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Hypertherm XPR300, Instruction Manual

The Hypertherm XPR300, a high-performance plasma cutting system, revolutionizes metal fabrication. Our user-friendly manual equips you with comprehensive Replacement Part Procedures. Easily download this valuable resource for free from our manualshive.com, empowering you to optimize your cutting processes and achieve exceptional results.

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Installation

3

136

809480

Instruction Manual

XPR300

How to install the consumables

The torch head that comes with the XPR torch assembly kit (428488) has 300 A mild steel 
consumable parts pre-installed.

For guidance about how to choose the best consumables for your cutting or marking needs, see the 

XPR300 Cut Charts Instruction Manual

 (809830). If you need to change the consumable parts, 

follow this procedure.

See 

Sample configurations for consumables

 on page 141.

If you need to exchange consumable parts, follow these steps.

1.

Remove the power from the cutting system:

a.

Set the line-disconnect switch to the OFF position.

b.

Make sure that the green power LED is not illuminated on the plasma power supply, gas 
connect console, or torch connect console.

2.

If you have not already done so, choose the best consumables for your cutting or marking 
needs.

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.

4.

Use a clean, lint-free cloth to wipe the internal and external surfaces of 
the torch.

WARNING

ELECTRIC SHOCK CAN KILL

Disconnect electrical power before doing any installation steps.

The line-disconnect switch must REMAIN in the OFF position until all 
installation steps are complete.

See the 

Safety and Compliance Manual

 (80669C) for more safety 

precautions.

Summary of Contents for XPR300

Page 1: ...XPR300 Plasma Instruction Manual 809480 Revision 2 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 2 English Original instructions November 2017 Hypertherm Inc Hanover NH 03755 USA www hypertherm com ...

Page 4: ...apan 81 6 6225 1183 Tel 81 6 6225 1184 Fax HTJapan info hypertherm com Main Office Email TechSupportAPAC hypertherm com Technical Service Email Hypertherm Europe B V Vaartveld 9 4704 SE Roosendaal Nederland 31 165 596907 Tel 31 165 596901 Fax 31 165 596908 Tel Marketing 31 0 165 596900 Tel Technical Service 00 800 4973 7843 Tel Technical Service technicalservice emea hypertherm com Technical Servi...

Page 5: ...ngshandleiding 80669C Het niet volgen van de veiligheidsinstructies kan resulteren in persoonlijk letsel of schade aan apparatuur De handleidingen kunnen in elektronische en gedrukte vorm met het product worden meegeleverd De handleidingen elke handleiding beschikbaar in alle talen zijn ook verkrijgbaar via de Documentenbibliotheek op www hypertherm com DANSK DANISH ADVARSEL Inden Hypertherm udsty...

Page 6: ... din cadrul secţiunii Bibliotecă documente aflată pe site ul www hypertherm com TÜRKÇE TURKISH UYARI Bir Hypertherm ekipmanını çalıştırmadan önce ürün kullanım kılavuzunda ve Güvenlik ve Uyumluluk Kılavuzu nda 80669C yer alan güvenlik talimatlarını okuyun Güvenlik talimatlarına uyulmaması durumunda kişisel yaralanmalar veya ekipman hasarı meydana gelebilir Kılavuzların kopyaları elektronik ve bası...

Page 7: ... reducing emissions SC 21 Mains supply SC 21 Maintenance of cutting equipment SC 21 Cutting cables SC 21 Equipotential bonding SC 21 Earthing of the workpiece SC 22 Screening and shielding SC 22 Warranty SC 23 Attention SC 23 General SC 23 Patent indemnity SC 23 Limitation of liability SC 23 National and local codes SC 23 Liability cap SC 24 Insurance SC 24 Transfer of rights SC 24 ...

Page 8: ...quirements 35 Document requirements 35 Operator qualifications 36 Qualifications of service personnel 37 System electrical requirements 38 Code conformity 38 Input power requirements 39 Circuit breaker and fuse requirements 40 Plasma power supply 40 Main power cord requirements 40 Line disconnect switch requirements 40 Remote on off switch 41 Process gas requirements Core VWI and OptiMix gas conne...

Page 9: ...nd control cables 56 Distance requirements for ventilation and access 56 Distance requirements for communications 57 Wireless compliance 57 Torch mounting bracket requirements 58 Torch lifter requirements 58 CNC requirements 59 Adjustable settings 59 Display settings 59 Diagnostics and troubleshooting 60 Recommended grounding and shielding 61 Introduction 61 Types of grounding 61 Grounding practic...

Page 10: ...ose blue 99 Nitrogen hose black 99 Air hose black 99 Hydrogen OptiMix only red 99 Argon VWI or OptiMix only black 99 F5 VWI or OptiMix only red 99 Shield water VWI or OptiMix only blue 99 How to connect the plasma power supply and gas connect console Core VWI or OptiMix 100 Label in the plasma power supply 100 Connect the coolant hose set 101 Connect the power cable 103 Connect the CAN cable 104 H...

Page 11: ...steel sample configurations 141 Mild steel 30 A O2 O2 141 Mild steel 80 A 130 A 170 A and 300 A O2 Air 142 Non ferrous stainless steel and aluminum sample configurations 143 Non ferrous 40 A N2 N2 and Air Air 143 Non ferrous 60 A F5 N2 N2 N2 N2 H2O and Air Air 144 Non ferrous 80 A F5 N2 N2 N2 N2 H2O Air Air 145 Non ferrous 130 A N2 N2 H2 Ar N2 N2 N2 H2O 146 Non ferrous 170 A N2 N2 H2 Ar N2 N2 N2 H...

Page 12: ...of input circuits 187 5 Coolant Installation 189 Overview 189 How to fill the cutting system with coolant 190 6 Operation 193 Overview 193 Controls and indicators 194 Controls 194 CNC 194 Wireless device 194 Indicators 195 Green power ON LEDs 195 CNC display 196 Sequence of operation 197 States of operation for the XPR cutting system 197 Powerup State 1 197 Initial checks State 2 198 Gas purge pum...

Page 13: ...ications 217 Underwater cutting 217 Mirror cutting 218 Process selection 219 How to use process IDs to access optimal settings 220 Process ID offsets overrides 220 How to use cut charts 221 Process core thickness PCT 221 Process categories 221 How to select consumables 224 Factors of cut quality 225 Dross 225 How to get the results you want 225 General recommendations for all processes 225 Recomme...

Page 14: ...46 Remove old coolant from the coolant system 247 8 Diagnostics and Troubleshooting 251 Overview 251 Safety considerations 252 Initial inspection steps 253 Remove the power from the cutting system 254 Examine the PCBs 256 Measure the line voltage between the terminals inside the plasma power supply 258 Diagnostic codes 260 How to diagnose and troubleshoot diagnostic codes 260 CAN codes 500 503 510...

Page 15: ...Plasma power supply I O PCB 141371 321 Plasma power supply fan power distribution PCB 141384 322 Gas connect console control PCB 141375 323 Gas connect console high frequency PCB 141354 324 Torch connect console ohmic PCB 141368 324 Torch connect console control PCB 141334 325 9 Parts List 327 Plasma power supply 327 Outer panels 328 Fans 329 Coolant system 330 Coolant adapters in the rear compart...

Page 16: ...9 359 Other consumable and torch parts 360 Plasma power supply to gas connect console connections 361 Pilot arc lead with strain relief 361 Negative lead with strain relief 361 Power cable 362 Coolant hose set 362 CAN cable 363 Gas connect console to torch connect console connections 363 Pilot arc and coolant hose set assembly Core 363 Power CAN and 3 gas assembly Core 363 Pilot arc coolant hose s...

Page 17: ...et 4 of 22 384 Plasma power supply 4 Sheet 5 of 22 385 Plasma power supply 5 Sheet 6 of 22 386 Plasma power supply 6 Sheet 7 of 22 387 Plasma power supply 7 Sheet 8 of 22 388 Gas connect console 1 Sheet 9 of 22 389 Gas connect console 2 Sheet 10 of 22 390 Torch connect console Sheet 11 of 22 391 Coolant system Sheet 12 of 22 392 Gas system 1 Sheet 13 of 22 393 Gas system 2 Sheet 14 of 22 394 Gas s...

Page 18: ...Contents 18 809480 Instruction Manual XPR300 ...

Page 19: ...specifications 48 Table 12 Purity measurement methods for coolant water 51 Table 13 Recommendations for where to position system components 55 Table 14 Length ranges for interconnect hoses cables and leads 55 Table 15 Maximum distance between the plasma power supply and controlling device 57 Table 16 Equipment to lift or move the plasma power supply 83 Table 17 Torque specifications 119 Table 18 R...

Page 20: ...rocess category options and expected quality speed results for non ferrous processes 223 Table 30 Inspection preventive maintenance and cleaning tasks 232 Table 31 Inspection tasks for consumables 237 Table 32 PCB names and locations 256 Table 33 Diagnostic codes in the XPR web interface 261 Table 34 Diagnostic codes 262 Table 35 Minimum and maximum ohmic resistance values for thermistors 297 Tabl...

Page 21: ...nt 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 th...

Page 22: ...ies where direct connection 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 ...

Page 23: ...horized 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 above is exclusive and is in lieu of all other warranties express implied statutory o...

Page 24: ...erein 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 ab...

Page 25: ... 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 26: ...nition 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 power LED illuminates when power is supplied to the console For some cutting systems a remote on off switch controls the power that goes to the console Torch connect console The torch connect console has proportional valves solenoid valves and press...

Page 27: ...24 76 cm 49 12 in 590 kg 1 300 lb Maximum open circuit voltage U0 360 VDC Maximum output current I2 300 A Output voltage U2 50 VDC 210 VDC Duty cycle rating X 100 at 63 kW 40 C 104 F Operational ambient temperature range 0 C 40 C 32 F 104 F Applies only to cutting systems 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 N...

Page 28: ... 680 kg 1 500 lb Part number Voltage VAC U1 Phase Frequency Hz Rated input current at 63 kW output A I1 Regulatory approval Safety EMC Power kVA 10 U1 X I1 X1 73 078620 200 3 50 60 206 cCSAus 71 43 078621 208 60 198 cCSAus 078622 220 50 60 188 cCSAus 078623 240 60 172 cCSAus 078624 380 50 60 109 CCC 078625 400 50 60 103 CE RCM EAC UKr and AAA 078626 415 50 99 CE RCM EAC UKr and AAA 078627 440 60 9...

Page 29: ...part numbers and dimensions For mounting dimensions see Position and mount the gas connect consoles on page 84 1 2 3 Varies See 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 1...

Page 30: ... the mounting brackets is on the bottom of the torch connect console However you can move the mounting brackets to either side Side placement with the torch lead connection on the bottom can minimize the risk of leaked water or coolant collecting inside of the torch connect console and damaging electrical components For mounting dimensions see Position and mount the torch connect console on page 8...

Page 31: ...rface length Overall sleeve length Combined weight torch head receptacle consumables Combined weight with sleeve Short 11 1 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 pres...

Page 32: ...he data plate have been tested for compliance with the European Low Voltage Directive and the European Electromagnetic Compatibility EMC Directive EMC filters needed to comply with the European EMC Directive are incorporated within versions of the product with a CE marking Eurasian Customs Union CU mark CE versions of products that include an EAC mark of conformity meet the product safety and EMC ...

Page 33: ...ate 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 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 34: ...Specifications 1 34 809480 Instruction Manual XPR300 ...

Page 35: ...tion Manual 809490 XPR300 VDC3 Board Installation Field Service Bulletin 809700 XPR300 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 correct as of the date of its release Subsequen...

Page 36: ... How to operate all controls How to identify and respond to fault conditions How to do maintenance A copy of the instruction manual Do not operate the cutting system if you cannot follow all of the safety instructions or if you cannot satisfy the minimum operator qualifications See the Safety and Compliance Manual 80669C Radio Frequency Warning Manual 80945C and Safety instructions related to inst...

Page 37: ...sed 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 See the Safety and Compliance Manual 80669C Radio Frequency Warning Manual 80945C and Safety instructions related to installation on page 76 or if you cannot satisfy the...

Page 38: ...act a licensed electrician for information about the codes in your location A licensed electrician must do any installation modification inspection or repair of electrical equipment or electrical systems WARNING ELECTRIC SHOCK CAN KILL Disconnect electrical power before doing any installation or maintenance All work requiring removal of the plasma power supply panels must be done by a qualified te...

Page 39: ...d length meet the codes in your location Part number Input voltage VAC Phase Rated input current at 63 kW output A Recommended time delay fuse size A Recommended size for the main power cord 90 C 194 F mm2 AWG Power kVA 078620 200 3 206 250 141 3 4 0 71 43 078621 208 198 250 141 3 4 0 078622 220 188 250 141 3 4 0 078623 240 172 225 111 9 3 0 078624 380 109 150 53 5 1 0 078625 400 103 150 70 5 1 0 ...

Page 40: ...alled inrush resistor 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 Plasma power supply You must connect the plasma power supply to one of the branch feed circuits Use a separate primary line disconnect switch for the plasma power supply See Line disconnect switch requirements on page 40 Main power ...

Page 41: ...he CNC For information about how to do this see How to install a remote on off switch on page 185 WARNING ELECTRIC SHOCK CAN KILL When the remote on off switch is set to OFF 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 220 VAC on the power distribution board Input side of the contac...

Page 42: ... Table 7 on page 43 for supply gas quality pressure and flow requirements CAUTION Gas leaks or pressure and 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 it can decrease Cut quality Cut speed Cut thickness capabilities See Table 7 on page 43 for the recommended ...

Page 43: ...Nitrogen is required for all mild steel processes Air is required for H2 mix processes Code conformity All customer supplied equipment must meet applicable national and local codes for supply gas and supply gas plumbing Contact a licensed plumber for more information about the codes in your location Any installation modification or repair of supply gas equipment or plumbing systems must be done by...

Page 44: ...xhaust ventilation system to remove the oxygen enriched atmosphere that can collect when oxygen is used as the plasma gas for cutting 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 You must supply the flashback arrestors for your cutting system or you can get them from your cutting machine ...

Page 45: ...ithin recommended specifications contact your cutting machine supplier or regional Hypertherm Technical Service team Fitting type Size N2 Ar 5 8 inch 18 RH internal inert gas B Air 9 16 inch 19 JIC 6 F5 H2 9 16 inch 18 LH fuel gas B O2 9 16 inch RH oxygen CAUTION Never use PTFE tape on any joint preparation All hoses hose connections and hose fittings used for supply gas plumbing must be designed ...

Page 46: ...consistent supply gas pressure Low quality gas regulators can also cause problems with system performance and decrease cut quality Synthetic lubricants that contain esters which are used in some air compressors will damage polycarbonates used in the air filter bowl Single stage gas regulation Reduces source gas pressure to the necessary delivery pressure in 1 step Delivery pressure is not tightly ...

Page 47: ...erm 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 Quality Minimum and maximum pressure Flow rate required Deionized water is not recommended to use as shield water Deionized water will react with the copper components in the system and result in decreased life of...

Page 48: ...make sure to tighten all connections to the recommended torque specifications in Table 11 on page 48 Hoses are available from Hypertherm See Water optional shield fluid blue on page 369 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 only required ...

Page 49: ...nformation 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 CAUTION 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 wit...

Page 50: ...culation below The maximum percentage of propylene glycol should never exceed 50 See Estimate the total coolant volume for your cutting system on page 246 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 glycol as coolant For operations in very warm temperat...

Page 51: ...for coolant water Always use water that meets the specifications in Table 12 on page 51 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 th...

Page 52: ...onsole and torch use the following limitations and requirements Site requirements on page 55 Length requirements for hoses cables and leads on page 55 Bend radius requirements for hoses cables and leads on page 56 Distance requirements between high frequency leads and control cables on page 56 Distance requirements for ventilation and access on page 56 Distance requirements for communications on p...

Page 53: ...ed numeric control CNC 1 Computerized numeric 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 Gas reg...

Page 54: ...meric 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 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 l...

Page 55: ...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 electrical noise Electrical noise 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 less...

Page 56: ...gh frequency leads and control cables Separate the pilot arc lead negative lead or any power cables that have a voltage higher than 120 VAC 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 pla...

Page 57: ...s 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 Wire...

Page 58: ...ounting sleeve is larger than the torch mounting sleeve for HPR torches Modification or replacement of previous mounting hardware is necessary for XPR300 torches Mounting brackets are available from Hypertherm See Torch bracket on page 355 of the Parts List Torch lifter requirements You must supply the motorized torch lifter for your cutting system Choose a lifter that has the following specificat...

Page 59: ...splay 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 Transformer temperature Cool...

Page 60: ...troubleshooting 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 see the XPR300 CNC Communication Protocol 809810 ...

Page 61: ... system that 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 chass...

Page 62: ...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 connections and for interconnections between all parts of the Hypertherm...

Page 63: ...able 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 cable...

Page 64: ...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 65: ... for XPR300 cutting systems Chassis and RFI ground AC earth ground 1 2 3 4 5 6 7 8 9 10 11 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 chassis 9 Torch height control module 10 Gas connect console Connect to table ground bus bar 11 DC power ground work lead ...

Page 66: ...Qualifications and Requirements 2 66 809480 Instruction Manual XPR300 ...

Page 67: ... order in good condition Contact your cutting machine supplier if any parts are damaged or missing Inspect the items for damage that may have occurred during shipment If you find evidence of damage see Claims below All communications regarding this equipment must include the model number and serial number Record your product information and register your product s serial number at www hypertherm c...

Page 68: ...lect Regulatory from the All Categories menu 3 Select Acoustical Noise Data Sheets from the All subcategories menu Proper handling and safe use of chemicals Material Safety Data Sheets MSDS and Safety Data Sheets SDS are part of a hazard communication plan that supplies detailed information about hazardous chemicals The information includes the chemical s toxicity and reactivity first aid for expo...

Page 69: ...re VWI or OptiMix on page 100 5 Connect the work lead to the plasma power supply and the cutting table See How to connect the work lead to the plasma power supply and cutting table on page 105 6 Connect the gas connect console to the torch connect console See How to connect the gas connect console to the torch connect console on page 110 7 Install and connect the supply gas plumbing and water See ...

Page 70: ... cord is the correct size and correctly installed See Main power cord requirements on page 40 You must supply the main power cord for your cutting system Make sure that there is a separate primary line disconnect switch for the plasma power supply See Line disconnect switch requirements on page 40 You must supply the line disconnect switch for your cutting system Make sure that the emergency stop ...

Page 71: ...ype installed in the correct locations and correctly installed See Regulators for supply gases on page 46 You must supply the gas regulators for your cutting system Make sure that the plumbing conforms to all applicable codes Shield water VWI and OptiMix See Shield water requirements VWI and OptiMix on page 47 You must supply the shield water for your cutting system Make sure that the water qualit...

Page 72: ...irements if applicable check table type Water table Downdraft table Other specify Hoses cables and leads The cutting system comes with the cables and leads that connect system components See the following sections in the Parts List for part numbers and descriptions Plasma power supply to gas connect console connections on page 361 Gas connect console to torch connect console connections on page 36...

Page 73: ...r supply and the cutting table is correctly installed See How to connect the work lead to the plasma power supply and cutting table on page 105 Make sure that the connections between the gas connect console and torch connect console are correctly installed See How to connect the gas connect console to the torch connect console on page 110 Core See Connect the gas connect console Core to the torch ...

Page 74: ...to connect the torch receptacle to the torch connect console on page 128 Make sure that the hoses cables and leads are correctly installed Make sure that the connections are the correct type and correctly installed Make sure that there is no damage or kinks Make sure that there are no coils in the cables that can create noise problems Minimum bend radius 15 24 cm 6 inches Make sure that the distan...

Page 75: ...orch into the torch receptacle on page 138 Make sure that the torch is correctly installed into the lifter See Torch lifter requirements on page 58 You must supply the motorized torch lifter for your cutting system Electrical power Make sure that electrical power is supplied to the cutting system See How to connect electric power to the cutting system on page 139 CNC interface Make sure that the c...

Page 76: ...e power cord to the cutting system The line disconnect switch must REMAIN in the OFF position until all installation steps are complete In the United States use a lock out tag out procedure until installation is complete In other countries follow the appropriate national and local safety procedures When the line disconnect switch is in the ON position there is line voltage throughout the cutting s...

Page 77: ...oses 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 Hypertherm recommends that you install an exhaust ventilation system to remove the hydrogen enriched atmosphere that can collect when hydrogen is used as the plasma gas for cutting Flashback arres...

Page 78: ...TION Never use PTFE tape on any joint preparation Use only a liquid or paste thread sealant on male threads Some air compressors use synthetic lubricants that contain esters Esters will damage the polycarbonate in the air filter bowl All hoses hose connections and hose fittings used for supply gas plumbing must be designed for use with the appropriate gas and pressure rating NEVER connect a supply...

Page 79: ...R connect a supply gas to a hose connection or fitting that is not designed for that gas type or pressure If you replace any fittings on the consoles or if you use the wrong fittings it can cause the internal valves to malfunction because contaminants can get into the valves Gas leaks or pressure and flow rates that are outside of recommended ranges can Cause problems with system performance Resul...

Page 80: ...therCAT shown 3 Controller area network CAN cable 4 Power cable 120 VAC 5 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 For the best results ...

Page 81: ...EtherCAT shown 3 CAN cable 4 Power cable 120 VAC 5 Coolant hose set 1 supply 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 ...

Page 82: ...you plan where to position system components use the following Site requirements on page 55 Length requirements for hoses cables and leads on page 55 Bend radius requirements for hoses cables and leads on page 56 Distance requirements between high frequency leads and control cables on page 56 Distance requirements for ventilation and access on page 56 Distance requirements for communications on pa...

Page 83: ...y lift and support the plasma power supply If you use the lift eye to lift the plasma power supply make sure that you lift only the plasma power supply so that you do not exceed the maximum lift eye rating See Table 1 on page 27 If you use a lift truck to lift the plasma power supply use one whose forks extend along the entire bottom of the plasma power supply Use the lift truck slots located on t...

Page 84: ...at and bottom mounted as shown in Figure 1 and Figure 2 Never position the gas connect console at an angle or on its side Followed the requirements in Requirements to position system components on page 52 All 3 gas connect consoles Core VWI and OptiMix have 3 mounting holes on the bottom panel For mounting dimensions see Figure 1 on page 85 and Figure 2 on page 86 If you have questions about when ...

Page 85: ... 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 Gas outlet side of gas connect console Never position the gas connect console at an angle or on its sides ...

Page 86: ...he 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 Gas outlet side of gas connect console Never position the gas connect console at an angle or on its sides ...

Page 87: ...shown in Figure 3 Followed the requirements in Requirements to position system components on page 52 The factory location for the mounting brackets is on the bottom of the torch connect console However you can move the mounting brackets to either side There are 3 mounting orientations bottom and either side For mounting dimensions see Figure 3 on page 88 and Figure 4 on page 89 If you have questio...

Page 88: ...Installation 3 88 809480 Instruction Manual XPR300 Figure 3 Side mount orientation and mounting dimensions for the torch connect console 339 85 mm 13 38 in 135 mm 5 31 in 6 35 mm 0 25 in ...

Page 89: ...Installation 3 XPR300 Instruction Manual 809480 89 Figure 4 Bottom mounting for the torch connect console 339 85 mm 13 38 in 135 mm 5 31 in 6 35 mm 0 25 in ...

Page 90: ... components It is important to follow all grounding and shielding recommendations See Recommended grounding and shielding on page 61 Ground system components after you position them and before you connect the hoses cables and leads Figure 5 Plasma power supply grounding detail ...

Page 91: ...Installation 3 XPR300 Instruction Manual 809480 91 Figure 6 Gas connect consoles grounding detail Figure 7 Torch connect console grounding detail Core VWI OptiMix M6 ground stud M6 ground stud ...

Page 92: ...Installation 3 92 809480 Instruction Manual XPR300 Figure 8 Torch lead collar grounding detail Ground connection 6 36 mm 1 4 in flat terminal ...

Page 93: ...ELECTRIC SHOCK CAN KILL Disconnect electrical power before doing any installation All work requiring removal of the plasma power supply panels must be done by a qualified technician See the Safety and Compliance Manual 80669C for more safety precautions The plasma power supply contains dangerous electric voltages that can cause injury or death Even if the cutting system is turned OFF you can still...

Page 94: ...nstallation 3 94 809480 Instruction Manual XPR300 Figure 9 Remove the rear panel from the plasma power supply Removal of the rear panel is usually all that is necessary to complete the installation steps ...

Page 95: ...Installation 3 XPR300 Instruction Manual 809480 95 Figure 10 Remove panels from the gas connect console Move the panel horizontally to remove it ...

Page 96: ...Installation 3 96 809480 Instruction Manual XPR300 Figure 11 Remove top and side panel from the torch connect console ...

Page 97: ...bel that has a part number Do not order or use cables or leads that are longer than necessary If you coil a cable or lead because it is too long electrical interference or noise can occur Electrical interference or noise can have a negative effect on system performance For part numbers and specifications see the Parts List on page 327 Coolant hose set The coolant hose set includes 1 supply hose wi...

Page 98: ...s 1 supply hose with green bands and 1 return hose with red bands Power CAN 3 gas assembly only for Core 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 ...

Page 99: ... 3 XPR300 Instruction Manual 809480 99 Oxygen hose blue Nitrogen hose black Air hose black Hydrogen OptiMix only red Argon VWI or OptiMix only black F5 VWI or OptiMix only red Shield water VWI or OptiMix only blue ...

Page 100: ...sma power supply and gas connect console Core VWI or OptiMix Label in the plasma power supply RS422 Power Pilot Arc CNC Discrete Pilot Arc Work CAN RS422 Negative Power V RS422 Negative Work Out In EtherCAT 210566 REVB CAN CNC Discrete Coolant Supply Green Coolant Return Red ...

Page 101: ...lant hose set on page 362 of the Parts List Connect the coolant hose set to the plasma power supply 1 Connect the coolant return hose red to the coolant return fitting red 2 Connect the coolant supply hose green to the coolant supply fitting green 1 2 1 Coolant return hose red band 2 Coolant supply hose green band Red 1 2 Green ...

Page 102: ...ose set to the gas connect console 1 Connect the coolant return hose red to the coolant return fitting red bottom 2 Connect the coolant supply hose green to the coolant supply fitting green top Red 1 2 Green Never position the gas connect console at an angle or on its sides ...

Page 103: ... the power cable Figure 13 Power cable For lengths see Power cable on page 362 of the Parts List Figure 14 Connect the power cable To plasma power supply male cable connector To gas connect console female cable connector Plasma power supply Gas connect console ...

Page 104: ...CAN cable Figure 15 CAN cable For lengths see CAN cable on page 363 of the Parts List Figure 16 Connect the CAN cable and finger tighten To gas connect console female cable connector To plasma power supply male cable connector Plasma power supply Gas connect console ...

Page 105: ...nnect the work lead to the plasma power supply and cutting table Figure 17 Work lead For lengths see Work lead on page 366 of the Parts List Figure 18 Connect the work lead to the plasma power supply shown and cutting table To plasma power supply To cutting table ...

Page 106: ...e 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 For lengths see Negative lead with strain relief on page 361 of the Parts List 3 To plasma power supply To gas ...

Page 107: ...Installation 3 XPR300 Instruction Manual 809480 107 Figure 20 Connect the negative lead with strain relief Plasma power supply Gas connect console ...

Page 108: ... Connect the pilot arc lead with strain relief Figure 21 Pilot arc lead with strain relief For lengths see Pilot arc lead with strain relief on page 361 of the Parts List Figure 22 Connect the pilot arc lead with strain relief to the plasma power supply ...

Page 109: ... 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 try to connect the pilot arc lead Move the panel horizontally to remove it ...

Page 110: ...t console on page 114 Connect the pilot arc and coolant hose set assembly Figure 24 Pilot arc and coolant hose set assembly For lengths see Pilot arc and coolant hose set assembly Core on page 363 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 These installation steps are for the Core gas connect console...

Page 111: ...he 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 position 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 112: ... the torch connect 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 position 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 113: ... For lengths see Power CAN and 3 gas assembly Core on page 363 of the Parts List Figure 26 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 Torch connect console 1 2 3 4 5 1 2 3 5 4 ...

Page 114: ...r assembly Figure 27 Pilot arc coolant hose set and shield water assembly For lengths see Pilot arc coolant hose set and shield water assembly VWI or OptiMix on page 364 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 These installation steps are for the VWI or OptiMix gas connect console To gas connect c...

Page 115: ...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 position 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 116: ...o 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 position it into the groove on the console collar g Push the coupler into the console collar and tighten the clamp a e d ...

Page 117: ...embly VWI or OptiMix on page 364 of the Parts List Figure 29 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 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 console Torch connect console 1 2 3 4 6 7 5 1 2 3 4 5 6 7 ...

Page 118: ... 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 Hypertherm recommends that you install an exhaust ventilation system to remove the hydrogen enriched atmosphere that can collect when hydrogen is used as the plasma gas for cutting Flashback arrestors are required to stop the spread of fire to t...

Page 119: ...ix gas connect consoles on page 42 Make sure that the gas regulators supply gas plumbing and supply gases that you choose satisfy all minimum requirements See Process gas requirements Core VWI and OptiMix gas connect consoles on page 42 Use the torque specifications in Table 17 when you tighten any gas supply fittings Table 17 Torque specifications Torque Specifications Gas or water hose size N m ...

Page 120: ...sults position a gas regulator within 3 meters 10 feet of the gas connect console If your supply gas is positioned more than 3 meters 10 feet from the gas connect console Hypertherm recommends a 2 stage gas regulator configuration 1 Use a single stage regulator for high pressure at the source 2 Use a second regulator for normal pressure at the 3 meter 10 feet location After installation is complet...

Page 121: ...s or hose fittings can crack or leak Do not alter 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 into the valves Some air compressors use synthetic lubricants that contain esters Esters will damage the polycarbonate in the air filter bowl Gas leaks or pressure and flow rates that...

Page 122: ... of leaks in the system make sure to tighten all connections to the torque specifications in Table 17 on page 119 After installation is complete pressurize the entire system and look for gas leaks A licensed plumber can do this for you CAUTION All hoses hose connections and hose fittings used for supply gas plumbing must be designed for use with the appropriate gas and pressure rating NEVER connec...

Page 123: ...he gas connect console Hypertherm recommends a 2 stage configuration 1 Use single stage regulator for high pressure at the source and 2 use a second regulator for normal pressure at the 3 meter 10 feet location Oxygen O2 Nitrogen N2 Air Regulators Oxygen O2 Nitrogen N2 Air CAUTION Cutting system performance can be bad if a supply gas hose is connected to the wrong port on a gas connect console NEV...

Page 124: ...ose connections or hose fittings can crack or leak Do not alter 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 into the valves Some air compressors use synthetic lubricants that contain esters Esters will damage the polycarbonate in the air filter bowl Gas leaks or pressure and f...

Page 125: ...system make sure to tighten all connections to the torque specifications in Table 17 on page 119 After installation is complete pressurize the entire system and look for gas leaks A licensed plumber can do this for you CAUTION All hoses hose connections and hose fittings used for supply gas plumbing must be designed for use with the appropriate gas and pressure rating NEVER connect a supply gas to...

Page 126: ...normal pressure at the 3 meter 10 feet location 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 Nitrogen N2 Air Oxygen O2 WARNING An explosion can occur if a supply gas hose is connected to the wrong port on a VWI or OptiMix gas connect console NEVER connect a supply gas to a hose conne...

Page 127: ...console see Connect supply gases to the gas connect console Core on page 121 If you have a VWI or OptiMix gas connect console but choose to not use shield water you can ignore this installation step Make sure to follow Shield water requirements VWI and OptiMix on page 47 if you do use shield water If using shield water the temperature range for cutting system operation is reduced to above 0 C to 4...

Page 128: ...or end of the torch 3 Slide the torch mounting sleeve onto the torch end of the torch lead assembly Make sure to position the mounting sleeve away from the connector ends so that the ends are not covered This lets you access the connector ends 4 Align the color coded leads in the torch lead assembly with the corresponding connectors in the torch receptacle Good alignment minimizes twisted leads Tw...

Page 129: ...uch Table 20 Torque specifications b Insert the plasma valve connector and finger tighten Do not use tools c Connect the pilot arc lead yellow and finger tighten Do not use tools d Connect the ohmic lead yellow and finger tighten Do not use tools Coolant return hose red Torque Specifications Gas or water hose size N m in lbf ft lbf Up to 10 mm 3 8 inch 8 5 9 5 75 84 6 25 7 12 mm 1 2 inch 16 3 19 0...

Page 130: ...tor until it stops approximately 13 mm 0 5 inch This is a push to connect fitting g Connect plasma gas hose 2 yellow Push the hose into the connector until it stops approximately 13 mm 0 5 inch This is a push to connect fitting h Connect plasma gas hose 1 black Push the hose into the connector until it stops approximately 13 mm 0 5 inch This is a push to connect fitting Coolant supply hose green S...

Page 131: ... 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 torch during mounting sleeve installation 7 Reposition the collar on the torch end of the torch lead a Pull the collar towards the torch end of the torch lead assembly b Tighten the hose clamp that holds the collar in position Tighten the clamp Pull th...

Page 132: ...ured torch lead lengths are critical for system performance Never alter the lengths of the torch leads Cut quality and the lifespan of consumables will be decreased if you alter the torch leads 7 8 9 1 2 3 4 5 6 2 To torch connect console To torch 1 Protective sleeve 2 Plasma valve cable 3 Ohmic lead 4 Pilot arc lead 5 Coolant return hose red 6 Coolant supply hose green 7 Shield gas hose 8 Plasma ...

Page 133: ...tacles in the torch connect console 2 Connect the torch lead assembly to the torch connect console a Hand tighten the coupler of the torch lead assembly Do not use tools b Connect the plasma valve cable to its connector then finger tighten Do not use tools Remove plug to access the ohmic wire if you use a third party ohmic circuit ...

Page 134: ...r than the torch mounting sleeve for HPR torches Modification or replacement of previous mounting hardware is necessary for XPR300 torches 1 Remove the power from the cutting system a Set the line disconnect switch to the OFF position b Make sure that the green power LED is not illuminated on the plasma power supply gas connect console or torch connect console 2 Install the torch mounting bracket ...

Page 135: ...rch receptacle 5 Make sure that the torch is level at a 0 angle in all directions as shown in Figure 35 on page 135 Remove the consumables including the water tube from the torch You can use a digital level to measure alignment for 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 r...

Page 136: ...witch to the OFF position b Make sure that the green power LED is not illuminated on the plasma power supply gas connect console or torch connect console 2 If you have not already done so choose the best consumables for your cutting or marking needs 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 f...

Page 137: ...ghten an electrode b Install the swirl ring into the nozzle c Install the nozzle and swirl ring assembly d Install the nozzle retaining cap e Install the shield f Install the shield cap Figure 36 Install the consumables on the torch 6 Install the torch in the torch receptacle See How to install the torch into the torch receptacle on page 138 7 Install the torch and attached receptacle in the torch...

Page 138: ...icant can prevent gas flow Remove excess lubricant if found 2 Put the torch body into the torch receptacle and hand tighten a Rotate the torch body with slight upward force until you feel it engage into position in the receptacle b Hand tighten the torch coupler nut until the coupler nut no longer rotates Hand tighten only Do not use tools 3 Make sure that the torch body is fully inserted into the...

Page 139: ...F position until all installation steps are complete 2 Connect the main power cord to the plasma power supply Figure 37 on page 140 a Connect the ground lead PE from the main power cord to the ground terminal of TB1 b Connect the W V and U leads from the main power cord to the corresponding TB1 terminals CAUTION Any installation modification or repair of electrical equipment or electrical systems ...

Page 140: ... W V and U power leads from the main power cord to the line disconnect switch Table 21 on page 140 Table 21 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 ground Green yellow ...

Page 141: ...ce daily before system operation For information about how to do this see Examine the consumable parts on page 237 in the Maintenance section of this manual Ferrous mild steel sample configurations Mild steel 30 A O2 O2 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 retaini...

Page 142: ...rror cutting 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 ...

Page 143: ...l and aluminum sample 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 144: ...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 145: ... 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 146: ...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 147: ...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 148: ...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 149: ...d discrete compatible controller See How to connect to the plasma power supply with the XPR web interface on page 153 See How to connect to the plasma power supply with discrete on page 176 If you use wireless you must also use discrete to fully operate the cutting system See Table 22 on page 150 Serial RS 422 and discrete Use this method with a serial RS 422 and discrete compatible controller See...

Page 150: ... to change the device that has control on page 180 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 XPR web interface RS 422 EtherCAT Not required Preferred Alternative Alternative XPR web interface Required Alt...

Page 151: ...ose EtherCAT cables that follow the Beckhoff specification You can find the cable design specification at infosys beckhoff com Type Cat5e 2 pair 4 wire double shielded Wire Construction Stranded tinned wire Diameter 0 75 mm 7 X 0 25 mm 22 AWG Insulation Polyethylene 1 5 mm 0 06 inch diameter Core Construction Filler as central element Layer 1 4 wires 2 pair Sequence of colors White yellow blue ora...

Page 152: ...location shown in Figure 39 These connectors add noise filtering Do not connect directly to the PCB Separate EtherCAT cable from the pilot arc lead negative lead or any power cables that have a voltage higher than 120 VAC See Distance requirements between high frequency leads and control cables on page 56 Do not route the EtherCAT cable close to the gas connect console EtherCAT in from the CNC Eth...

Page 153: ...to one network and access multiple plasma 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 If you us...

Page 154: ...en power 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...

Page 155: ...cated 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 Go to Web interface screen information on page 166 for more information on the interface menus 7 To fully operate the cutting system you must also use discrete See How to connect to the plasma power supply with discrete...

Page 156: ...e 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 154 to connect the wireless set up device to the plasma power supply 2 Choose Connect on the Other s...

Page 157: ... 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 b Static IP Not supported Advanced users only 4 Choose Next to go to the Wireless Configuration Summary screen This page shows information about the SSID Channel and Secur...

Page 158: ...k The plasma power supply now resets and connects to the new network To access the web interface after setup see Access the XPR web interface after setup in network mode on page 161 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 See How to connect to the plasma p...

Page 159: ...el 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 b Static IP Not supported 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 Ser...

Page 160: ...k The plasma power supply now resets and connects to the new network To access the web interface after setup see Access the XPR web interface after setup in network mode on page 161 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 See How to connect to the plasma p...

Page 161: ...s 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 See Figure 40 for an example Figure 40 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 IP addr...

Page 162: ... limited AP IP address in the Configure screen 1 Choose Other Configure 2 On the Configure screen go down to Change Limited AP IP Address 3 Type the Current Setup Password and the New IP Address 4 Choose Apply 5 Choose Yes The change takes effect after you cycle the power 6 Cycle the power to the plasma power supply ...

Page 163: ...RNING ELECTRIC SHOCK CAN KILL Disconnect electrical power before doing any installation All work requiring removal of the plasma power supply panels must be done by a qualified technician See the Safety and Compliance Manual 80669C for more safety precautions The plasma power supply contains dangerous electric voltages that can cause injury or death Even if the cutting system is turned OFF you can...

Page 164: ...pply 5 Wait 30 seconds 6 Remove the power from the cutting system a Set the line disconnect switch to the OFF position b Make sure that the green power 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 Always use caution when servicing a plasma power sup...

Page 165: ... panel of the plasma power supply 9 Supply power to the cutting system a Set the line disconnect switch to the ON position b Make sure that the green power LED is illuminated on the plasma power supply 10 Wait 30 seconds The wireless module is now reset to the factory default settings ...

Page 166: ...control 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 see How to change the device that has control on page 180 Client ID This is the identifier for a device that communicates with the plasma power supply...

Page 167: ... XPR300 Instruction Manual 809480 167 Plasma power supply 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 ...

Page 168: ...w Test Pierceflow and Gas Leak Test The gas leak test is only available on XPR cutting systems equipped with a VWI or OptiMix gas connect console See How to do a gas leak test VWI and OptiMix on page 309 The test starts when you choose the button The button becomes active red and the active valves are indicated with a gray highlight The gases shown on Line A Line B and shield are different dependi...

Page 169: ... 809480 169 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 For definitions see Diagnostic codes on page 260 in Diagnostics and Troubleshooting ...

Page 170: ...reen 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 171: ...n 4 XPR300 Instruction Manual 809480 171 Other On this screen you can view the software versions and monitor the status of the wireless connection From this screen you can also access the Configure Connect and Update commands ...

Page 172: ...n change the connection name limited AP password limited AP IP address or the setup password You cannot use specialcharacters 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 ...

Page 173: ...B inside the plasma power supply For information on how to install this board see the XPR300 VDC3 Board Installation Field Service Bulletin 809700 1 Remove the rear panel of the plasma power supply See How to remove the external panels from the system components on page 93 2 Put End A Figure 41 of the serial RS 422 cable through the hole in the bottom of the rear compartment in the plasma power su...

Page 174: ...6 in the Parts List Table 23 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 175: ...t for Communication 4 XPR300 Instruction Manual 809480 175 Figure 42 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 176: ...ion on signals and protocols see XPR discrete communication in the XPR300 CNC Communication Protocol 809810 1 Remove the rear panel of the plasma power supply See How to remove the external panels from the system components on page 93 2 Put End A Figure 43 of the discrete cable through the hole in the bottom of the rear compartment in the plasma power supply See Figure 44 on page 179 3 Connect J14...

Page 177: ... 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 fire the torch Blue 8 Hold Black 9 Input1 Pierce complete The CNC notifies the plasma system to maintain the shield preflo...

Page 178: ...0 mA maximum A jumper is required on J17 to use 24 V power 5 Shield ohmic contact is used to interface to plasma interface boards that have their own ohmic contact circuit See How to use ohmic contact sense on page 182 5 Output2 Auto pierce detect Notifies the CNC that the plasma power supply has detected that the system has pierced through the workpiece and is ready to begin motion Green 6 Auto p...

Page 179: ...Connect for Communication 4 XPR300 Instruction Manual 809480 179 Figure 44 Connect the discrete cable to the plasma power supply Discrete cable to the CNC ...

Page 180: ...he cutting system a Set the line disconnect switch to the ON position b Make sure that the green power LED is illuminated on the plasma power supply How to disable the wireless connection If you want to completely disable the wireless connection use this procedure WARNING ELECTRIC SHOCK CAN KILL Disconnect electrical power before doing any installation All work requiring removal of the plasma powe...

Page 181: ... board to the ON position This disables the wireless Figure 45 Main control board note DIP switch S3 location 4 Install the side panel of the plasma power supply 5 Supply power to the cutting system a Set the line disconnect switch to the ON position b Make sure that the green power LED is illuminated on the plasma power supply WARNING ELECTRIC SHOCK CAN KILL Always use caution when servicing a pl...

Page 182: ...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 46 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 183: ... switch to the OFF position b Make sure that the green power LED is not illuminated on the 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 insi...

Page 184: ... PCB connection for ohmic inside the lifter Figure 48 Example external ohmic diagram 6 9 J4 J3 J2 J27 J1 7 1 2 3 4 5 6 9 8 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 ...

Page 185: ...nnect console Torch connect console Contactor enable Pump relay enable Fan enable CNC outputs WARNING ELECTRIC SHOCK CAN KILL Disconnect electrical power before doing any maintenance When the remote on off switch is set to OFF 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 220 VAC on ...

Page 186: ...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 187: ... 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 188: ...Connect for Communication 4 188 809480 Instruction Manual XPR300 ...

Page 189: ...eads Contact your cutting machine supplier to reorder coolant For information about how to calculate the approximate total volume of coolant for your cutting system see Estimate the total coolant volume for your cutting system on page 246 The plasma power supply ships with the coolant filter 027005 and coolant pump screen 127559 installed Additional coolant filters and screens are available from H...

Page 190: ... You can see the coolant level from the fill port inlet as you pour the coolant CAUTION 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 it may need to be replaced Never use automotive antifreeze ...

Page 191: ...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 or XPR web interf...

Page 192: ...Coolant Installation 5 192 809480 Instruction Manual XPR300 ...

Page 193: ...orch positions and process settings you need on page 209 Process selection on page 219 How to use cut charts on page 221 How to select consumables on page 224 Factors of cut quality on page 225 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 194: ...gnostic screen Test screen 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 XPR300 CNC Communication Protocol 809810 Wireless device A wireless device can control cutting system operation A wireless device with...

Page 195: ...en power ON LED on the plasma power supply When illuminated the green LED on the plasma power supply Figure 49 gas connect console Figure 50 on page 196 and torch connect console Figure 50 on page 196 indicate that Power is supplied to the XPR cutting system The line disconnect switch or breaker for the unit is set to the ON I position The unit is ready for use ...

Page 196: ...nect console left and on the torch connect console right CNC display Except for the green 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 197: ...te 1 The operator supplies power to the cutting system 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 Is Poweru...

Page 198: ...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 See Diagnostics and Troubleshooting on page 251 Yes Wait for process selection by the operator Select a process ID Continue to Gas purge pump ...

Page 199: ... necessary to complete a purge is based on 1 the type of operator selected process that the CNC or 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 Stage 2...

Page 200: ...a Start there is no limit to how long the system waits for input Yes For new process selection continue to Initial checks State 2 on page 198 OR For a Plasma Start command continue to Preflow charge DC State 7 on page 200 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 ...

Page 201: ... the DC bus voltage within the acceptable range No Yes Turn ON the high frequency circuit ignition arc created Continuously monitor Chopper 1current Is the Chopper 1 current above the minimum current No Yes Continuously monitor Chopper 1 current Is Ignite State 8 complete and successful No Diagnose and troubleshoot the problem See Diagnostics and Troubleshooting on page 251 Yes Continue to Pilot a...

Page 202: ...thin the acceptable range No Yes Continuously monitor Chopper 1 current Is the DC bus voltage within the acceptable range No Yes Continuously monitor Chopper 1 current Is the current for Chopper 1 within the acceptable range No Yes Continuously monitor Chopper 1 current Is the current for the work lead within the acceptable range Chopper 2 becomes active during this time No Yes Is the Pilot arc St...

Page 203: ...ected process 50 A only Chopper 1 becomes active If the operator selected process 50 A Chopper 1 becomes active first then Chopper 2 Both Chopper 1 and Chopper 2 become active Is the Rampup State 11 complete and successful No Diagnose and troubleshoot the problem See Diagnostics and Troubleshooting on page 251 Yes Continue to Steady State 12 on page 204 ...

Page 204: ...ge 251 Yes Continuously monitor Chopper 1 current Do the gas pressures remain within the acceptable range No Yes Continuously monitor Chopper 1 current Do the temperatures remain within the acceptable range No Yes Continuously monitor Chopper 1 current Does the current for Chopper 1 remain within the acceptable range If the process is less than 50 A only Chopper 1 is active Note If the operator se...

Page 205: ...ess than 50 A only Chopper 1 stops not Chopper 2 If the operator selected process is equal to or greater than 50 A Chopper 1 stops first then Chopper 2 stops Both Chopper 1 and Chopper 2 stop Decrease gas flow to the final setpoint Is Rampdown State 13 complete and successful No Diagnose and troubleshoot the problem See Diagnostics and Troubleshooting on page 251 Yes Continue to End of cycle State...

Page 206: ...current to the ohmic board the cutting system automatically opens the high voltage relay and disables the ohmic sense circuit For wet processes make sure to set your torch height control to stall force If you do not the CNC will be unable to detect the workpiece and the torch could crash against the workpiece when the ohmic relay is disabled During a dry process the cutting system closes the high ...

Page 207: ...urges for OptiMix or VWI XPR cutting systems If you have an XPR cutting system equipped with an OptiMix or VWI gas connect 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 ...

Page 208: ...the shield gas then the XPR cutting system will purge the water with N2 Core XPR cutting systems skip the gas change purge Core XPR cutting systems use only process setup purges See Process setup purges for all XPR cutting systems on page 208 Process 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 autom...

Page 209: ...also 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 ...

Page 210: ...e The angle of the torch relative to the workpiece has an effect on the bevel cut angle of the metal The torch and consumable parts are designed so that the torch position can range from 0 52 so that the torch tip remains the closest point to the workpiece If you need an angle greater than 52 you can raise the torch to increase the clearance ...

Page 211: ... 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 XPR300 torches have a 76 cone angle that makes it possible to tilt or position the torch up to 52 If you need an angle greater than 52 you can raise the torch to increase the clearance 5 Torch center line The imaginary line along the central...

Page 212: ...on thinner metals 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 See the XPR300 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 together with ...

Page 213: ...le however to cut other types of stainless steel and aluminum Non ferrous process availability is based on the type of gas connect console that you have Core VWI or OptiMix Table 26 Available non ferrous processes by gas connect console type and gas 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...

Page 214: ...thickness Metal type Metric mm English in Stainless steel Aluminum 1 0 036 40 A N2 N2 40 A Air Air 3 0 105 3 5 0 125 60 A N2 N2 60 A Air Air 5 0 188 60 A N2 N2 6 0 250 80 A F5 N2 80 A N2 H2O 10 0 375 12 0 500 130 A H2 mix N2 130 A N2 H2O 16 0 625 170 A H2 mix N2 170 A N2 H2O 20 0 750 300 A H2 mix N2 25 1 000 300 A N2 H2O 50 2 000 75 3 000 ...

Page 215: ... 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 called a wet process Wet processes deliver an overall goo...

Page 216: ... 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 called a wet process For aluminum wet processes generally produce a smoother edge tha...

Page 217: ...e table manufacturer and other experts prior to cutting aluminum 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 ...

Page 218: ...charts See the XPR300 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...

Page 219: ...rocess category See Process categories on page 221 When you select a process ID from the CNC or the Operate screen in the XPR web interface the cutting system automatically activates the pre programmed settings for that process based on the values in the database On screen options let you select monitor and control processes directly from the CNC or the Operate screen in the XPR web interface Manu...

Page 220: ...ecks State 2 of operation See States of operation for the XPR cutting system on page 197 3 If none of the processes are satisfactory a Select the closest available process b Send the necessary offset command or commands to adjust the setting or settings as necessary See Process ID offsets overrides on page 220 If you have an unusual process requirement contact your cutting machine supplier or regi...

Page 221: ...ality 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 usually in the middle of the overall range of thicknesses This optimized range is called the process core thickness PCT Thicknesses...

Page 222: ...ductivity 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 Greater 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 possible Very good excellen...

Page 223: ...cess 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 Greater 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 dr...

Page 224: ...switch from a perpendicular position process to bevel cutting or from bevel cutting to a perpendicular position process This also eliminates the need to inventory two different sets of consumables perpendicular and bevel For guidance on how to select consumables including part numbers by process type and metal and how to install the consumables see the following XPR300 Cut Charts Instruction Manua...

Page 225: ...mmands to make incremental changes to the original value values within limits See Process ID offsets overrides on page 220 Do not allow the torch to touch the workpiece during cutting system operation Contact with the workpiece can damage the torch nozzle and shield It can also damage the surface of the workpiece Make sure that the torch is perpendicular at a 90 angle to the workpiece for perpendi...

Page 226: ...ce Allow a lead in distance that is approximately the same thickness as the metal to be pierced For example for 50 mm 2 inch metal use a 50 mm 2 inch lead in Keep the torch above cut height until it passes over the puddle of molten metal created by the pierce Puddle avoidance minimizes shield damage Make sure to follow transfer height and pierce height recommendations during piercing processes See...

Page 227: ... offers True Bevel bevel compensation 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 choose the best pier...

Page 228: ...r Program torch movement 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 e...

Page 229: ...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 230: ...Operation 6 230 809480 Instruction Manual XPR300 ...

Page 231: ...ction of the manual describes maintenance steps that you must do daily before system operation For instructions about preventive maintenance such as weekly monthly and yearly tasks see the XPR300 Preventative Maintenance Program PMP Instruction Manual 809490 For recommendations about how to diagnose and troubleshoot performance issues see Diagnostics and Troubleshooting on page 251 For printed cir...

Page 232: ...O rings X Examine 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 Exami...

Page 233: ...wing at least once daily before system operation Examine the gas regulators on page 235 Examine the shield water regulator if applicable on page 235 Examine the connections and fittings on page 235 Examine the consumable parts torch and torch receptacle on page 236 Examine the torch lead on page 242 ...

Page 234: ... out procedure until maintenance is complete In other countries follow the appropriate national and local safety procedures See the Safety and Compliance Manual 80669C for more safety precautions The plasma power supply contains dangerous electric voltages that can cause injury or death Even if the cutting system is turned OFF you can still get a serious electric shock if the cutting system remain...

Page 235: ...ure that the supply gas pressures and flow rates are within the recommended range See Table 7 on page 43 Adjust the regulator regulators if necessary Examine the shield water regulator if applicable If your cutting system uses water as a shield fluid examine the shield water settings before you start cutting system operation Make sure that the water pressure and flow rate is within the recommended...

Page 236: ...ers and specifications see the Parts List on page 327 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 torch receptacle Remove the torch and consumable parts 1 Remove the power fr...

Page 237: ...d 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 rings ...

Page 238: ... excess silicone lubricant Dry O rings Apply a thin film of silicone lubricant 027055 to O rings that appear dry Electrode Surface of electrode center Emitter wear a pit forms as the emitter wears For 300 A mild steel electrodes replace the electrode when the pit depth is 1 5 mm 0 06 inch or greater For electrodes for less than 300 A replace the electrode when the pit depth is 1 mm 0 04 inch or gr...

Page 239: ... external surfaces b Use compressed air to remove debris from internal and external surfaces The nozzle retaining cap can retain debris Make sure to clean it thoroughly c Use clean water if you choose to wash consumables parts in water Use water from the faucet to soak or rinse them Never use the water from a cutting table to wash consumable parts Cutting table water has contaminants that will dam...

Page 240: ...torch Dry O rings Over lubricated O rings Cracks in the torch main body Cracks in the torch insulator 3 Replace any O rings that have damage or excess wear Torch rebuild kits are available from Hypertherm See Preventive maintenance kits on page 369 of the Parts List 4 If you find cracks in the torch main body or torch insulator replace the entire torch main body See How to install the torch into t...

Page 241: ...consumables on page 136 Torch in the torch receptacle See How to install the torch into the torch receptacle on page 138 Examine the torch receptacle 1 Complete the following procedure before continuing a Remove the power from the cutting system on page 234 2 Examine the torch receptacle Look for Cuts nicks damage or excess wear on the O ring on the torch receptacle The O ring on the torch recepta...

Page 242: ...to install the torch into the torch receptacle on page 138 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 tight Tighten loose connections if found but do not make the connections too ...

Page 243: ...e or excess wear Torch rebuild kits are available from Hypertherm See Preventive maintenance kits on page 369 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 any maintenance T...

Page 244: ...to install the torch into the torch receptacle on page 138 How to measure the pit depth of an electrode 1 Complete the following procedures before continuing a Remove the power from the cutting system on page 234 b Remove the torch and consumable parts on page 236 2 Use an electrode pit depth gauge to measure the pit depth on the electrode See Figure 53 on page 244 A pit depth gauge is available f...

Page 245: ...come into contact flush skin or eyes with water If swallowed seek immediate medical attention CAUTION 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 it may need to be replaced Never use automoti...

Page 246: ...quent 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 see the XPR300 Preventative Maintenance Program PMP Instruction Manual 809490 Adding new coolant to the reservoir when the coolant lev...

Page 247: ... 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 bottom ...

Page 248: ...nt 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 for lubrication e Close the valve at the bottom of the reser...

Page 249: ...olant 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 the coolant pump screen Rinse it with water if you find debris b Exam...

Page 250: ...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 251: ... 809490 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 mul...

Page 252: ...umber to install modify inspect or repair any plumbing equipment or plumbing systems For complete safety information see the Safety and Compliance Manual 80669C WARNING ELECTRIC SHOCK CAN KILL Disconnect electrical power before doing any troubleshooting or diagnostic work All work requiring removal of the plasma power supply panels must be done by a qualified technician See the Safety and Complian...

Page 253: ...e issue that does not result in a diagnostic code make sure to first look for obvious problems or damage Always start with the following inspection steps Make sure that the cutting system is connected to electric power See How to connect electric power to the cutting system on page 139 Make sure that the line disconnect switch is set to ON See Line disconnect switch requirements on page 40 Examine...

Page 254: ... to electric power you can be injured or killed and the plasma power supply can be damaged See the Safety and Compliance Manual 80669C for more safety precautions The line disconnect switch must be in the OFF position before you connect the power cord to the cutting system The line disconnect switch must REMAIN in the OFF position until all installation steps are complete In the United States use ...

Page 255: ...tem can cause injury or death Use extreme caution if you do diagnosis or maintenance tasks when the line disconnect switch is in the ON position The plasma power supply contains dangerous electric voltages that can cause injury or death Even if the cutting system is turned OFF you can still get a serious electric shock if the cutting system remains connected to an electric power source Use extreme...

Page 256: ...wer from the cutting system See Remove the power from the cutting system on page 254 2 Remove the external panel or panels from the system component that has the PCB that you want to examine See Table 32 Table 32 PCB names and locations WARNING ELECTRIC SHOCK CAN KILL Disconnect electrical power before doing any troubleshooting or diagnostics All work requiring removal of the plasma power supply p...

Page 257: ...als inside the plasma power supply on page 258 7 If you cannot find or resolve the problem with these corrective actions contact your cutting machine supplier or regional Hypertherm Technical Service team Fan power distribution PCB Plasma power supply See Fans on page 329 Control PCB Gas connect console See Gas connect console manifold side parts on page 341 High frequency high voltage ignition PC...

Page 258: ...lectrician or the electric company that supplies electricity for more information 4 If the voltage between any 2 of the 3 lines is less than the supply voltage a Remove the power from the cutting system See Remove the power from the cutting system on page 254 b Examine the power cord for damage WARNING The plasma power supply contains dangerous electric voltages that can cause injury or death Even...

Page 259: ...09480 259 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 54 U GND W V ...

Page 260: ...2 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 261: ... or easy to do Alert These codes describe an Alert condition or conditions that can have a negative effect on productivity or quality Operator action is necessary to resolve an Alert code Outcomes can be poor during these conditions Resolve an Alert code as soon as possible Error These codes describe an Error condition or conditions that can have an adverse effect on productivity or quality or cau...

Page 262: ...e torch connect console Core VWI or OptiMix cannot receive communications at least once per second from the main control through the CAN 504 Failure Ch1 MainCAN t o Chopper 1 is unable receive communications at least once per second from the main control through the CAN 505 Failure Ch2 MainCAN t o Chopper 2 is unable to receive communications at least once per second from the main control trough t...

Page 263: ... o no pilot arc The sensor in Chopper 1 did not measure current during the 600 millisecond ignite period 1 Make sure that the pierce height is correct 2 Examine the consumables Replace the consumables that have damage or excess wear 3 Do a torch lead test See How to do a torch lead test on page 313 521 Alert Pilot arc t o no pilot arc The sensor in the work lead is unable to measure for at least 5...

Page 264: ...ke sure that they are correct Replace them if you find damage or excess wear 523 Error Preflow purge t o The XPR cutting system is unable to complete the preflow purge within 45 consecutive seconds The process does not get selected 524 Error Cutflow purge t o The XPR cutting system is unable to complete the cutflow purge within 45 consecutive seconds The process does not get selected 525 Error Ine...

Page 265: ... or pressure problems 2 Make sure that the inlet gas pressure for Line A P1 or Line B P2 are in the correct range 7 93 bar 7 24 bar 115 psi 105 psi during gas flow 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...

Page 266: ...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 consumables or consumables that have damage or excess wear 6 Use the gas volume monitors located near the pressure transducers to look for gas le...

Page 267: ...t 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 534 Alert Low psi Shield For at least 600 milliseconds the shield gas pressure is less than 75 of the setpoint and the setpoint is more than 0 See Low shield gas pressure code 534 on page 291 540...

Page 268: ...nt setpoint and the setpoint is more than the setpoint for that process setpoints vary by process type 1 Examine the consumables Replace consumables that have damage or excess wear 2 Do a test for gas leaks Replace leaking components if found 3 Examine contactors Replace damaged components if found 4 Look for DC bus errors 5 Examine the following components Choppers Inductors 6 Replace damaged cho...

Page 269: ...art removed ignite The Plasma Start switch is turned OFF during an Ignite State 576 Info Start removed pilot The Plasma Start switch is turned OFF during a Pilot arc state 577 Info Start removed rampup The Plasma Start switch is turned OFF during a Rampup State 580 Error Over temp Ind1 The temperature for the inductor Inductor 1 2 3 or 4 is more than 160 C 320 F When conditions are normal it takes...

Page 270: ...N cable and jumper block 507 508 for CAN network and bus 600 602 for no CAN communication on page 285 601 Error No chopper found Chopper 1 does not identify itself to the main control PCB through the CAN for at least 30 seconds 1 Confirm that the chopper ID connector is connected to J8 2 Connect the connectors if necessary 3 If connected see CAN codes 500 503 510 513 for gas connect console 504 50...

Page 271: ...A A catastrophic failure of a consumable part is detected on the Channel A Chopper 1 current signature 1 Inspect the consumable parts for damage and excess wear 2 If any consumable part needs replacement see How to install the consumables on page 136 611 Failure Ch1 Torch Protect ChB A catastrophic failure of a consumable part is detected on the Channel B Chopper 1 current signature 612 Failure Ch...

Page 272: ...rogram the path of the torch into the scrap area for rampdown 621 Failure Over voltage DC bus The DC bus voltage is more than 414 V Confirm that the incoming AC line does not exceed specifications See Input power requirements on page 39 622 Failure Under voltage DC bus The DC bus voltage is less than 280 V 623 Error Ch1 DC at Idle The chopper Chopper 1 or Chopper 2 is in idle state and the chopper...

Page 273: ...how long the system waits for input See Sequence of operation on page 197 645 Info System is off For your information Power is supplied to the cutting system and the customer supplied remote on off switch is in 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 See Sequence of operation on page 197 6...

Page 274: ...measure the resistance from the thermistor See How to measure resistance from thermistors on page 315 668 Error Thermistor Fault Ch2 Chopper 2 detects a shorted temperature sensor near the IGBT 670 Error Thermistor Fault Coolant The main control detects a shorted coolant temperature sensor Use a digital multimeter to measure the resistance from the thermistor See How to measure resistance from the...

Page 275: ...sure resistance from thermistors on page 315 691 Error Node reset The main control receives a console reset message after power is supplied to the XPR cutting system 1 Inspect the grounding High frequency noise can reset the CAN node 2 Make sure that the green power ON LED on the gas connect console and torch connect console is illuminated 3 If the green power ON LEDs are not illuminated make sure...

Page 276: ... The nitrogen N2 inlet pressure for the mixing module in the gas connect console only for OptiMix is less than 7 24 bar 105 psi 699 Error Mix Fault General diagnostic code for the mixing module in the gas connect console No operator action necessary 700 Alert Gas Inlet F5 GCC The F5 inlet pressure for P6 in the gas connect console only for VWI or OptiMix is less than 5 52 bar 80 psi or greater tha...

Page 277: ... TCC The air inlet pressure in the torch connect console is less than 5 52 bar 80 psi or greater than 8 61 bar 125 psi for at least 200 milliseconds 705 Alert Shield Gas Inlet Ar TCC The argon Ar inlet pressure in the torch connect console is less than 5 52 bar 80 psi or greater than 8 61 bar 125 psi for at least 200 milliseconds 706 Error No sensor P1 TCC The P1 pressure sensor in the torch conne...

Page 278: ...ted 715 Error No sensor P9 GCC The P9 pressure sensor in the gas connect console is not detected 716 Error Process Invalid The operator selected process is not supported by this XPR cutting system 1 See the cut charts for guidance about how to select a process ID for a supported process See the XPR300 Cut Charts Instruction Manual 809830 2 Use the CNC screen or XPR web interface to find and select...

Page 279: ...that the inlet pressures for N2 Ar and H2 are consistently within acceptable range 3 Use the gas volume monitors located near the pressure transducers for P21 V1 and V10 to look for gas obstructions or leaks 721 Error Mix param checksum The mixing parameter checksum failed 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...

Page 280: ...ch connect console 2 Replace the torch V1 valve if you find damage or excess wear 733 Alert Solenoid error V4 There is an over current condition for receptacle valve V4 at the PCB in the torch connect console 1 Examine the wiring for the valve 2 Connect the valve wire to another valve If the error goes away the valve is bad 3 Replace the bad valve 734 Alert Solenoid error V5 There is an over curre...

Page 281: ...receptacle valve V10 at the PCB in the torch connect console 740 Alert Solenoid error V11 There is an over current condition for receptacle valve V11 at the PCB in the torch connect console 741 Alert Solenoid error V12 There is an over current condition for receptacle valve V12at the PCB in the torch connect console 742 Alert Mix I2C1 Alert There is a mixing alert for I2C1 1 Examine the cable used...

Page 282: ... a 3 phase error in Chopper 2 755 Alert Low level Coolant The coolant level is low Fill the coolant reservoir with coolant See Coolant Installation on page 189 756 Info Leak test results Reports the result of a gas leak test 0 leak in V1 V12 or hose 1 leak in B1 2 leak in V1 or B1 3 leak in V1 V10 or hose 4 leak in B3 5 leak in V10 or B3 6 leak test failed 7 leak test passed 8 leak in V4 V5 V6 or ...

Page 283: ...ant solenoid fault The coolant solenoid driver detects an over current condition 764 Alert Main contactor fault The main contactor driver detects an over current condition 765 Alert Inrush contactor fault The inrush contactor driver detects an over current condition 766 Alert Pump enable fault The pump enable driver detects an over current condition 767 Alert Remote relay fault The remote on off r...

Page 284: ...A Line A Air inlet pressure is below 5 52 bar 80 psi or above 8 62 bar 125 psi 772 Alert High Inlet Line A Line A inlet pressure P2 exceeds 9 99 bar 145 psi Lower the air or O2 inlet pressure 773 Information System reverted to VWI A mixed fuel process was selected and the gas leak test failed or any purge process exceeds its time limit to complete purging times out Review the diagnostic code histo...

Page 285: ...steps a For code 504 alone Examine the CAN cable connection between Chopper 1 and Chopper 2 Look for loose connections bent 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 c...

Page 286: ...the green LEDs on both boards are illuminated examine the PCB 2 and PCB 3 chopper boards Make sure that LED D3 and D4 on PCB 2 and PCB 3 are blinking once per second indicates the microprocessor on 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 J8 f If the LEDs a...

Page 287: ... the plasma power supply and gas connect console is connected Disconnect the CAN cable connection between the gas connect console and torch connect console g If D24 and D25 stop flickering one of the following conditions can be the problem There is a bad connection between the plasma power supply and the gas connect console Reconnect or replace the CAN cable if necessary There is a bad connection ...

Page 288: ...king indicates the microprocessor on the PCB is functional e If LED D30 and D31 are blinking once per second examine LEDs D24 and D25 Flickering indicates the microprocessor on the PCB is functional f If LED D24 and D25 are flickering and you have codes 600 and 602 make sure that the connection between the main power supply and gas connect console is good Make sure that the CAN cable between the p...

Page 289: ...ed 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 Technical Services team Te...

Page 290: ...Low shield water pressure code 532 1 Make sure that the shield water pressure supplied to the cutting system is between 2 76 bar 7 93 bar 40 psi 115 psi If the pressure is less than 2 76 bar 40 psi then a booster water pump can be necessary to avoid system shut down or bad cut quality See Shield water requirements VWI and OptiMix on page 47 2 Examine all water hoses and water hose inlet fittings L...

Page 291: ...the XPR300 Cut Charts Instruction Manual 809830 4 Send a command to test preflow Make sure that the pressure is within the correct range for the active process For information about how to do this see the instruction manual that came with your CNC 5 Send a command to test cutflow and continue with the following steps Make sure that the pressure on P14 is achieved An error occurs only if the value ...

Page 292: ...lso can see coolant levels on the CNC screen or XPR web interface 2 If the coolant reservoir is not full fill it with coolant See Coolant Installation on page 189 3 If the coolant reservoir level is acceptable but the code continues a Examine the coolant hoses Look for restrictions or blockages b Examine the consumables Make sure they are correct for the operator selected process c Examine the coo...

Page 293: ... the frequency on J8 pin 3 pulse and pin 2 ground If there are no pulses replace the flow sensor 7 If you cannot find or resolve the problem with these corrective actions contact your cutting machine supplier or regional Hypertherm Technical Service team High coolant flow codes 543 544 A failed coolant pump can cause a high coolant flow diagnostic code 543 To make sure that the coolant pump is ope...

Page 294: ...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 coolant level is slightly above the level switch Examine the hoses...

Page 295: ...agnostic 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 5 Remove the power from the cutting system See Remove the power from the cutting system on page 254 6 Remove the pump side and front panels of the plasma pow...

Page 296: ...us obstruction dust or debris a Disconnect the connector for 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 each thermistor wire based on the following codes and connector pin locations c Look for a resistance value that is outside of the minimum or ...

Page 297: ...g fault or if thermistor replacement is necessary e If the resistance value is at or very near 0 ohms Inspect the wiring between each thermistor and its connector pins Look for shorts between wires or to the ground Thermistor temperature Minimum resistance Ohms Maximum resistance Ohms 25ºC 77ºF 9 000 11 000 35ºC 95ºF 5 000 7 000 45ºC 113ºF 3 900 4 900 55ºC 131ºF 2 500 3 500 65ºC 149ºF 1 500 2 500 ...

Page 298: ...more of the following steps based on the diagnostic code s Replace chopper 1 PCB 2 for error code 560 over temp Ch1 Replace chopper 2 PCB 3 for error code 561 over temp Ch2 Replace copper pipe thermistor assembly for error code 587 Over temp Coolant h If the resistance is within range continue cutting system operation i If the thermistor resistance is within range when the thermistor is disconnect...

Page 299: ...s illuminated a Remove the power from the cutting system See Remove the power from the cutting system on page 254 b Remove the connector from J14 on the rear of the plasma power supply c Supply power to the cutting system d Examine the LED D50 on PCB 1 Look for illumination 8 If LED D50 is illuminated when the discrete cable remains disconnected examine the PCB for dust or other contaminants Use c...

Page 300: ...do not find visible damage to the discrete cable remove the discrete cable from PCB1 Look for an open circuit between pins 3 and 4 of J14 13 If the cable is good make sure that the CNC output is set to OFF 14 If there is a short circuit make sure that the discrete cable is not shorted and that the CNC start signal output is set to OFF A closed circuit can indicate that the CNC sent a plasma start ...

Page 301: ...mance and over temp diagnostic codes 3 While all of the fans continue to operate allow the cutting system to cool 4 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 supply to locate the 2 magnetics 254 mm 10 in...

Page 302: ... compressed air is often necessary to clear this area Make sure to minimize fan rotation during compressed air use You can use a gloved hand to hold a fan in position if necessary 9 If the rotation for both magnetics fans is good and there is no obvious obstruction dust or debris a Disconnect the connector from the control board PCB 1 for the magnetics b Use a digital multimeter to measure the res...

Page 303: ... Service team They can help you to decide if there is a wiring fault or if thermistor replacement is necessary e If the resistance is at or very near 0 ohms Inspect the wiring between each thermistor and its connector pins Look for shorts between wires or to the ground Thermistor temperature Minimum resistance Ohms Maximum resistance Ohms 25ºC 77ºF 9 000 11 000 35ºC 95ºF 5 000 7 000 45ºC 113ºF 3 9...

Page 304: ... cutting machine supplier or Hypertherm Technical Service team for code 586 Over temp Xfmr h If the resistance is within range continue cutting system operation 10 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 Hyperth...

Page 305: ...or code 697 The H2O inlet pressure for code 701 2 For H2 N2 Ar make sure that the pressure is at least 7 24 bar 105 psi 3 For H2O make sure that the pressure is at least 2 07 bar 30 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...

Page 306: ... 5 52 bar 80 psi and 8 61 bar 125 psi 3 Use the regulators to increase or decrease the inlet pressure 4 If the pressure remains too low examine gas hoses and gas inlet fittings Look for Damage or kinks that can restrict flow Leaks that can decrease pressure 5 Replace the hoses if you find damage or kinks 6 Reposition the hoses if you find fixable kinks 7 Replace any fitting that has damage 8 Tight...

Page 307: ...e 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 with these corrective actions contact your cutting machine ...

Page 308: ...he acceptable range Process gas requirements Core VWI and OptiMix gas connect consoles on page 42 3 If the pressure of the gas inlet is inconsistent a Use a 2 stage regulator that maintains consistent gas pressure with high pressure gas cylinders Make sure that the 2 stage regulator can deliver the necessary gas flow WARNING The plasma power supply contains dangerous electric voltages that can cau...

Page 309: ...r in the XPR300 Replacement Parts Procedures Field Service Bulletin 809970 4 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 VWI and OptiMix CAUTION Gas leaks or pressure and flow rates that are outside of recommended ranges can Cause proble...

Page 310: ...tting 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 You must supply the flashback arrestors for your cutting system You can get them from your cutting machine supplier Hydrogen is a flammable gas that presents an explosion hazard Keep flames away from cylinders and hoses that contain hydro...

Page 311: ...hanger and coolant filter assembly c Remove the coolant hose from the coolant filter assembly Use a container to catch coolant leaks d Attach the in line flow meter 128933 to the hose e Look at the flow meter measurements Make sure that the flow is between 3 79 L min 11 36 L min 1 gal min 3 gal min Coolant flow measurements from different parts of the cooling system can identify the location of an...

Page 312: ... 6 If you find obstructions remove them Replace damaged parts if found 7 If coolant flow remains slow and it has been more than 6 months since the last coolant replacement replace the coolant See Replace all of the coolant on page 246 Hypertherm recommends coolant replacement every 6 months For complete preventative maintenance information see the XPR300 Preventative Maintenance Program PMP Instru...

Page 313: ... to do a torch lead test 1 Remove the power from the cutting system See Remove the power from the cutting system on page 254 2 Locate the start circuit assembly PCB 4 3 Install a temporary jumper wire between J5 nozzle and J1 work on the start circuit PCB 4 1 1 2 3 D4 D6 2 3 ...

Page 314: ...ics and Troubleshooting 8 314 809480 Instruction Manual XPR300 4 Locate the pilot arc relay CR 1 and remove the dust cover 5 Have a second person close push in the contact on the pilot arc relay 4 5 4 5 2 1 2 2 ...

Page 315: ... for a resistance value that is outside of the minimum or maximum in Table 37 Table 37 Minimum and maximum ohmic resistance values for thermistors Thermistor location Location of thermistor wires connector 1st connector pin 2nd connector pin Inductor 1A PCB 1 J1 4 pin 3 J1 4 pin 4 Inductor 1B PCB 1 J1 4 pin 5 J1 4 pin 6 Inductor 2A PCB 1 J1 4 pin 7 J1 4 pin 8 Inductor 2B PCB 1 J1 2 pin 1 J1 2 pin ...

Page 316: ...re electrical power to the cutting system d Repeat step 1 and step 2 6 If the resistance is within range continue cutting system operation 7 If the resistance remains below the minimum ohmic value or does not change after you allow the coolant to reach 85ºC 185ºF or below contact your cutting machine supplier or Hypertherm Technical Service team 8 If the thermistor resistance is within range when ...

Page 317: ...Diagnostics and Troubleshooting 8 XPR300 Instruction Manual 809480 317 PCB information Plasma power supply power distribution PCB 141425 LED Signal D1 120 VAC ...

Page 318: ...on Manual XPR300 Plasma 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 D5 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 ...

Page 319: ... D69 OHMIC CONTACT OUTPUT D105 Activity D15 SURGE INJ EN UNUSED IN THIS SYSTEM D78 CAN RX D108 PILOT ARC ENABLE D79 CAN TX D89 REMOTE ON OFF RELAY ENABLE D47 HX FAN 4 FEEDBACK D6 PILOT ARC RELAY D43 HX FAN 3 FEEDBACK D10 MARK RELAY D41 HX FAN 2 FEEDBACK D19 MAIN CONTACTOR D38 HX FAN 1 FEEDBACK D25 INRUSH CONTACTOR D36 MAG FAN 4 FEEDBACK D97 COOLANT SOLENOID D33 MAG FAN 3 FEEDBACK D100 PUMP ENABLE ...

Page 320: ...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 321: ...ics and Troubleshooting 8 XPR300 Instruction Manual 809480 321 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 322: ...Diagnostics and Troubleshooting 8 322 809480 Instruction Manual XPR300 Plasma power supply fan power distribution PCB 141384 ...

Page 323: ...uction Manual 809480 323 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 3V D16 5 V D25 CAN TX D17 A3 3 D18 D17 D16 D30 D1 D5 D6 D31 D25 D29 D15 D26 D24 ...

Page 324: ...cs and Troubleshooting 8 324 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 325: ...l LED Signal D58 V7 D87 STATUS LED D69 V9 D88 ACTIVITY LED D75 V10 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 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 326: ...and Troubleshooting 8 326 809480 Instruction Manual XPR300 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 LED Signal LED Signal ...

Page 327: ...XPR300 Instruction Manual 809480 327 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 328: ...p panel 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 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 329: ...wer LED assembly 1 2 229821 Fan assembly 292 cfm 48 VDC 120 mm 4 7 inch diameter CAB FAN3 CAB FAN4 2 3 229822 Fan assembly 890 cfm 48 VDC 254 mm 10 inch diameter HX FAN1 HX FAN2 MAG FAN1 MAG FAN2 4 4 229717 Heat exchanger assembly 1 5 003266 Solid state relay 1 6 141384 Fan power distribution PCB PCB6 1 2 1 3 3 4 5 6 ...

Page 330: ...6 428729 Coolant pump and motor assembly Adapter 1 5 8 inch UNF X 1 inch NPT X 16 JIC Plug with O ring Coolant pump screen coarse Pump and motor Adapter 1 inch 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 7 006132 Coolant bypass check valve 1 8 229721 Coolant solenoid valve assembly 1 9 229654 T...

Page 331: ...Quantity 1 015889 Elbow adapter 1 2 inch NPT X 1 2 inch tube 45 swivel 2 2 006154 Coolant check valve 1 3 015903 Red ring 1 13 inches inner diameter 1 4 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 5 015029 Adapter 1 2 inch NPT X 8 male 2 015898 Green ring 0 87 inch inner diameter not shown 1 6 015902 Green ring 1 13 inch inner di...

Page 332: ... 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 333: ... reference only 1 2 3 Part number Description Designator Quantity 1 Inductor 1A top 1B bottom L1 1 2 Inductor 2A top 2B bottom L2 1 3 Transformer horizontal 63 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 334: ...Manual XPR300 Control side view 1 Part number Description Designator Quantity 1 229671 Power source 88 VAC 264 VAC to 48 VDC 600 W PS2 1 2 141425 Power distribution PCB PCB7 1 108709 Fuse 10 A 250 VAC time delay on PCB7 F3 F4 F5 3 1 2 3 4 ...

Page 335: ... 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 Part number Description Designator Quantity ...

Page 336: ...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 337: ...Parts List 9 XPR300 Instruction Manual 809480 337 ...

Page 338: ... 3 1 3 229033 Terminal block 600 V 200 A 200 V 208 V 220 V 240 V TB1 1 4 209283 EMI filter with terminal block 400 V CE 5 029316 Terminal block 600 V 140 A 380 V 415 V 440 V 480 V 600 V 6 003276 Main contactor 200 V 208 V 220 V 240 V M_CON 1 003268 Main contactor 380 V 400 V 415 V 440 V 480 V 600 V 1 2 3 4 5 6 200 V 208 V 220 V 240 V plasma power supplies 400 V CE plasma power supplies 380 V 415 V...

Page 339: ...8367 RJ 45 coupler female female bulkhead shielded 2 223502 Green EtherCAT CNC interface cable 0 7 m 26 inches 1 223727 Black EtherCAT CNC interface cable 0 7 m 26 inches 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 340: ...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 341: ...X 5 16 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 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 inches i...

Page 342: ...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 343: ...Parts List 9 XPR300 Instruction Manual 809480 343 ...

Page 344: ...Parts List 9 344 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 345: ...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 346: ...Parts List 9 346 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 347: ...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 348: ...nsole mixer transducers and valves Part number Description Console Designator Quantity 1 Mixer You cannot purchase this part Shown for reference only OptiMix 1 2 223398 Pressure transducer VWI and OptiMix P6 P9 4 3 006167 Solenoid valve VWI and OptiMix B4 B5 2 VWI OptiMix 1 2 2 3 3 ...

Page 349: ...19 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 con...

Page 350: ...Easy Connect side 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 428338 Kit Tubing 1 006152 Check valve 1 2 1 3 4 ...

Page 351: ... Pressure 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 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 352: ...ity 229895 Manifold assembly 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 1 2 3 4 5 6 2 ...

Page 353: ...tion Designator Quantity 1 006077 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...

Page 354: ... sleeve assembly Short 420502 Torch mount sleeve assembly Extended 2 420220 Quick disconnect torch receptacle 3 420221 Quick disconnect torch 4 420368 Water tube 006155 Torch solenoid valve V1 229918 Torch solenoid valve tool 006169 Torch solenoid valve connector 428488 Torch assembly 300 A mild steel consumables 104879 2 25 inch spanner wrench 1 2 3 4 ...

Page 355: ...Parts List 9 XPR300 Instruction Manual 809480 355 Torch bracket Part number Description 428646 Torch lifter bracket 2 25 inch diameter sleeve ...

Page 356: ...0243 Nozzle 80 A 2 420246 Shield 80 A 2 420242 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 300 A 3 420279 Nozzle 300 A 3 420491 Shield 300 A 2 420406 Swirl ring 300 A 1 420368 Water tube 1 420200 Shield retaining cap 1 420365 Nozzle retain...

Page 357: ...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 358: ...ring 80 A 130 A 1 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 359: ...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 360: ...Parts List 9 360 809480 Instruction Manual XPR300 Other consumable and torch parts Part number Description 004629 Pit depth gauge 027055 Silicone lubricant 1 4 ounce 104119 Consumable tool ...

Page 361: ...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 362: ... 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 427476 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 363: ... 8 feet 223428 35 m 114 8 feet 223420 7 5 m 24 6 feet 223429 45 m 147 6 feet 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 428457 7 5 m 24 6 feet 428455 4 5 m 14 8 feet 428458 10 m 32 8 feet 428456 6 m 19 7 feet 428459 15 m 49 2 feet Part number Length Part number Length 4284...

Page 364: ...I or OptiMix Part number Length Part number Length 428353 3 m 9 8 feet 428356 7 5 m 24 6 feet 428354 4 5 m 14 8 feet 428357 10 m 32 8 feet 428355 6 m 19 7 feet 428358 15 m 49 2 feet Part number Length Part number Length 428363 3 m 9 8 feet 428366 7 5 m 24 6 feet 428364 4 5 m 14 8 feet 428367 10 m 32 8 feet 428365 6 m 19 7 feet 428368 15 m 49 2 feet ...

Page 365: ...8 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 fe...

Page 366: ... 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 367: ...er Length 428383 2 m 6 6 feet 428386 3 5 m 11 5 feet 428384 2 5 m 8 2 feet 428387 4 5 m 14 8 feet 428385 3 m 11 5 feet Part number Length Part number Length 124003 3 m 9 8 feet 124009 25 m 82 feet 124004 4 5 m 14 8 feet 124010 35 m 114 8 feet 124005 7 5 m 24 6 feet 124011 45 m 147 6 feet 124006 10 m 32 8 feet 124012 60 m 196 9 feet 124007 15 m 49 2 feet 124013 75 m 246 1 feet 124008 20 m 65 6 feet...

Page 368: ...8 15 m 49 2 feet 124024 75 m 246 1 feet 124019 20 m 65 6 feet Part number Length Part number Length 124025 3 m 9 8 feet 124031 25 m 82 feet 124026 4 5 m 14 8 feet 124032 35 m 114 8 feet 124027 7 5 m 24 6 feet 124033 45 m 147 6 feet 124028 10 m 32 8 feet 124034 60 m 196 9 feet 124029 15 m 49 2 feet 124035 75 m 246 1 feet 124030 20 m 65 6 feet Part number Length Part number Length 124036 3 m 9 8 fee...

Page 369: ...55 45 m 147 6 feet 124050 10 m 32 8 feet 124056 60 m 196 9 feet 124051 15 m 49 2 feet 124057 75 m 246 1 feet 124052 20 m 65 6 feet Part number Length 428639 Kit Filter torch rebuild without coolant 428640 Kit Filter torch rebuild with coolant 428641 Kit Electronics 200 V 240 V 428642 Kit Electronics 380 V 600 V Part number Length 229917 Torch connect console solenoid valve tool 229918 Torch soleno...

Page 370: ...per assembly Chopper 1 Chopper 2 1 141322 Control PCB PCB1 1 141371 I O PCB PCB5 1 141384 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 I...

Page 371: ...ure transducer VWI and OptiMix only P6 P9 1 006128 Solenoid valve VWI and OptiMix only B4 B5 1 141354 High frequency high voltage ignition PCB PCB2 1 Part number Description Designator Quantity 141368 Ohmic contact PCB PCB2 1 223477 Pressure transducer with wire and connector P1 P5 P14 1 Part number Description Designator Quantity 420220 Quick disconnect torch receptacle 1 420221 Quick disconnect ...

Page 372: ...mplete 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 oper...

Page 373: ...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 374: ...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 375: ...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 376: ... or regional Hypertherm Technical Service Team Valve states during cutting and piercing Mild Steel Cutting 30 A 80 A 130 A 170 A 300 A O2 Plasma Air Shield Core VWI and OptiMix Stage Gas Valve V1 V4 V5 V6 V7 V8 V9 V10 V11 V12 Preflow N2 Air Off Off Off On Off Off On Off Off Off Pierce flow O2 Air On Off Off On Off Off On Off Off On Cutflow O2 Air On Off Off On Off Off On Off On On 300 A 5 00 mm 2 ...

Page 377: ...ow N2 N2 Off Off On Off Off Off Off Off Off Off Pierce flow N2 N2 Off Off On Off Off Off Off Off On Off Cutflow N2 N2 Off Off On Off Off Off Off Off On Off Aluminum Cutting 40 A 60 A Air Plasma Air Shield Core VWI and OptiMix Stage Gas Valve V1 V4 V5 V6 V7 V8 V9 V10 V11 V12 Preflow N2 Air Off Off Off On Off Off Off Off Off Off Pierce flow Air Air On Off Off On Off Off Off Off Off Off Cutflow Air A...

Page 378: ... F5 N2 On Off On Off Off Off Off On On Off Cutflow F5 N2 On Off On Off Off Off Off On On Off Stainless Steel and Aluminum Cutting 60 A 80 A 130 A 170 A 300 A N2 Plasma H2O Shield VWI and OptiMix only Stage Gas Water Valve V1 V4 V5 V6 V7 V8 V9 V10 V11 V12 Preflow N2 H2O Off Off Off Off Off Off Off Off Off Off Pierce flow N2 H2O Off Off Off Off Off Off Off Off Off Off Cutflow N2 H2O Off Off Off Off ...

Page 379: ...Steel Stainless Steel and Aluminum Marking N2 Plasma N2 Shield Core VWI and OptiMix Stage Gas Valve 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 On Off Marking N2 N2 Off Off On Off Off Off Off Off Off Off ...

Page 380: ...Wiring Diagrams 10 380 809480 Instruction Manual XPR300 ...

Page 381: ...381 Overview Sheet 1 of 22 013403 013403 ...

Page 382: ...382 Plasma power supply 1 Sheet 2 of 22 013403 ...

Page 383: ...383 Plasma power supply 2 Sheet 3 of 22 013403 ...

Page 384: ...384 Plasma power supply 3 Sheet 4 of 22 013403 ...

Page 385: ...385 Plasma power supply 4 Sheet 5 of 22 013403 ...

Page 386: ...386 Plasma power supply 5 Sheet 6 of 22 013403 ...

Page 387: ...387 Plasma power supply 6 Sheet 7 of 22 013403 ...

Page 388: ...388 Plasma power supply 7 Sheet 8 of 22 013403 ...

Page 389: ...389 Gas connect console 1 Sheet 9 of 22 013403 ...

Page 390: ...390 Gas connect console 2 Sheet 10 of 22 013403 ...

Page 391: ...391 Torch connect console Sheet 11 of 22 013403 ...

Page 392: ...392 Coolant system Sheet 12 of 22 013403 ...

Page 393: ...393 Gas system 1 Sheet 13 of 22 013403 ...

Page 394: ...394 Gas system 2 Sheet 14 of 22 013403 ...

Page 395: ...395 Gas system 3 Sheet 15 of 22 013403 ...

Page 396: ...nd or THC installations EtherCAT cable EtherCAT cable EDGE Connect T 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 D...

Page 397: ...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 398: ...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 399: ...herm EDGE Connect T 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 400: ...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 401: ... 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 402: ...402 Wireless subsystem block diagram Sheet 22 of 22 013403 ...

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