical rough edged pit and rough surfaced electrode face If an electrode needs replacement because of emitter wear always replace the nozzle at the same time as the electrode Electrode amperage Replacement pit depth Description 130 A 1 mm 0 04 in In general for electrodes less than 130 A replace the electrode when the pit depth is 1 mm 0 04 in or greater ...

Page 252: ...consumable parts on page 242 2 Use an electrode pit depth gauge to measure the pit depth on the electrode Refer to Figure 63 on page 252 A pit depth gauge 004630 is available from Hypertherm Refer to Other consumable and torch parts on page 392 of the Parts List Figure 63 Use an electrode pit depth gauge to measure pit depth 10 0 20 40 30 4 0 2 3 1 80 60 70 50 90 Electrode not to scale Pit Replace...

Page 253: ...k immediate medical attention NOTICE LOW COOLANT LEVELS CAN DAMAGE THE CUTTING SYSTEM AND COOLANT PUMP Never operate the cutting system if you get a low coolant level notice There is a risk of serious damage to the cutting system and to the coolant pump if you operate the cutting system with no coolant or with low coolant If your coolant pump is damaged pump replacement can be necessary NOTICE AUT...

Page 254: ...nt replacement can be necessary because of environmental conditions including but not limited to contaminants in your coolant or diagnostic codes that indicate coolant problems For instructions about preventive maintenance such as weekly monthly and yearly tasks refer to the XPR Preventative Maintenance Program PMP Instruction Manual 809490 Adding new coolant to the reservoir when the coolant leve...

Page 255: ...at the front of the unit M6 10 mm hex screws hold the panel in position 3 Remove old coolant from the coolant reservoir a Connect a 3 8 inch inner diameter tube to the outlet of the valve on the bottom of the reservoir b Put the other end of the tube into an empty container Use a container that holds the approximate total coolant volume for your cutting system c Open the valve located on the botto...

Page 256: ...on the rear of the plasma power supply where the return coolant hose red band was previously connected d For no more than 30 seconds use the compressed air to blow all of the coolant back into to the reservoir and filter housing System components need the coolant to lubricate rotating surfaces If air flows through the cutting system for longer than 30 seconds it can eliminate the coolant necessary...

Page 257: ...o more than 30 seconds use the compressed air to blow all of the coolant into the container l Leave the coolant supply hose green band disconnected System components need the coolant to lubricate rotating surfaces If air flows through the cutting system for longer than 30 seconds it can eliminate the coolant necessary for lubrication 5 Clean and if needed replace the coolant pump screen a Clean th...

Page 258: ...you do not the new coolant will mix with the old coolant This will cause the new coolant to degrade faster a Put the disconnected end of the coolant return hose into an empty container Use a container that holds the approximate total coolant volume for your cutting system b Attach compressed air no more than 6 89 bar 100 psi to the disconnected end of the coolant supply hose green band c For appro...

Page 259: ...490 If you have questions about how to care for your cutting system contact your cutting machine supplier or regional Hypertherm Technical Service team You can find contact information for each regional office at www hypertherm com on the Contact us page The cutting system software generates a diagnostic code for most conditions that decrease cutting system performance Some conditions have multipl...

Page 260: ...ment or plumbing systems For more information refer to Qualifications of service personnel on page 41 and the Safety and Compliance Manual 80669C WARNING ELECTRIC SHOCK CAN KILL Disconnect electrical power before doing troubleshooting or diagnostic work All work requiring removal of the plasma power supply outer cover or panels must be done by a qualified technician See the Safety and Compliance M...

Page 261: ...ician to measure the line voltage between the terminals that are inside of the plasma power supply Refer to page 265 Remove the power from the cutting system WARNING ELECTRIC SHOCK CAN KILL Disconnect electrical power before doing troubleshooting or diagnostic work All work requiring removal of the plasma power supply outer cover or panels must be done by a qualified technician See the Safety and ...

Page 262: ...ing system can cause serious electric shock Electric shock can seriously injure or kill you Use extreme caution if you do diagnosis or maintenance tasks when the line disconnect switch is in the ON position WARNING ELECTRIC SHOCK CAN KILL The plasma power supply contains dangerous electric voltages that can seriously injure or kill you Even if the plasma power supply is turned OFF you can still ge...

Page 263: ...ntenance when the cutting system is connected to electricity 3 Make sure that the power indicator LED is not illuminated on the plasma power supply gas connect console or torch connect console Examine the PCBs 1 Remove the power from the cutting system Refer to Remove the power from the cutting system on page 261 2 Remove the external panel or panels from the system component that has the PCB that...

Page 264: ... Service team PCB name Location See the following drawings to PCB location page Power distribution PCB Plasma power supply Refer to Control side view 1 on page 369 Control PCB Plasma power supply Refer to Control side view 2 on page 370 Chopper assembly PCB Plasma power supply Refer to Control side view 2 on page 370 Start circuit assembly PCB Plasma power supply Refer to Control side view 1 on pa...

Page 265: ...upply lines If the incoming electric supply lines are good contact a licensed electrician or the electric company that supplies electricity for more information WARNING ELECTRIC SHOCK CAN KILL The plasma power supply contains dangerous electric voltages that can seriously injure or kill you Even if the plasma power supply is turned OFF you can still get a serious electric shock if the plasma power...

Page 266: ...m the cutting system Refer to Remove the power from the cutting system on page 261 b Examine the power cord for damage c Examine the fuses at the line disconnect switch Look for continuity d Repair or replace any damaged or defective parts if found 5 Repeat these steps until the line voltage between any 2 of the 3 lines is equal to the supply voltage Figure 64 U GND W V ...

Page 267: ...9 to respond to the diagnostic codes that show on the CNC or XPR web interface Diagnostic codes can include the following abbreviations GCC Gas connect console CAN Controller area network TCC Torch connect console t o Time out HF High frequency IGBT Insulated gate bipolar transistor Ch1 Chopper Ch2 Chopper 2 DC Direct current current Ind Inductor MagFan Magnetics fan HxFan Heat exchanger fan ...

Page 268: ...l Type Description Information These codes contain information about the current conditions In many cases operator action is not necessary for Information codes If action is necessary the steps are usually simple Alert These codes describe conditions that can reduce productivity or quality Resolve an Alert code as soon as possible Error These codes describe conditions that usually reduce productiv...

Page 269: ...ect console Core VWI or OptiMix cannot receive communications at least once per second from the main control PCB through the CAN Shut down Remote on off 503 Failure TCC Main CAN t o The torch connect console cannot receive communications at least once per second from the main control PCB through the CAN Shut down Remote on off 504 Failure Ch1 Main CAN t o Chopper 1 cannot receive communications at...

Page 270: ...AN Refer to CAN codes 500 503 510 513 for gas connect console 504 505 514 515 for CAN cable and jumper block 507 508 for CAN network and bus 600 602 for no CAN communication on page 311 Ramp down Remote on off 511 Failure Main Mix CAN t o The main control PCB cannot receive communications at least once per second from the gas connect console s mix module through the CAN Ramp down Remote on off 513...

Page 271: ...n contact with the workpiece 2 Examine the consumables Replace the consumables that have damage or excess wear 3 Make sure that both spark arrestors also known as spark ignitors illuminate brightly 4 Inspect the main contactor Look for black or rough surfaces that are difficult to remove Make sure that the contactor closes immediately after the Start command is applied 5 If the contactor is bad re...

Page 272: ... preflow routine within 30 seconds 1 Review the diagnostic code history for previous gas related codes Previous codes can indicate where to look for flow or pressure problems 2 Examine the consumables valves and inlet hoses Make sure that they are correct Replace them if you find damage or excess wear End of cycle Start or set process remote on off 523 Error Preflow purge t o The preflow purge can...

Page 273: ...oblems 2 Make sure that the inlet gas pressure for Line A P2 or Line B P1 are in the correct range 3 If the measurement is too high or too low use the regulators to adjust the pressure for the Line A Line B gas or F5 gas to the correct range 4 Examine the consumables Make sure that the correct consumables are installed Make sure that there is no damage or excess wear 5 Replace incorrect consumable...

Page 274: ...as to the correct range 4 Examine the consumables Make sure that the correct consumables are installed Make sure that there is no damage or excess wear 5 Replace incorrect consumables or consumables that have damage or excess wear 6 Use the gas volume monitors located near the pressure transducers to look for gas leaks Ramp down Set process remote on off 532 Alert Low psi H2O For a minimum of 200 ...

Page 275: ...ake sure that there is no damage or excess wear 5 Replace the incorrect consumables or consumables that have damage or excess wear 6 Use the gas volume monitors located near the pressure transducers to look for gas leaks Ramp down Set process remote on off 534 Alert Low psi Shield For a minimum of 600 milliseconds the shield gas pressure is less than 75 of the setpoint and the setpoint is more tha...

Page 276: ... L min 1 gal min Shut down Remote on off 543 Error High flow 1 Coolant For a minimum of 5 seconds after the coolant pump stops the coolant flow rate is more than 3 03 L min 0 8 gal min Refer to High coolant flow codes 543 544 on page 321 Shut down Set process remote on off 544 Failure High flow Coolant For a minimum of 1 second the coolant flow rate is more than 11 36 L min 3 0 gal min This code c...

Page 277: ...ge the choppers Make sure the code follows the change If yes it confirms the bad chopper Replace it If no go to step 6 6 Examine the following components Choppers Inductors 7 Replace the damaged choppers or inductors if found 8 Make sure that the arc remains on the workpiece during cutting 9 If the code continues contact your cutting machine supplier or regional Hypertherm Technical Service team E...

Page 278: ...f found 4 Look for DC bus errors 5 Exchange the choppers Make sure the code follows the change If yes it confirms the bad chopper Replace it If no go to step 6 6 Examine the following components Choppers Inductors 7 Replace the damaged choppers or inductors if found 8 Make sure that the arc remains on the workpiece during XPR cutting system operation 9 If the code continues contact your cutting ma...

Page 279: ...ound 4 Look for DC bus errors 5 Exchange the choppers Make sure the code follows the change If yes it confirms the bad chopper Replace it If no go to step 6 6 Examine the following components Choppers Inductors 7 Replace the damaged choppers or inductors if found 8 Make sure that the arc remains on the workpiece during XPR cutting system operation 9 If the code continues contact your cutting machi...

Page 280: ...Replace the damaged choppers or inductors if found 8 Make sure that the arc remains on the workpiece during XPR cutting system operation 9 If the code continues contact your cutting machine supplier or regional Hypertherm Technical Service team Shut down Remote on off 560 Error Over temp Ch1 The insulated gate bipolar transistor IGBT temperature for Chopper 1 is more than 75 C 167 F Refer to Over ...

Page 281: ...t switch is in the OFF position during Preflow State Refer to Start switch diagnostic codes 570 577 on page 325 End of cycle Start or set process remote on off 575 Info Start removed ignite The Plasma Start switch is in the OFF position during Ignite State End of cycle Start or set process remote on off 576 Info Start removed pilot The Plasma Start switch is in the OFF position during Pilot arc St...

Page 282: ...are normal it takes approximately 10 minutes for the XPR cutting system to cool Over temp codes can occur when cooling takes more than 10 minutes A high ambient temperature can have an effect on cooling time Refer to Over temp diagnostic codes Inductors 580 583 Transformers 586 on page 327 Ramp down 583 Error Over temp Ind4 Ramp down 586 Error Over temp Xfmr For a minimum of 5 seconds the temperat...

Page 283: ... For a minimum of 30 seconds after power is supplied to the cutting system Chopper 1 does not identify itself to the main control PCB through the CAN 1 Confirm that the chopper ID connector is connected to J8 2 Connect the connectors if necessary 3 If connected refer to CAN codes 500 503 510 513 for gas connect console 504 505 514 515 for CAN cable and jumper block 507 508 for CAN network and bus ...

Page 284: ...ct the consumable parts for damage and excess wear 2 If any consumable part needs replacement refer to Install the consumables on page 133 Ramp down Remote on off 611 Failure Ch1 Torch Protect ChB A catastrophic failure of a consumable part is found on the Channel B Chopper 1 current signature Ramp down Remote on off 612 Failure Ch2 Torch Protect ChA A catastrophic failure of a consumable part is ...

Page 285: ...t parts or nesting program Rampdown errors can occur when crossing large kerfs or cutting at incorrect heights End every cut with the plasma arc still attached to the workpiece Decrease the cutting speed when the end of the cut is near Stop the plasma arc before the part is completely cut allow completion of the cut during rampdown Program the path of the torch into the scrap area for rampdown Ram...

Page 286: ...k for loose or bad connections on pins 5 and 6 Tighten loose connections or replace bad connections 8 Make sure that LED D1 on the power distribution board 141425 is illuminated 9 If not illuminated examine the power distribution board Look for 120 VAC at the input J1 pins 5 6 Continuity on fuse FH2 with power OFF 120 VAC at the output J5 pins 7 8 and pins 9 10 10 If 120 VAC is not present on the ...

Page 287: ... 1 Inspect the consumable parts for damage and excess wear 2 If any consumable part needs replacement refer to Install the consumables on page 133 3 If the code continues contact your cutting machine supplier or regional Hypertherm Technical Service team End of cycle Remote on off 627 Error No DC output Ch2 No current produced within 250 milliseconds after Arc On State starts 1 Inspect the consuma...

Page 288: ... the OFF position disabled No operator action necessary XPR cutting system operation continues when the remote on off switch is set to the ON position Refer to Sequence of operation on page 207 None Start or set process remote on off 646 Info System turned off Power is removed from the XPR cutting system Shut down Start or set process remote on off 647 Info Process selected Shows the operator sele...

Page 289: ... in Inductor 2A Use a digital multimeter to measure the resistance from the thermistor Refer to How to measure resistance from thermistors on page 345 Shut down Remote on off 663 Error Thermistor Fault Ind 4 The main control PCB finds a shorted temperature sensor in Inductor 2B Shut down Remote on off 666 Error Thermistor Fault Xfmr The main control PCB finds a shorted temperature sensor in the tr...

Page 290: ...asure the resistance from the thermistor Refer to How to measure resistance from thermistors on page 345 Shut down Remote on off 677 Error No Thermistor Xfmr The main control PCB finds an open circuit in the transformer Use a digital multimeter to measure the resistance from the thermistor Refer to How to measure resistance from thermistors on page 345 Shut down Remote on off 678 Error No Thermist...

Page 291: ...node 2 Make sure that the green power indicator LED on the gas connect console and torch connect console is illuminated 3 If the LEDs are not illuminated examine the power distribution board 141425 Look for Loose and poorly connected connectors and CAN cables Evidence of 120 V D1 illuminated 4 If D1 is illuminated examine the plasma power supply control PCB 141322 Make sure that the remote on off ...

Page 292: ...the gas connect console is less than 8 3 bar 0 4 120 psi 5 None Set process remote on off 699 Error OptiMix only Mix Fault The main control PCB finds a mixing module fault in the gas connect console No operator action necessary Ramp down Set process remote on off 700 Alert VWI or OptiMix only Gas Inlet F5 GCC The F5 inlet pressure P6 in the gas connect console is less than 5 52 bar 80 psi or more ...

Page 293: ...econds the oxygen O2 inlet gas pressure P4 in the torch connect console is less than 5 52 bar 80 psi or more than 8 61 bar 125 psi None Set process remote on off 704 Alert Shield Gas Inlet Air TCC For a minimum of 200 milliseconds the air inlet pressure P4 in the torch connect console is less than 5 52 bar 80 psi or more than 8 61 bar 125 psi None Set process remote on off 705 Alert Shield Gas Inl...

Page 294: ...ess remote on off 711 Error No sensor P14 TCC The P14 pressure sensor in the torch connect console is not detected Ramp down Set process remote on off 712 Error VWI and OptiMix only No sensor P6 GCC The P6 pressure sensor in the gas connect console is not detected Ramp down Set process remote on off 713 Error VWI and OptiMix only No sensor P7 GCC The P7 pressure sensor in the gas connect console i...

Page 295: ... Only 1 communication method Serial EtherCAT or Wireless at a time can send a process ID to the XPR cutting system Refer to the Connect for Communication on page 147 and How to change the device that has control on page 192 for guidance about how to select or change the interface that controls the cutting system None Set process remote on off 3 invalid user source Another interface has control of ...

Page 296: ...rent capabilities For example argon assist and argon marking for mild steel are available for cutting systems equipped with OptiMix or VWI gas connect consoles but not with Core Refer to How to choose the torch positions and process settings you need on page 217 for information about different process capabilities None Set process remote on off 717 Alert OptiMix only Low voltage mix The supply vol...

Page 297: ...When this occurs the mixer reduces flow to prevent backflow which can affect cut quality 1 Make sure that the consumables are correct 2 Increase N2 Ar and H2 pressure during test cutflow within acceptable range 3 Make sure that you have the most recent XPR firmware You can log into the Xnet at www hypertherm com to download it None Start or set process remote on off 721 Error Mix param checksum Th...

Page 298: ...system clock There is a problem with the mixing system clock 1 Use the remote on off switch to turn OFF and then turn ON the cutting system 2 If the code continues replace the gas connect console Ramp down Set process remote on off 730 Alert Solenoid error V1 There is an over current condition for receptacle valve V1 at the PCB in the torch connect console 1 Inspect the valve driver cable connecti...

Page 299: ...ion for valve V5 at the PCB in the torch connect console Ramp down Set process remote on off 735 Alert Solenoid error V6 There is an over current condition for valve V6 at the PCB in the torch connect console Ramp down Set process remote on off 736 Alert Solenoid error V7 There is an over current condition for valve V7 at the PCB in the torch connect console Ramp down Set process remote on off 737...

Page 300: ... alert for I2C1 1 Examine the cable used to ground the gas connect console Connect any disconnected cable or repair a damaged cable if found 2 Make sure that all external panels for all system components are correctly installed Install loose or missing panels if found 3 Make sure that all hardware that holds the external panels is in position and is tight None Set process remote on off 743 Alert M...

Page 301: ...an connector The wiring to J2 and J5 on the fan power distribution PCB The wiring to J7 on the control PCB 1 2 Examine the 48 VDC power source output If not correct replace the 48 VDC power source 3 If you do not find any loose connections and the 48 VDC power source is good replace the fan None Set process remote on off 749 Alert Low Speed HxFan 2 The fan tachometer feedback is below the minimum ...

Page 302: ...the 48 VDC power source is good replace the fan None Set process remote on off 751 Alert Low speed CAB FAN1 Control Side Fan 2 Fan speed is below the minimum acceptable RPM value 1 Examine the fan Make sure that the following fan connections are good The fan connector The wiring to J8 Low speed CAB FAN2 control side Fan 2 on the fan power distribution PCB The wiring to J7 on the control PCB 1 2 Ti...

Page 303: ...s for excess wear Replace the contactor if excess wear is found Otherwise continue with the following steps 5 Inspect the following contactor components for loose connections Contactor Input to chopper Power cord 6 Tighten loose connections if found Otherwise continue with the following steps 7 If the code continues contact your cutting machine supplier or regional Hypertherm Technical Service tea...

Page 304: ...with the following steps 5 Inspect the following contactor components for loose connections Contactor Input to chopper Power cord 6 Tighten loose connections if found Otherwise continue with the following steps 7 If the code continues contact your cutting machine supplier or regional Hypertherm Technical Service team Shut down Remote on off 755 Alert Low level Coolant The coolant level is low Fill...

Page 305: ... page 338 None Start or set process remote on off 757 Error DC work exceeds limits The work lead current exceeds the setpoint by 5 A Make sure that you have the most recent XPR firmware You can log into the Xnet at www hypertherm com to download it If the code continues contact your cutting machine supplier or regional Hypertherm Technical Service team End of cycle Remote on off 758 Alert Main 24 ...

Page 306: ... damage or excess wear 2 Make sure that you have the most recent XPR firmware You can log into the Xnet at www hypertherm com to download it 3 If the code continues contact your cutting machine supplier or regional Hypertherm Technical Service team None Set process remote on off 765 Alert Inrush contactor fault The inrush contactor driver finds an over current condition 1 Inspect the inrush contac...

Page 307: ... off 768 Alert Gas inlet O2 Line A Line A O2 inlet pressure P2 is below 5 52 bar 80 psi or above 8 62 bar 125 psi Refer to Gas inlet pressure codes 768 771 on page 337 None Set process remote on off 769 Alert Gas Inlet Argon Line B Line B Argon inlet pressure P1 is below 5 52 bar 80 psi or above 8 62 bar 125 psi If you have a cutting system equipped with a Core or VWI gas connect console refer to ...

Page 308: ... been reset Reduce wireless connections to the XPR cutting system None Start or set process remote on off 777 Alert Pilot relay fault The pilot relay driver detects an over current condition 1 Remove the power for the XPR cutting system 2 Remove the control side panel from the plasma power supply 3 Examine the control PCB PCB 1 4 Remove J6 from the control PCB 5 Remove the cover from the pilot arc...

Page 309: ...ke sure that you have the most recent XPR firmware Log into the Xnet at www hypertherm com to download it None Set process remote on off 779 Alert Ch1 15V bus The Chopper 1 15 V bus is out of range below 13 V or above 17 V 1 Examine the 24 VDC on the connector J2 pins 1 and 2 on the Chopper 1 assembly 2 If the 24 VDC is absent examine the wiring on J2 of Chopper 1 Look for loose connections 3 If y...

Page 310: ...ply to access the 24 VDC power supply inside 2 Use a digital multimeter to find the presence of 24 VDC 2 VDC across the Positive and Negative terminals of the power source 3 If the voltage is outside of the 2 VDC limit replace the 24 VDC power supply 4 If 24 VDC 2 VDC is found across the Positive and Negative terminals of the power supply and the 784 diagnostic code continues look for 24 VDC 2 VDC...

Page 311: ...ent pins and bent sockets Tighten loose connections if found If you find bent sockets order a new cable If you find a bent pin try to straighten it If this does not work order a new cable b For code 503 and 504 together Examine the CAN cable connection between Chopper 2 and the control board PCB 1 on the plasma power supply Look for loose connections bent pins and bent sockets Tighten loose connec...

Page 312: ...n the control board is functional Make sure that the DIP switches on S2 are in the following positions 1 OFF 2 OFF 3 OFF 4 OFF Make sure that the CAN cable connector is fully engaged in J7 f If the LEDs are not functioning as described above contact your cutting machine supplier or regional Hypertherm Technical Service team g If LEDs are functioning as described above examine LEDs D33 and D34 Flic...

Page 313: ...d connection between the plasma power supply and the gas connect console Reconnect or replace the CAN cable if necessary There is a bad connection between the small CAN jumper cable for the gas connect console control board 141375 and the sheet metal located inside of the gas connect console Reconnect or replace the CAN cable if necessary h If the control board is functional and the code continues...

Page 314: ...nection between the main power supply and gas connect console is good Make sure that the CAN cable between the plasma power supply and gas connect console is connected Disconnect the CAN cable connection between the gas connect control board 141375 and the mixer in the same console The gas connect console mixer and torch connect consoles can appear to communicate even when the CAN cable between th...

Page 315: ...w LED is not illuminated a CAN communication failure can be the problem Examine the CAN cable between the control board 141375 and the mixer Look for a loose connection or bent pins If the green LED is blinking once per second and the red LED is illuminated steady no flickering the mixer in the gas connect console can be the problem Contact your cutting machine supplier or regional Hypertherm Tech...

Page 316: ...al f If the RX LED D34 is not flickering the CAN cable between the gas connect console and torch connect console is disconnected Reconnect the CAN cable if necessary g If the RX LED is flickering and the CAN TX LED D35 is not flickering replace the control board 141334 inside of the torch connect console If replacement is necessary contact your cutting machine supplier or regional Hypertherm Techn...

Page 317: ... fixable kinks 5 Replace any fitting that has damage 6 Tighten loose connections if found 7 Examine water regulators Look for debris that can block the flow path 8 Adjust the inlet water pressures to at least 2 77 bar 40 psi when cutting if necessary The Hypertherm supplied regulator that is connected to the gas connect console is pre set at the factory Do not adjust this regulator 9 If you cannot...

Page 318: ...st cutflow and continue with the following steps Make sure that the pressure on P14 is achieved An error occurs only if the value is less than 75 of the setpoint for at least 600 milliseconds a If the pressure is too high or too low use the optional external shield gas regulator to decrease or increase the pressure b Examine voltage going to J21 1 and J21 2 for B2 and J7 for V11 Refer to Valve sta...

Page 319: ...ant Refer to Coolant Installation on page 199 3 If the coolant reservoir level is acceptable but the code continues a Make sure that the coolant pump is ON and the gauge is spinning b Make sure that the bypass is working c Examine the coolant hoses Look for restrictions or blockages d Examine the consumables Make sure they are correct for the operator selected process e Examine the coolant filter ...

Page 320: ...d pin 2 examine the wiring harness that connects to J8 Look for a short If no short is found replace the control PCB b If the voltage on J8 pin 1 and pin 2 is 15 VDC examine the flow sensor output in frequency at the control PCB Measure the frequency on J8 pin 3 pulse and pin 2 ground If the value differs more than 0 8 L min 0 2 gal min or if there are no pulses 0 Hz replace the flow sensor 7 If y...

Page 321: ...an effect on coolant flow c Set the line disconnect switch to the ON position d Use the CNC or XPR web interface to send a process command to the cutting system The coolant pump starts automatically any time a process command is sent e If the code continues Examine the flow meter Look for air bubbles in the sight glass Air bubbles can cause the flow meter to give a higher flow value Make sure the ...

Page 322: ...he temperature limit you can see reduced performance and over temp diagnostic codes 3 While all of the fans continue to operate allow the cutting system to cool 4 Reference the XPR web interface Make sure that the heat exchanger fan speed is within the acceptable range heat exchanger fan 1 heat exchanger fan 2 WARNING ELECTRIC SHOCK CAN KILL Disconnect electrical power before doing troubleshooting...

Page 323: ...pressed air use You can use a gloved hand to hold a fan in position if necessary 8 Make sure that the heat exchanger fans have no obvious obstruction dust or debris a Disconnect the connector for the choppers or remove the coolant thermistor wires from the connector This makes it easier to measure only the resistance for the thermistors b Use a digital multimeter to measure the resistance from eac...

Page 324: ...above 100 ohms and below the minimum Remove the electrical power from the cutting system Refer to Remove the power from the cutting system on page 240 Allow the coolant to reach 85ºC 185ºF or below It can take a long time for the coolant to reach 85ºC 185ºF if the ambient temperature is high Contact your cutting machine supplier or regional Hypertherm Technical Service team for guidance about how ...

Page 325: ...ntrol PCB 141322 on page 351 or Plasma power supply chopper PCB 141319 on page 354 9 If the code continues or if you cannot find or resolve the problem with these corrective actions contact your cutting machine supplier or regional Hypertherm Technical Service team Start switch diagnostic codes 570 577 1 Use the CNC or XPR web interface to verify the status of the cutting system Make sure that a c...

Page 326: ...er 10 If the LED is not illuminated skip to step 12 11 If the code stops and LED D50 is not illuminated with the discrete cable still disconnected examine the discrete cable for damage Look for Shorts across the line Damaged cable Bad relays Loose connections Replace the discrete cable if you find damage Refer to Discrete CNC interface cable on page 397 in Parts List 12 If you do not find visible ...

Page 327: ...o operate allow the cutting system to cool Before you continue with the next step make sure that the magnetics reach a temperature of 160ºC 320ºF or below 3 Without removing the external side panel on the plasma power supply look through the ventilation trusses on the plasma power supply to examine both magnetic fans inside Look through the ventilation trusses on the front of the plasma power supp...

Page 328: ... of compressed air is often necessary to clear this area Consider the use of personal protective equipment to protect yourself from airborne particulates and debris Make sure to minimize fan rotation during compressed air use You can use a gloved hand to hold a fan in position if necessary 8 If both magnetics fans have no obvious obstruction dust or debris a Disconnect the connector from the contr...

Page 329: ... between each thermistor and its connector pins Look for shorts between wires or to the ground 9 If the thermistor resistance is within range when the thermistor is disconnected from the control PCB and the code continues when the thermistor is reconnected to the control PCB contact your cutting machine supplier or regional Hypertherm Technical Service team They can help you decide if control PCB ...

Page 330: ... connections 4 If the connections are good and the code continues replace PCB5 I O PCB 5 If you cannot find or resolve the problem with these corrective actions contact your cutting machine supplier or regional Hypertherm Technical Service team WARNING ELECTRIC SHOCK CAN KILL Disconnect electrical power before doing troubleshooting or diagnostic work All work requiring removal of the plasma power ...

Page 331: ...the water inlet pressure is at least 2 07 bar 40 psi 4 When gas flow is less than the pressure range use the regulators to increase the pressure if necessary Do not exceed the recommended pressures 5 If the pressure remains too low examine the gas hoses and gas inlet fittings Look for Damage or kinks that can restrict flow Leaks that can decrease pressure WARNING ELECTRIC SHOCK CAN KILL Disconnect...

Page 332: ...nd or resolve the problem with these corrective actions contact your cutting machine supplier or regional Hypertherm Technical Service team Shield gas inlet pressure in the torch connect console diagnostic codes 702 705 1 Look at the CNC screen or XPR web interface to identify the inlet pressure inside the torch connect console Look at The N2 inlet pressure P4 for code 702 The O2 inlet pressure P4...

Page 333: ...Reposition the hoses if you find fixable kinks 7 Replace any fitting that has damage 8 Tighten loose connections if found 9 If you cannot find or resolve the problem with these corrective actions contact your cutting machine supplier or regional Hypertherm Technical Service team Gas connect console Acceptable gas inlet pressures in the torch connect console N2 O2 Air Ar Core 7 5 bar 0 4 110 psi 5 ...

Page 334: ... pressure is above 7 5 bar 110 psi or below 6 2 bar 90 psi Ar shield inlet P4 pressure is above 7 5 bar 110 psi or below 6 2 bar 90 psi Follow these steps to adjust the N2 regulator 1 Install 1 of the following sets of consumables 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 choose 1 of the following processes 2100 for 300 A N2 N2 alumi...

Page 335: ...P4 on the XPR web interface is 6 9 bar 100 psi Follow these steps to adjust the Ar regulator 1 Install 1 of the following sets of consumables 300 A O2 Air 170 A O2 Air 2 Use the XPR web interface to choose 1 of the following processes 1205 for O2 N2 mild steel 1157 for O2 Air Ar pierce assist mild steel 3 Remove the cover for OptiMix gas connect console 4 Pull up the Ar regulator knob so the orang...

Page 336: ...ansducer for the gas connect console 3 Make sure that the pressure transducer is plugged in correctly on the following PCBs Torch connect console control PCB Gas connect console control PCB 4 Re install the pressure transducer if any incorrect connections are found 5 If you find damage replace the damaged control PCB 6 Replace the pressure transducer 7 If you cannot find or resolve the problem wit...

Page 337: ... consoles on page 46 3 If the gas inlet pressure is not within the acceptable range adjust it a Use a 2 stage regulator that can delivery the necessary gas flow and can maintain consistent gas pressure with high pressure gas cylinders WARNING ELECTRIC SHOCK CAN KILL The plasma power supply contains dangerous electric voltages that can seriously injure or kill you Even if the plasma power supply is...

Page 338: ...to Process gas inlet pressure in the torch connect console diagnostic codes 702 705 769 770 for OptiMix equipped cutting systems on page 334 5 If you have a Core or VWI gas connect console or if the code continues or if you cannot find or resolve the problem with these corrective actions contact your cutting machine supplier or regional Hypertherm Technical Service team How to do a gas leak test V...

Page 339: ...pread of fire to the supply gases unless a flashback arrestor is not available for a specific gas or pressure As an installer or user you must supply the exhaust ventilation and flashback arrestors for your cutting system You can get them from your cutting machine supplier HYDROGEN GAS CAN CAUSE AN EXPLOSION OR FIRE Hydrogen is a flammable gas that can cause an explosion or fire Keep flames away f...

Page 340: ...bstruction or leak can be the cause Do a container test 1 Obtain an empty container that has a capacity of at least 3 79 liters 1 US gallon and volume measurements if possible 2 Remove the power from the cutting system Refer to Remove the power from the cutting system on page 240 WARNING ELECTRIC SHOCK CAN KILL The plasma power supply contains dangerous electric voltages that can seriously injure ...

Page 341: ...at the amount of coolant in the container It should be at least 1 89 liters 0 5 US gallon 9 If the flow rate is outside of the correct range an internal obstruction or leak can be the cause 10 If you find obstructions remove them Replace damaged parts if found 11 If coolant flow remains slow and it has been more than 6 months since the last coolant replacement replace the coolant Refer to Replace ...

Page 342: ...resolve the problem with these corrective actions contact your cutting machine supplier or regional Hypertherm Technical Service team How to test continuity between the nozzle and workpiece 1 Remove the power from the cutting system Refer to Remove the power from the cutting system on page 240 2 Locate the start circuit assembly PCB 4 1 1 ...

Page 343: ...on Manual 809480 343 3 Install a temporary jumper wire between J5 nozzle and J1 work on the start circuit PCB 4 141360 2 3 D4 D6 2 3 NOTICE Never fire an arc when a temporary jumper wire is installed on the PCB Sparking and damage to the PCB can occur ...

Page 344: ...son close push in the contact on the pilot arc relay 6 Measure the ohms between the nozzle and the workpiece Less than 3 ohms is good A value greater than 3 ohms indicates a faulty connection between the torch and ignition console or between the ignition console and the power supply or between the power supply work lead and workpiece 4 5 5 6 2 1 2 2 ...

Page 345: ...uit power supply to gas connect console to torch connect console to torch receptacle Look for insulation damage and short circuits to ground How to measure resistance from thermistors 1 Use a digital multimeter to measure the resistance from each thermistor wire based on the following connector pin locations 2 Look for a resistance value that is outside of the minimum or maximum in Table 39 Thermi...

Page 346: ...r cutting machine supplier or Hypertherm Technical Service team 7 If the thermistor resistance is within range when the thermistor is disconnected from the control PCB and the code continues when the thermistor is reconnected to the control PCB contact your cutting machine supplier or regional Hypertherm Technical Service team They can help you decide if control PCB replacement is necessary Refer ...

Page 347: ...r to access the bullet connector on the torch receptacle block side located inside the torch connect console 4 Use a digital multimeter to measure the resistance from the torch tip to the ohmic relay Refer to Figure 65 on page 348 WARNING ELECTRIC SHOCK CAN KILL When the line disconnect switch is in the ON position there is line voltage throughout the cutting system Voltages in the cutting system ...

Page 348: ...c relay is connected to J4 pin 2 and that the ohmic wire from the lifter is connected to J4 pin 1 c Adjust or tighten connections if needed then continue with step 7 7 Supply electrical power to the cutting system 8 Make sure that the torch is not touching the workpiece 9 Use a digital multimeter to look for 24 VDC between the workpiece or chassis ground and the torch tip J3 or J4 10 If there is n...

Page 349: ...ol PCB Refer to Torch connect console control PCB 141334 on page 359 e Make sure that LED D2 and D15 both illuminate f If both LEDs illuminate make sure that the CNC is receiving ohmic contact signals from the cutting system or torch height controller If receiving ohmic contact signals refer to the instruction manual that came with your CNC for troubleshooting recommendations g If LED D2 is not il...

Page 350: ...Diagnostics and Troubleshooting 8 350 809480 Instruction Manual XPR300 PCB information Plasma power supply power distribution PCB 141425 LED Signal D1 120 VAC ...

Page 351: ... power supply control PCB 141322 D28 D47 D78 D104 D105 D79 D51 D80 D85 D81 D82 D84 D49 D4 D52 D43 D41 D38 D36 D33 D31 D24 D20 D45 D15 D94 D95 D89 D6 D2 D3 D10 D19 D25 D97 D64 D56 D50 D86 D53 D54 D61 D66 D68 D69 D100 D103 D17 D108 PROG WIFI MODE SEL RUN ENABLE CNC 24V OUT DISABLE ...

Page 352: ...31 MAG FAN 2 FEEDBACK D28 MAG FAN 1 FEEDBACK D5 3 3 V D20 MAGNETIC FANS ENABLE D24 HEAT EXCHANGER FAN ENABLE D45 COOLANT FLOW D86 REMOTE ON OFF D50 PLASMA START D56 MOTION D64 HOLD OUT D53 HOLD IN D54 PIERCE COMPLETE D61 CNC ERROR D66 READY FOR START D68 AUTO PIERCE DETECT D69 OHMIC CONTACT OUTPUT D15 SURGE INJ EN UNUSED IN THIS SYSTEM D108 PILOT ARC ENABLE D89 REMOTE ON OFF RELAY ENABLE D6 PILOT ...

Page 353: ...U programming mode ON DFU OFF Run Default is OFF 2 3 3V logic power ON USB OTG OFF Internal power supply Default is OFF 3 RS 422 Serial ID0 Default is OFF 4 RS 422 Serial ID1 Default is OFF DIP switch 3 positions 1 Wireless module programming ON Enabled OFF Disabled Default is OFF 2 Wireless module transmit ON From micro controller OFF Disabled Default is ON 3 Wireless module transmit ON From J20 ...

Page 354: ...upply chopper PCB 141319 LED Signal LED Signal D22 15V AND 15V POWER D1 DCA D14 5 V D2 DCB D21 3 3 V D3 STATUS D32 OVER CURRENT CHANNEL B D4 ACTIVITY D31 OVER CURRENT CHANNEL A D10 5VB D96 USBFLAG D33 CAN TX D6 18V AND 5V POWER D34 CAN RX D22 D14 D21D32 D31 D96 D1 D3D4 D10 D33D34 D6 D2 ...

Page 355: ...ics and Troubleshooting 8 XPR300 Instruction Manual 809480 355 Plasma power supply start circuit PCB 141360 Plasma power supply I O PCB 141371 LED Signal LED Signal D4 PILOT ARC ENABLE D6 18V AND 5V POWER D4 D6 ...

Page 356: ...Diagnostics and Troubleshooting 8 356 809480 Instruction Manual XPR300 Plasma power supply fan power distribution PCB 141384 ...

Page 357: ...uction Manual 809480 357 Gas connect console control PCB 141375 LED Signal LED Signal D15 24 V D24 CAN RX D29 B5 D30 Status D26 B4 D31 Activity D19 HF D1 USBFLAG D18 3 3 V D16 5 V D25 CAN TX D17 A3 3 D18 D17 D16 D30 D1 D5 D6 D31 D25 D29 D15 D26 D24 ...

Page 358: ...cs and Troubleshooting 8 358 809480 Instruction Manual XPR300 Gas connect console high frequency PCB 141354 Torch connect console ohmic PCB 141368 LED Signal D1 HIGH FREQUENCY ENABLE LED Signal D2 Ohmic contact ...

Page 359: ...D45 A3 3 V D51 V6 D4 V11 D41 V5 D63 B3 D84 V12 D46 3 3 V D16 V4 D23 USB FLAG D64 V8 D43 5 V D34 CAN RX D44 24 V D35 CAN TX D70 V1 TORCH VALVE D48 B1 D76 V2 NOT USED IN THIS SYSTEM D57 B2 D18 V3 NOT USED IN THIS SYSTEM D49 HV RELAY D8 NOT USED IN THIS SYSTEM D15 OHMIC CONTACT D58 D51 D41 D16 D84 D64 D35 D34 D75 D69 D87 D45 D46 D70 D63 D15 D43 D44 D23 D49 D76 D18 D8 D4 D88 D24 D25 D57 D48 ...

Page 360: ...Diagnostics and Troubleshooting 8 360 809480 Instruction Manual XPR300 ...

Page 361: ...XPR300 Instruction Manual 809480 361 Parts List Plasma power supply Part number Voltage AC 078620 200 078621 208 078622 220 078623 240 078624 380 078625 400 078626 415 078627 440 078628 480 078629 600 ...

Page 362: ...el with labels 1 2 428727 Side panel with labels and handles 2 3 101300 Base 1 4 428725 Front panel with H not shown and power indicator LED label 1 5 101314 Lower right liquid cooling rear corner panel 1 6 101307 Lower left control rear corner panel 1 7 428726 Rear panel with label and handles 1 7 1 2 3 4 5 6 2 ...

Page 363: ...9002 Power indicator LED 1 2 229821 Fan 292 cfm 48 VDC 120 mm 4 7 inch diameter CAB FAN3 CAB FAN4 2 3 229822 Fan 890 cfm 48 VDC 254 mm 10 inch diameter HX FAN1 HX FAN2 MAG FAN1 MAG FAN2 4 4 229717 Heat exchanger only 1 5 003266 Solid state relay 1 6 141384 Fan power distribution PCB PCB6 1 2 1 3 3 4 5 6 ...

Page 364: ...R300 Coolant system Part number Description Quantity 1 127014 Coolant reservoir cap 1 2 229741 Coolant flow meter 1 3 229775 Coolant level sensor 1 4 101281 Coolant filter bracket 1 1 3 5 7 8 9 2 6 13 4 10 11 12 14 1 3 5 7 8 9 2 6 13 4 10 12 11 14 ...

Page 365: ...MNPT X 1 inch MNPT hexagonal collar Adapter 1 inch MNPT X 3 8 inch FNPT X 1 4 inch FNPT Adapter 3 8 inch hexagonal Coolant solenoid valve assembly 1 8 006132 Coolant bypass check valve 1 9 229721 Coolant solenoid valve assembly 1 10 229654 Thermistor Copper pipe clip with electrical connector 1 11 127559 Coolant pump screen coarse 1 12 229843 Plug and O ring 1 13 002561 Coolant reservoir 1 14 0061...

Page 366: ...ch NPT X 1 2 inch tube 45 swivel 2 2 015903 Red ring 1 13 inches inner diameter 1 3 015888 Adapter 1 2 inch FNPT X 1 1 2 inch length bulkhead 2 015899 Red ring 0 87 inch inner diameter not shown 1 4 015029 Adapter 1 2 inch NPT X 8 male 2 015898 Green ring 0 87 inch inner diameter not shown 1 5 015902 Green ring 1 13 inch inner diameter 1 1 2 3 4 5 4 3 1 ...

Page 367: ... 4 inch NPT X 1 2 inch tube 45 swivel in the top of the coolant reservoir 1 015510 Adapter 1 4 inch X hexagonal collar between the flow meter and coolant reservoir 1 015663 Adapter 1 4 inch NPT X 1 2 inch tube in the flow meter and coolant bypass check valve 2 015668 Elbow adapter 1 2 inch NPT X 1 2 inch tube 90 in the coolant filter fine assembly 2 104807 Nut for chopper fitting on the back of ch...

Page 368: ...ly 1 2 3 Part number Description Designator Quantity 1 428844 Kit Inductor 1A top 1B bottom L1 1 2 428845 Kit Inductor 2A top 2B bottom L2 1 3 Transformer horizontal 66 5 kW 3 phase 200 V 50 Hz 60 Hz T2 1 208 V 60 Hz 220 V 50 Hz 60 Hz 240 V 60 Hz 380 V 50 Hz 60 Hz 400 V 50 Hz 415 V 50 Hz 440 V 50 Hz 60 Hz 480 V 60 Hz 600 V 60 Hz ...

Page 369: ...wer distribution PCB PCB7 1 108709 Fuse 10 A 250 VAC time delay on PCB7 F3 F4 F5 3 3 Control transformer assembly 3 kVA 229809 200 V 50 Hz 60 Hz T1 1 229810 208 V 60 Hz 3 kVA 229811 220 V 50 Hz 60 Hz 229812 240 V 60 Hz 229813 380 V 50 Hz 229814 400 V 50 Hz 229815 415 V 50 Hz 229816 440 V 50 Hz 60 Hz 229794 480 V 60 Hz 229817 600 V 60 Hz 4 229678 Start circuit assembly PCB4 1 1 2 3 4 ...

Page 370: ...trol PCB PCB1 1 3 208394 Fuse holder 2P 30 A 600 V 1 208395 Fuse 8 A 600 V Class R used in 380 V 400 V 415 V 440 V 480 V 600 V F1 F2 2 208397 Fuse 15 A 600 V Class R used in 200 V 208 V 220 V 240 V 4 141371 I O PCB PCB5 1 5 003277 Pilot arc relay 24 VDC coil 60 A 28 VDC contacts CR1 1 6 101316 Pilot arc relay cover 1 7 229679 Chopper assembly Chopper 1 Chopper 2 2 3 4 1 2 5 6 7 ...

Page 371: ... Chopper 1 1 Part number Description Designator Quantity 1 229697 Inrush contactor assembly 80 A IEC AC 3 3 phase 120 VAC IR_CON 1 2 209274 Inrush resistor assembly 2 Ω X 3 1 3 229033 Terminal block 600 V 200 A 200 V 208 V 220 V 240 V 380 V 400 V 415 V TB1 1 4 029316 Terminal block 600 V 140 A 380 V 440 V 480 V 600 V Part number Description Designator Quantity 1 2 3 4 5 200 V 208 V 220 V 240 V pla...

Page 372: ... 429060 Main contactor assembly 380 V 400 V 415 V 440 V 480 V 600 V 6 141511 VDC3 PCB Optional for use with RS 422 and discrete cutting systems 1 Part number Description 078631 Core gas connect console 078632 VWI gas connect console 078633 OptiMix gas connect console Part number Description Designator Quantity Core VWI OptiMix ...

Page 373: ...Insulator Core VWI OptiMix 1 2 229837 Coil assembly Core VWI OptiMix T2 1 3 229838 High frequency high voltage transformer Core VWI OptiMix T1 1 4 009045 EMI filter Core VWI OptiMix 1 5 141354 High frequency high voltage ignition PCB Core VWI OptiMix PCB2 1 6 075678 Socket head cap screw M5 0 8 X 10 mm hexagonal Core VWI OptiMix 1 1 2 3 4 5 6 Inside view ...

Page 374: ...6 inch tube Core VWI OptiMix 2 3 229640 Power source 88 VAC 264 VAC to 24 VDC VWI OptiMix only 1 4 141375 Control PCB Core VWI OptiMix PCB1 1 5 229825 Green power indicator LED assembly Core VWI OptiMix 1 6 104757 Coolant manifold Core VWI OptiMix 1 7 015029 Adapter 1 2 inch NPT X 8 male Core VWI OptiMix 4 8 015898 Green ring 0 87 inches inner diameter Core VWI OptiMix 2 9 015899 Red ring 0 87 inc...

Page 375: ...adapters 3 015876 1 4 inch NPT X 1 4 inch tube 2 4 015811 1 4 inch NPT X 8 mm tube 3 5 015853 Male elbow 1 4 inch NPT X 5 16 inch tube 1 Threaded adapters with thread sealant applied 6 015012 1 4 inch NPT X 6 male air output and input 2 7 015103 1 4 inch NPT X RH B inert female nitrogen output and input 2 8 015116 1 8 inch NPT X RH A male oxygen output 1 9 015009 1 4 inch NPT X RH B male oxygen in...

Page 376: ...Parts List 9 376 809480 Instruction Manual XPR300 VWI gas connect console input and output manifolds and adapters 1 7 8 9 6 3 5 6 4 11 10 2 8 6 7 5 11 11 12 12 12 13 14 15 16 17 18 14 ...

Page 377: ...ch tube 1 8 015876 1 4 inch NPT X 1 4 inch tube 1 9 015853 Elbow 1 4 inch NPT X 5 16 inch tube 90 1 10 015909 Elbow 3 8 inch NPT X 5 16 inch tube 90 Threaded adapters with thread sealant applied 11 015103 1 4 inch NPT X RH B inert female 3 12 015012 1 4 inch NPT X 6 male 3 13 015009 1 4 inch NPT X RH B male 1 14 015922 1 4 inch X hexagonal collar 2 15 015230 1 4 inch NPT X LH B 1 16 015116 Adapter...

Page 378: ...Parts List 9 378 809480 Instruction Manual XPR300 OptiMix gas connect console input and output manifolds and adapters 6 8 1 5 9 7 10 3 13 4 4 13 9 2 7 10 12 14 18 19 20 14 15 16 17 11 ...

Page 379: ...ube 1 8 015907 1 4 inch NPT X 3 8 inch tube 1 9 015909 Elbow 3 8 inch NPT X 5 16 inch tube 1 10 015910 3 8 inch NPT X 5 16 inch tube 1 11 015906 Dual connection 1 8 inch NPT X 1 4 inch tube 1 12 015908 Elbow 1 4 inch NPT X 3 8 inch tube 1 Threaded adapters with thread sealant applied 13 015103 1 4 inch NPT X RH B inert female 3 14 015012 1 4 inch NPT X 6 male 3 15 015009 1 4 inch NPT X RH B male 1...

Page 380: ...ers and valves Part number Description Console Designator Quantity 1 229703 Mixer module OptiMix 1 528057 Kit Mixer module and cable ties OptiMix 1 2 011101 Regulator OptiMix 2 3 223398 Pressure transducer VWI and OptiMix P6 P9 4 4 006167 Solenoid valve VWI and OptiMix B4 B5 2 VWI OptiMix 1 3 3 4 4 2 ...

Page 381: ...9 Wire harness VWI 229720 Wire harness OptiMix 428490 Kit Tubing Core 1 428491 Kit Tubing VWI 428492 Kit Tubing OptiMix 223709 CAN cable 0 38 m 1 2 ft to external connector Core VWI OptiMix 1 223710 CAN cable 0 48 m 1 6 ft male female Core VWI 1 223711 CAN cable 0 5 m 1 6 ft male female OptiMix 1 223712 CAN cable 0 39 m 1 3 ft male female OptiMix 1 Part number Description 078618 Torch connect cons...

Page 382: ... top Part number Description Designator Quantity 1 428730 Torch receptacle block 1 2 229882 Ohmic relay and bracket 1 3 420376 Torch lead connector 1 4 075544 Machine screw M6 X 10 mm Phillips pan head 4 3 shown Part number Description Designator Quantity 1 428338 Kit Tubing 1 2 006152 Check valve 2 2 1 3 4 2 1 ...

Page 383: ...sure transducer with wire and connector P1 P5 P14 6 2 229640 Power source 88 VAC 264 VAC to 24 VDC PS1 1 3 141334 Control PCB PCB1 1 4 141368 Ohmic contact PCB PCB2 1 5 229825 Green power indicator LED assembly 1 6 101366 Bracket 2 1 shown 229780 Valve cable 40 mm 1 6 inches 8 229800 Valve cable 279 4 mm 11 inches 1 229655 Wire harness 1 3 2 1 4 5 6 ...

Page 384: ... Solenoid valves Proportional valves All manifolds All fittings 1 1 229965 Solenoid valve V4 V12 9 8 shown 229917 Solenoid valve 229965 tool 2 015905 Adapter 1 8 inch NPT O ring seal X 1 4 inch tube 2 3 428756 Bottom manifold assembly Bottom manifold Adapter Critical orifice Solenoid valve 1 4 015811 Adapter 1 4 inch NPT O ring seal X 8 mm tube 1 1 2 3 4 5 6 2 ...

Page 385: ...06077 Check valve 1 8 inch FPT 2 2 006157 Check valve 1 4 inch NPT female 1 Threaded adapters with thread sealant applied 3 015517 1 8 inch hexagonal collar 2 4 015116 1 8 inch NPT X RH A 1 5 015226 1 8 inch NPT X 6 male 1 6 015103 1 4 inch NPT X RH B inert female 1 7 015007 1 4 inch NPT X 5 male 1 8 015922 1 4 inch hexagonal collar 1 9 015210 1 8 inch NPT X LH A male 1 Part number Description Des...

Page 386: ...embly Extended 2 420220 Quick disconnect torch receptacle 3 420221 Quick disconnect torch 4 420368 Water tube 5 044028 O ring for quick disconnect torch Refer to Preventive maintenance kits on page 401 6 006155 Torch solenoid valve V1 7 229918 Torch solenoid valve V1 tool 006169 Torch solenoid valve connector 428488 Torch assembly 300 A mild steel consumables 104879 2 25 inch spanner wrench 1 2 3 ...

Page 387: ...Parts List 9 XPR300 Instruction Manual 809480 387 Torch bracket Part number Description 428646 Torch lifter bracket 2 25 inch diameter sleeve ...

Page 388: ...42 Swirl ring 80 A 130 A 2 420249 Electrode 130 A 3 420252 Nozzle 130 A 3 420255 Shield 130 A 2 420261 Nozzle 170 A 3 420258 Electrode 170 A 3 420513 Shield 170 A 2 420260 Swirl ring 170 A 1 420276 Electrode 220 A 3 420270 Nozzle 220 A 3 420273 Shield 220 A 2 420368 Swirl ring 220 A 1 420276 Electrode 300 A 3 420279 Nozzle 300 A 3 420491 Shield 300 A 2 420406 Swirl ring 300 A 1 420368 Water tube 1...

Page 389: ...420472 Shield 170 A H2O 1 420324 Nozzle 170 A 3 420327 Shield 170 A 1 420358 Swirl ring 300 A fuel 1 420475 Shield 300 A H2O 1 420359 Nozzle 300 A 2 420362 Shield 300 A 2 420303 Electrode 40 A 80 A 3 420309 Shield 60 A 80 A 2 420294 Electrode 40 A 80 A aluminum air air 1 420300 Shield 60 A 80 A H2O 1 420314 Swirl ring 40 A 170 A multiple processes 1 420323 Swirl ring 60 A 300 A multiple processes ...

Page 390: ...ring 80 A 130 A 2 420249 Electrode 130 A 3 420252 Nozzle 130 A 3 420255 Shield 130 A 2 420261 Nozzle 170 A 3 420258 Electrode 170 A 3 420513 Shield 170 A 2 420260 Swirl ring 170 A 1 420276 Electrode 300 A 3 420279 Nozzle 300 A 3 420491 Shield 300 A 2 420406 Swirl ring 300 A 1 420368 Water tube 2 420200 Shield retaining cap 2 420365 Nozzle retaining cap 2 104879 2 25 inch spanner wrench 1 104119 Co...

Page 391: ...2 420318 Shield 130 A 1 420472 Shield 170 A H2O 1 420324 Nozzle 170 A 3 420327 Shield 170 A 1 420358 Swirl ring 300 A fuel 1 420475 Shield 300 A H2O 1 420359 Nozzle 300 A 2 420362 Shield 300 A 2 420303 Electrode 40 A 80 A 3 420309 Shield 60 A 80 A 2 420294 Electrode 40 A 80 A aluminum air air 1 420300 Shield 60 A 80 A H2O 1 420314 Swirl ring 40 A 170 A multiple processes 1 420323 Swirl ring 60 A 3...

Page 392: ...ble and torch parts Part number Description 1 004630 Pit depth gauge 2 004629 Gauge point 027055 Silicone lubricant 1 4 ounce 104119 Consumable tool 428764 XPR robotic torch teach accessory 429013 XPR electrode torque tool 10 0 20 40 30 4 0 2 3 1 80 60 70 50 90 1 2 ...

Page 393: ...3532 10 m 32 8 feet 223538 60 m 196 9 feet 223533 15 m 49 2 feet 223539 75 m 246 1 feet 223534 20 m 65 6 feet Part number Type Length Part number Type Length 223573 2 0 3 m 9 8 feet 223527 4 0 60 m 196 9 feet 223574 2 0 4 5 m 14 8 feet 223528 4 0 75 m 246 1 feet 223575 2 0 7 5 m 24 6 feet 223551 2 0 3 m 9 8 feet 223576 2 0 10 m 32 8 feet 223552 2 0 4 5 m 14 8 feet 223577 2 0 15 m 49 2 feet 223553 ...

Page 394: ... 223447 35 m 114 8 feet 223439 7 5 m 24 6 feet 223448 45 m 147 6 feet 223441 10 m 32 8 feet 223449 60 m 196 9 feet 223444 15 m 49 2 feet 223450 75 m 246 1 feet 223445 20 m 65 6 feet Part number Length Part number Length 428475 3 m 9 8 feet 428481 25 m 82 feet 428476 4 5 m 14 8 feet 428482 35 m 114 8 feet 428477 7 5 m 24 6 feet 428483 45 m 147 6 feet 428478 10 m 32 8 feet 428484 60 m 196 9 feet 428...

Page 395: ...223422 10 m 32 8 feet 223430 60 m 196 9 feet 223425 15 m 49 2 feet 223431 75 m 246 1 feet 223426 20 m 65 6 feet Part number Length Part number Length 428454 3 m 9 8 feet 428458 10 m 32 8 feet 428455 4 5 m 14 8 feet 428459 15 m 49 2 feet 428456 6 m 19 7 feet 428982 18 m 59 1 feet 428457 7 5 m 24 6 feet Part number Length Part number Length 428464 3 m 9 8 feet 428468 10 m 32 8 feet 428465 4 5 m 14 8...

Page 396: ... 10 m 32 8 feet 428354 4 5 m 14 8 feet 428358 15 m 49 2 feet 428355 6 m 19 7 feet 428981 18 m 59 1 feet 428356 7 5 m 24 6 feet Part number Length Part number Length 428363 3 m 9 8 feet 428367 10 m 32 8 feet 428364 4 5 m 14 8 feet 428368 15 m 49 2 feet 428365 6 m 19 7 feet 428980 18 m 59 1 feet 428366 7 5 m 24 6 feet The 18 meter 59 1 feet assembly is compatible only with the 2 meter 6 6 feet or 2 ...

Page 397: ...3508 1 5 m 4 9 feet 223514 22 5 m 73 8 feet 223672 2 5 m 8 2 feet 223515 30 m 98 4 feet 223509 3 m 9 8 feet 223516 45 m 147 6 feet 223510 6 m 19 7 feet 223517 60 m 196 9 feet 223511 7 5 m 24 6 feet 223714 75 m 246 1 feet 1 12 1 8 J14 J19 Part number Length Part number Length 223691 3 m 9 8 feet 223700 20 m 65 6 feet 223692 4 5 m 14 8 feet 223701 22 5 m 73 8 feet 223693 6 m 19 7 feet 223702 25 m 82...

Page 398: ... 32 8 feet 223686 35 m 114 8 feet 223678 12 m 39 4 feet 223687 37 5 m 123 feet 223679 13 5 m 44 3 feet 223688 45 m 147 6 feet 223680 15 m 49 2 feet 223689 60 m 196 9 feet 223681 16 5 m 54 1 feet 223690 75 m 246 1 feet Part number Type Length Part number Type Length 223628 2 0 3 m 9 8 feet 223648 4 0 60 m 196 9 feet 223629 2 0 4 5 m 14 8 feet 223649 4 0 75 m 246 1 feet 223630 2 0 7 5 m 24 6 feet 22...

Page 399: ...r Lead length Strain relief length Part number Lead length Strain relief length 428825 2 m 6 6 feet 0 5 m 20 inches 428831 2 m 6 6 feet 1 2 m 48 inches 428826 2 5 m 8 2 feet 428832 2 5 m 8 2 feet 428827 3 m 9 8 feet 428833 3 m 9 8 feet 428828 3 5 m 11 5 feet 428834 3 5 m 11 5 feet 428829 4 m 13 1 feet 428835 4 m 13 1 feet 428830 4 5 m 14 8 feet 428836 4 5 m 14 8 feet 428978 6 m 20 feet 428979 6 m ...

Page 400: ...t 124008 20 m 65 6 feet 124013 75 m 246 1 feet Part number Length Part number Length 124014 3 m 9 8 feet 124020 25 m 82 feet 124015 4 5 m 14 8 feet 124108 30 m 98 4 feet 124016 7 5 m 24 6 feet 124021 35 m 114 8 feet 124017 10 m 32 8 feet 124022 45 m 147 6 feet 124018 15 m 49 2 feet 124023 60 m 196 9 feet 124019 20 m 65 6 feet 124024 75 m 246 1 feet Part number Length Part number Length 124025 3 m ...

Page 401: ...24040 15 m 49 2 feet 124045 60 m 196 9 feet 124041 20 m 65 6 feet 124046 75 m 246 1 feet Part number Length Part number Length 124047 3 m 9 8 feet 124053 25 m 82 feet 124048 4 5 m 14 8 feet 124111 30 m 98 4 feet 124049 7 5 m 24 6 feet 124054 35 m 114 8 feet 124050 10 m 32 8 feet 124055 45 m 147 6 feet 124051 15 m 49 2 feet 124056 60 m 196 9 feet 124052 20 m 65 6 feet 124057 75 m 246 1 feet Part nu...

Page 402: ...PR300 Tools Part number Description 229917 Torch connect console solenoid valve tool 229918 Torch solenoid valve tool 104879 2 25 inch spanner wrench 004629 Pit depth gauge 104119 Consumable tool 1 13897 Hypertherm Waterjet part number TDS meter ...

Page 403: ...41384 Fan power distribution PCB PCB6 1 141425 Power distribution PCB PCB7 1 108709 Fuse 10 A 250 VAC time delay on PCB7 F3 F4 F5 2 208397 Fuse 15 A 600 V Class R used in 200 V 208 V 220 V 240 V F1 F2 2 208395 Fuse 8 A 600 V Class R used in 380 V 400 V 415 V 440 V 480 V 600 V 2 003277 Pilot arc relay CR1 1 229697 Inrush contactor assembly 80 A IEC AC 3 3 phase 120 VAC IR_CON 1 003276 Main contacto...

Page 404: ...ion Designator Quantity 141368 Ohmic contact PCB PCB2 1 223477 Pressure transducer with wire and connector P1 P5 P14 1 006167 Solenoid valve B1 B3 1 229965 Solenoid valve V4 V12 1 Part number Description Designator Quantity 420220 Quick disconnect torch receptacle 1 420221 Quick disconnect torch 1 420368 Water tube 1 006155 Torch solenoid valve 1 ...

Page 405: ...e body protection 3 Hazardous voltage Risk of electric shock or burn 3 1 Wear insulating gloves Replace gloves when wet or damaged 3 2 Protect from shock by insulating yourself from work and ground 3 3 Disconnect power before servicing Do not touch live parts 4 Plasma fumes can be hazardous 4 1 Do not inhale fumes 4 2 Use forced ventilation or local exhaust to remove the fumes 4 3 Do not operate i...

Page 406: ...Parts List 9 406 809480 Instruction Manual XPR300 ...

Page 407: ...lp you understand the organization of the wiring diagrams Sheet numbers are located in the lower right hand corner of each page References to other pages use the following connection symbol Use the sheet number to find the reference sheet Line up the coordinates A D on the Y axis and numbers 1 4 on the X axis of each sheet to find the reference blocks similar to a road map C Sheet 4 D3 Reference b...

Page 408: ...ay normally open Circuit breaker Inductor Relay solid state AC Coax shield LED Relay solid state DC Current sensor Lamp Relay solid state Current sensor MOV Resistor DC supply Pin SCR Diode Socket Shield Door interlock Plug Shunt Fan PNP transistor Spark gap Feed through LC Potentiometer Switch flow Filter AC Push button normally closed Switch level normally closed Fuse Push button normally open S...

Page 409: ...y open NC on Voltage source Switch 1 pole 2 throw Time delay closed NO off Zener diode Switch 1 pole 2 throw center off Transformer Switch temperature normally closed Transformer air core Switch temperature normally open Transformer coil Terminal block Triac Time delay closed NC off VAC source Torch symbols Electrode Nozzle Shield Torch Torch HyDefinition ...

Page 410: ...een Refer to Gas system on page 186 On this screen you can see which valves are active when the gas is flowing Active valves are indicated with a gray highlight On the Gas System screen enable the desired mode Test Preflow Test Pierceflow or Test Cutflow for the process you want to view Active valves are indicated with a gray highlight Valve states by process ID Process IDs 1001 1002 1003 1152 115...

Page 411: ...04 8005 8006 Block type Gas V1 V4 V5 V6 V7 V8 V9 V10 V11 V12 Preflow N2 N2 Off Off On Off Off Off Off Off Off Off Cutflow N2 N2 Off Off On Off Off Off Off Off Off Off Piercing N2 N2 Off Off On Off Off Off Off Off Off Off Process IDs 2010 2011 2028 2052 2055 2058 Block type Gas V1 V4 V5 V6 V7 V8 V9 V10 V11 V12 Preflow N2 H2O Off Off Off Off Off Off Off Off Off Off Cutflow N2 H2O Off Off Off Off Off...

Page 412: ... Off On Off On Off Off On Process IDs 1102 1101 Block type Gas V1 V4 V5 V6 V7 V8 V9 V10 V11 V12 Preflow N2 Air Off Off Off On Off Off On Off Off Off Cutflow O2 Air On Off Off On Off Off On Off On Off Piercing O2 Air On Off Off On Off Off On Off Off Off Process IDs 1103 1104 1105 1106 1107 Block type Gas V1 V4 V5 V6 V7 V8 V9 V10 V11 V12 Preflow N2 Air Off Off Off On Off Off On Off Off Off Cutflow O...

Page 413: ...2001 2002 2003 2004 2005 Block type Gas V1 V4 V5 V6 V7 V8 V9 V10 V11 V12 Preflow N2 N2 Off Off On Off Off Off Off On Off Off Cutflow F5 N2 On Off On Off Off Off Off On On Off Piercing F5 N2 On Off On Off Off Off Off On On Off Process IDs 2006 2007 2012 2013 2014 2015 2024 2025 2026 Block type Gas V1 V4 V5 V6 V7 V8 V9 V10 V11 V12 Preflow N2 N2 Off Off On Off Off Off Off Off Off Off Cutflow N2 N2 Of...

Page 414: ... Off Off On Off Off Process IDs 9004 9005 9006 9014 9015 9016 9017 Block type Gas V1 V4 V5 V6 V7 V8 V9 V10 V11 V12 Preflow Ar N2 Off Off On Off Off On Off Off Off Off Cutflow Ar N2 Off Off On Off Off On Off Off Off Off Piercing Ar N2 Off Off On Off Off On Off Off Off Off Process ID 8007 Block type Gas V1 V4 V5 V6 V7 V8 V9 V10 V11 V12 Preflow N2 Air Off Off Off On Off Off On Off Off Off Cutflow N2 ...

Page 415: ...Off Off On Off Process IDs 1202 1204 1207 Block type Gas V1 V4 V5 V6 V7 V8 V9 V10 V11 V12 Preflow N2 N2 Off Off On Off Off Off On Off Off Off Cutflow O2 N2 On Off On Off Off Off On Off Off On Piercing O2 N2 On Off On Off Off Off On Off Off On Process IDs 2027 2101 Block type Gas V1 V4 V5 V6 V7 V8 V9 V10 V11 V12 Preflow N2 Air Off Off Off On Off Off Off Off Off Off Cutflow Air Air On Off Off On Off...

Page 416: ... Off On Off Off On Off Cutflow Ar N2 Off On On Off Off On Off Off Off Off Piercing Ar N2 Off On On Off Off On Off Off Off Off Process IDs 1060 1061 7016 7017 Block type Gas V1 V4 V5 V6 V7 V8 V9 V10 V11 V12 Preflow N2 Air Off Off Off On Off Off On Off On Off Cutflow O2 Air On Off Off On Off Off On Off On On Piercing O2 Air On Off Off On Off Off On Off On On Process ID 1157 Block type Gas V1 V4 V5 V...

Page 417: ...417 Overview Sheet 1 of 22 013403 013403 ...

Page 418: ...418 Plasma power supply 1 Sheet 2 of 22 013403 ...

Page 419: ...419 Plasma power supply 2 Sheet 3 of 22 013403 ...

Page 420: ...420 Plasma power supply 3 Sheet 4 of 22 013403 ...

Page 421: ...421 Plasma power supply 4 Sheet 5 of 22 013403 ...

Page 422: ...422 Plasma power supply 5 Sheet 6 of 22 013403 ...

Page 423: ...423 Plasma power supply 6 Sheet 7 of 22 013403 ...

Page 424: ...424 Plasma power supply 7 Sheet 8 of 22 013403 ...

Page 425: ...425 Gas connect console 1 Sheet 9 of 22 013403 ...

Page 426: ...426 Gas connect console 2 Sheet 10 of 22 013403 ...

Page 427: ...427 Torch connect console Sheet 11 of 22 013403 ...

Page 428: ...428 Coolant system Sheet 12 of 22 013408 ...

Page 429: ...429 Gas system 1 Sheet 13 of 22 013403 ...

Page 430: ...430 Gas system 2 Sheet 14 of 22 013403 ...

Page 431: ...431 Gas system 3 Sheet 15 of 22 013403 ...

Page 432: ...THC installations EtherCAT cable EtherCAT cable EDGE Connect TC and or EtherCAT enabled CNC THC DIP switch setting example Unit 2 Plasma power supply Unit 1 Plasma power supply Unit 3 Plasma power supply Unit 4 Plasma power supply 141322 Control board Serial terminator DIP switch Serial ID DIP switch Serial terminator DIP switch Serial ID DIP switch Serial terminator DIP switch Serial ID DIP switc...

Page 433: ...ng switch S1 position 1 and position 2 on the control board and the termination jumper J6 or J8 on the serial isolation board in the controller Only remove the termination jumper on the serial isolation board that is connected to the plasma power supply Discrete cable Discrete cable Serial RS 422 CNC interface Customer supplied DIP switch setting example Unit 2 Plasma power supply Unit 1 Plasma po...

Page 434: ...parallel from one set of CNC outputs to all XPR plasma power supplies Discrete cable Discrete cable CNC interface Unit 2 Plasma power supply Unit 1 Plasma power supply Unit 3 Plasma power supply Unit 4 Plasma power supply Discrete cable 141322 Control board Serial terminator DIP switch Serial ID DIP switch Serial terminator DIP switch Serial ID DIP switch Serial terminator DIP switch Serial ID DIP...

Page 435: ...herm EDGE Connect TC CNC examples shown with EtherCAT drives Please see the CNC documentation for installation and connection details 2 Torch height controller not shown See the THC documentation for voltage divider installation and connection details EtherCAT cable EtherCAT cable 013403 ...

Page 436: ...Sheet 20 of 22 Discrete cable Notes 1 See the CNC documentation for installation and connection details 2 Torch height controller not shown See the THC documentation for voltage divider installation and connection details Serial RS 422 cable 013403 ...

Page 437: ... Sheet 21 of 22 Discrete cable Notes 1 See the CNC documentation for installation and connection details 2 Torch height controller not shown See the THC documentation for voltage divider installation and connection details 013403 ...

Page 438: ...438 Wireless subsystem block diagram Sheet 22 of 22 013403 ...

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