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Hypertherm XPR300 Instruction Manual

Plasma
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XPR300™
Plasma
Instruction Manual
809480 | Revision 2 | English

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Summary of Contents for Hypertherm XPR300

  • Page 1 XPR300™ Plasma Instruction Manual 809480 | Revision 2 | English...
  • Page 2 All other trademarks are the property of their respective holders. One of Hypertherm’s long-standing core values is a focus on minimizing our impact on the environment. Doing so is critical to our, and our customers’, success. We are always striving to become better environmental stewards; it is a process we care deeply about.
  • Page 3 XPR300 Instruction Manual 809480 Revision 2 English Original instructions November 2017 Hypertherm Inc. Hanover, NH 03755 USA www.hypertherm.com...
  • Page 4 México, D.F. C.P. 01780 (Technical Service Email) 52 55 5681 8109 Tel 52 55 5683 2127 Fax South America & Central America: Hypertherm Brasil Ltda. Soporte.Tecnico@hypertherm.com (Technical Service Email) Rua Bras Cubas, 231 – Jardim Maia Guarulhos, SP – Brasil...
  • Page 5 한국어 / KOREAN product worden meegeleverd. De handleidingen, elke handleiding 경고! Hypertherm 장비를 사용하기 전에 제품 설명서와 안전 및 규정 beschikbaar in alle talen, zijn ook verkrijgbaar via de “Documentenbibliotheek” 준수 설명서 (80669C)에 나와 있는 안전 지침을 읽으십시오. 안전 지침을...
  • Page 6 Kópia návodu, ktorá je dodávaná s produktom, môže mať elektronickú alebo tlačenú podobu. Kópie návodov, vo všetkých dostupných jazykoch, sú k dispozícii aj v sekcii z „knižnice Dokumenty“ na www.hypertherm.com.

  • Page 7: Table Of Contents

    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 XPR300 Instruction Manual 809480...
  • Page 8 Shield water requirements (VWI and OptiMix) .................... 47 Plumbing and hose requirements for shield water ................48 Additional regulator requirement for shield water (optional) ............48 Torque requirements for gas or water plumbing and hose connections........48 809480 Instruction Manual XPR300...
  • Page 9 Installation checklist..........................70 Verify system requirements ....................... 70 Verify installation steps ......................73 Safety instructions related to installation ................... 76 Configuration with Core gas connect console ................80 Configuration with VWI or OptiMix gas connect console ............. 81 XPR300 Instruction Manual 809480...
  • Page 10 Connect the power, CAN, and 3-gas assembly (Core)..........113 Connect the gas connect console (VWI or OptiMix) to the torch connect console.... 114 Connect the pilot arc, coolant hose set, and shield water assembly......114 Connect the power, CAN, and 5-gas assembly............... 117 809480 Instruction Manual XPR300...
  • Page 11 Access the XPR web interface after setup in network mode ........161 Change the limited AP IP address ..................162 Reset the wireless module......................... 163 Web interface screen information ....................166 Plasma power supply ......................167 Gas system..........................168 Log............................... 169 Operate............................170 Other ............................171 XPR300 Instruction Manual 809480...
  • Page 12 Pilot arc State (9) ........................202 Rampup State (11) ........................203 Steady State (12)........................204 Rampdown State (13)......................205 End of cycle State (14)......................206 High-voltage relay stages (closed or opened) in the ohmic circuit.......... 206 809480 Instruction Manual XPR300...
  • Page 13 Recommendations for marking processes................. 227 Recommendations for bevel-cutting processes ............... 227 How to maximize the life of consumable parts ................228 Arc Response Technology..........................228 Automatic torch protection ........................ 228 Automatic rampdown error protection .................... 229 XPR300 Instruction Manual 809480...
  • Page 14 Over-temp diagnostic codes – Choppers (560 – 561) and Coolant (587) ..... 295 Start switch diagnostic codes (570 – 577) ..............299 Over temp diagnostic codes – Inductors (580 – 583), Transformers (586)..... 301 Current sensor diagnostic codes (631) ................304 809480 Instruction Manual XPR300...
  • Page 15 Gas connect console manifold side parts..................341 Core, VWI, and OptiMix gas connect console manifold side ........341 Core gas connect console manifolds and adapters ............342 VWI gas connect console input and output manifolds and adapters......344 XPR300 Instruction Manual 809480...
  • Page 16 Torch connect console to torch receptacle connection ................. 367 Torch lead .............................. 367 Supply hoses..............................367 Oxygen hose (blue)..........................367 Nitrogen or Argon hose (black) ......................368 Air hose (black)............................. 368 Hydrogen or nitrogen-hydrogen (F5) (red) ..................368 Water (optional shield fluid) (blue)....................369 809480 Instruction Manual XPR300...
  • Page 17 EtherCAT connection to EDGE Connect/T/TC (Sheet 19 of 22) ........... 399 Discrete and serial RS-422 CNC connections (Sheet 20 of 22) ..........400 Discrete CNC connections (Sheet 21 of 22) ................401 Wireless subsystem block diagram (Sheet 22 of 22)..............402 XPR300 Instruction Manual 809480...
  • Page 18 Contents 809480 Instruction Manual XPR300...

  • Page 19: List Of Tables

    Table 22 – Communication requirements and options................150 Table 23 – Pinout for serial RS-422 interface cable................174 Table 24 – Pinout for J14 on the discrete cable ..................177 Table 25 – Pinout for J19 on the discrete cable ..................177 XPR300 Instruction Manual 809480...
  • Page 20 Table 35 – Minimum and maximum ohmic resistance values for thermistors ........297 Table 36 – Minimum and maximum ohmic resistance values for thermistors ........303 Table 37 – Minimum and maximum ohmic resistance values for thermistors ........315 809480 Instruction Manual XPR300...

  • Page 21: Electromagnetic Compatibility (Emc

    Introduction Methods of reducing emissions Mains supply Hypertherm’s CE-marked equipment is built in compliance with standard EN60974-10. The equipment should be installed and used in Cutting equipment must be connected to the mains supply according to accordance with the information below to achieve electromagnetic the manufacturer’s recommendations.

  • Page 22: Earthing Of The Workpiece

    Electromagnetic Compatibility (EMC) Earthing of the workpiece Where the workpiece is not bonded to earth for electrical safety, nor connected to earth because of its size and position, for example, ship’s hull or building steel work, a connection bonding the workpiece to earth may reduce emissions in some, but not all instances.

  • Page 23: Warranty

    Hypertherm not in strict conformity herein and as follows: if Hypertherm is notified of a defect (i) with respect with Hypertherm’s specifications and in cases of designs, processes,...

  • Page 24: Liability Cap

    At all times you will have and maintain insurance in such quantities and types, and with coverage sufficient and appropriate to defend and to hold Hypertherm harmless in the event of any cause of action arising from the use of the products.

  • Page 25: Specifications

    Gases – Hydrogen (H ), argon (Ar), nitrogen (N ), oxygen (O ), water (H O), F5 (95% nitrogen, 5% hydrogen) Mixed-fuel gas – A mixture of H -Ar-N created in the OptiMix gas connect console. XPR300 Instruction Manual 809480...

  • Page 26: Xpr Cutting System Description

    45 mm (1.77 in.) for mild steel and 38 mm (1.50 in.) for both stainless steel and aluminum. The maximum cutting capacity (edge start) is 80 mm (3.15 in.) for mild steel, 75 mm (2.95 in.) for stainless steel, and 50 mm (1.97 in.) for aluminum. 809480 Instruction Manual XPR300...

  • Page 27: Plasma Power Supply (Part Number Varies)

    Note: Only VWI- and OptiMix-equipped cutting systems can use water as a shield fluid. Power factor (cosθ) 0.98 at 63 kW Cooling Forced air (Class F) XPR300 Instruction Manual 809480...

  • Page 28: Table 2 - Plasma Power Supply Part Numbers And Specifications

    078622 50 – 60 cCSAus 078623 cCSAus 078624 50 – 60 CE, RCM, 078625 50 – 60 EAC, UKr, 71.43 and AAA CE, RCM, 078626 EAC, UKr, and AAA 078627 cCSAus 078628 cCSAus 078629 cCSAus 809480 Instruction Manual XPR300...

  • Page 29: Gas Connect Console (Part Number Varies)

    (8.12 in.) (14.75 in.) (20.56 in.) 42.15 lb 434.59 mm 524.00 mm 24.36 kg OptiMix 078633 (17.11 in.) (20.63 in.) 53.70 lb  For mounting dimensions, see Position and mount the gas connect consoles on page 84. XPR300 Instruction Manual 809480...

  • Page 30: Torch Connect Console (078618)

     For mounting dimensions, see Position and mount the torch connect console on page 87. 809480 Instruction Manual XPR300...

  • Page 31: Torch (Part Number Varies)

    Rated arc striking voltage 15.3 kV Maximum gas pressure at inlet 7.9 bar, 792 kPa (115 psi) Minimum gas pressure at inlet 7.2 bar, 723 kPa (105 psi) Maximum torch-side and torch-front force 22.5 Kg (50 lb) XPR300 Instruction Manual 809480...

  • Page 32: Symbols And Marks

    The CE versions of products that include a UkrSEPRO mark of conformity meet the product safety and EMC requirements for export to the Ukraine. Serbian AAA mark CE versions of products that include a AAA Serbian mark meet the product safety and EMC requirements for export to Serbia. 809480 Instruction Manual XPR300...

  • Page 33: Iec Symbols

    The terminal for the Direct current (DC) external protective (earth) conductor Alternating current (AC) Power is ON Power is OFF Plasma torch cutting A 1-phase or 3-phase inverter-based power Gouging source Volt/amperage curve, AC input power “drooping” characteristic connection XPR300 Instruction Manual 809480...
  • Page 34 Specifications 809480 Instruction Manual XPR300...

  • Page 35: Qualifications And Requirements

    XPR300 CNC Communication Protocol Application Note (809810)  XPR300 Preventive Maintenance Program Instruction 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.

  • Page 36: Operator Qualifications

    (See the Safety and Compliance Manual [80669C], Radio Frequency Warning Manual [80945C], and Safety instructions related to installation on page 76.)  Additional qualifications apply for personnel who do maintenance and troubleshooting (Qualifications of service personnel on page 37). 809480 Instruction Manual XPR300...

  • Page 37: Qualifications Of Service Personnel

     maintenance on the cutting system or equipment.  The entity responsible for workplace safety where your XPR300 cutting system is used must do a risk assessment and establish the criteria for service personnel training and qualifications. Do not do any service or maintenance on the cutting system or equipment if you cannot ...

  • Page 38: System Electrical Requirements

    Contact 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. 809480 Instruction Manual XPR300...

  • Page 39: Input Power Requirements

    * AWG recommendations comply with Table 310-15 of the US National Electric Code 1990 Handbook.  Contact a licensed electrician to make sure that your main power cord size and length meet the codes in your location. XPR300 Instruction Manual 809480...

  • Page 40: Circuit Breaker And Fuse Requirements

    A means for disconnecting the cutting system shall be provided according to the installation, safety, and emergency requirements for the local codes and regulations, taking into account the input power requirements. Hypertherm does not supply this means of disconnection. 809480...

  • Page 41: Remote On-Off Switch

    A convenient location for a remote on-off switch is near the CNC.  For information about how to do this, see How to install a remote on-off switch on page 185. XPR300 Instruction Manual 809480...

  • Page 42: Process Gas Requirements (Core, Vwi, And Optimix Gas Connect Consoles)

    • 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 pressures and flow rates. 809480 Instruction Manual XPR300...

  • Page 43: Code Conformity

    (110 psi ± 5 psi) 85 scfh * Water can be used as a shield fluid for XPR300 plasma power supplies that have a VWI or OptiMix gas connect console. See Shield water requirements (VWI and OptiMix) on page 47 for the specifications and requirements for water that is used for shield purposes.

  • Page 44: Plumbing For Supply Gases

     Do not use steel or aluminum.   Supply-gas hoses are available from Hypertherm. (See Supply hoses on page 367.)  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.

  • Page 45: Table 8 - Recommended Gas Fitting Sizes

    Qualifications and Requirements Hypertherm recommends an internal diameter of 10 mm (0.375 inch) for supply-gas hoses that are 76 m (250 feet) or less. Table 8 on page 45 describes the recommended sizes for gas fittings. Table 8 – Recommended gas fitting sizes...

  • Page 46: Regulators For Supply Gases

    Your gas supplier can recommend the best gas regulator (regulators) for the conditions at your site.  Local regulations and the type of gas that is used can influence the recommended inlet gas fittings for your gas connect console. (See Table 8 – Recommended gas fitting sizes on page 45.) 809480 Instruction Manual XPR300...

  • Page 47: Shield Water Requirements (Vwi And Optimix)

    Dissolved ionized solids (such as salts and minerals) increase the electrical conductivity of a solution. Total dissolved solids can be tested with a TDS meter (13897) available from Hypertherm. * Water that does not meet minimum purity specifications can cause excessive deposits on the torch nozzle and shield.

  • Page 48: Plumbing And Hose Requirements For Shield Water

    To decrease the risk of leaks in the cutting system, 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.

  • Page 49: Coolant Requirements

    If your coolant pump is damaged, it may need to be replaced. Never use automotive antifreeze in place of Hypertherm coolant. Antifreeze contains chemicals that damage the torch coolant system.

  • Page 50: Coolant Requirements For Operation Between -10°C - 40°C (14°F - 104°F)

    Qualifications and Requirements Coolant requirements for operation between -10°C – 40°C (14°F – 104°F) Use Hypertherm premixed coolant (028872) when operating in a temperature range of -10°C to 40°C (14°F to 104°F).  If using shield water, the temperature range for cutting system operation is reduced to above 0°C to 40°C (32°F to 104°F).

  • Page 51: Flow Requirements For Coolant

    (gpg of CaCO at 25°C (77°F) (ppm of NaCl) Pure water 0.055 18.3 (For reference only. Do not use.) Maximum purity 0.206 0.010 Minimum purity 0.054 0.43 Maximum potable water (For reference only. Do 1000 0.001 not use.) XPR300 Instruction Manual 809480...

  • Page 52: Requirements To Position System Components

    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 page 57  809480 Instruction Manual XPR300...

  • Page 53: Recommended Configuration With The Core Gas Connect Console

    7 Negative lead connect console) 8 Pilot arc and coolant hose set assembly 12 Hoses for supply gases a Pilot arc lead 13 Gases Core: O , and air b Coolant hose set (1 supply, 1 return) XPR300 Instruction Manual 809480...

  • Page 54: Recommended Configuration With The Vwi Or Optimix Gas Connect Console

    13 Gases and water b Coolant hose set (1 supply, 1 return) VWI: O , air, N , Ar, F5, and water c Shield water hose (VWI or OptiMix) OptiMix: O , air, N , Ar, F5, water, H 809480 Instruction Manual XPR300...

  • Page 55: Site Requirements

    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. XPR300 Instruction Manual 809480...

  • Page 56: Bend Radius Requirements For Hoses, Cables, And Leads

    If possible, use a separate track to isolate each lead and cable. If separate tracks are not possible, Hypertherm recommends a minimum separation distance 150 mm (6 inches) between the high-frequency leads and control cables. Separate the pilot arc...

  • Page 57: Distance Requirements For Communications

    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.

  • Page 58: Torch Mounting Bracket Requirements

     Does not interfere with the torch lifter   The XPR300 torch mounting 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.)

  • Page 59: Cnc Requirements

    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  Coolant temperature  Coolant flow  Pressure transducers  Fan speeds  XPR300 Instruction Manual 809480...

  • Page 60: Diagnostics And 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). 809480 Instruction Manual XPR300...

  • Page 61: Recommended Grounding And Shielding

     The grounding practices in this section have been used on many installations with excellent results, and Hypertherm recommends that these practices be a routine part of the installation process. The actual methods used to implement these practices may vary from system to system, but should remain as consistent as possible.

  • Page 62: Grounding Practices

    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 system.
  • Page 63 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 (Belden 1800F or equivalent). Use a cable with a braided shield, not a foil shield.
  • Page 64 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 809480 Instruction Manual XPR300...

  • Page 65: Example Grounding Diagram

    10 Gas connect console. Connect to table ground bus bar. * 5 Gantry ground bus bar 11 DC power ground (work lead) 6 Torch height control lifter * The ignition console is integrated into the gas connect console for XPR300 cutting systems. XPR300 Instruction Manual 809480...
  • Page 66 Qualifications and Requirements 809480 Instruction Manual XPR300...

  • Page 67: Installation

    Record your product information and register your product’s serial number at  www.hypertherm.com. Before you set up this equipment, read the safety information included with your equipment.  Failure to follow safety instructions can result in personal injury or in damage to equipment. XPR300 Instruction Manual 809480...

  • Page 68: Claims

    Claims for damage during shipment – If your equipment was damaged during shipment, file  a claim with the carrier. You can contact Hypertherm for a copy of the bill of lading. If you need additional assistance, call the nearest Hypertherm office listed in the front of this manual.

  • Page 69: Installation Requirements

    All installation and service of the electrical systems must obey national and local electrical codes. A qualified person must do this work. Contact the nearest Hypertherm Technical Service team listed in the front of this manual or your authorized Hypertherm cutting machine supplier with any technical questions.

  • Page 70: Installation Checklist

    You must supply the emergency-stop switches for your cutting system. Make sure that the remote on-off switch is correctly installed. See Remote on-off switch on page 41. You must supply the remote on-off switch for your cutting system. 809480 Instruction Manual XPR300...
  • Page 71 Make sure that the shield water regulator meets requirements, if applicable (VWI and OptiMix). See Additional regulator requirement for shield water (optional) on page 48. Additional water pressure regulators are only required when the water pressure is above 7.92 bar (115 psi). XPR300 Instruction Manual 809480...
  • Page 72 Make sure that the spacing and ventilation for the plasma power supply meets requirements. See Distance requirements for ventilation and access on page 56. Hypertherm recommends a minimum distance of 1 meter (3.3 feet) between the plasma power supply and other system components, or between the plasma power supply and an obstacle.

  • Page 73: Verify Installation Steps

    Pilot arc and coolant hose set assembly. See Connect the pilot arc and coolant hose set assembly on page 110. Power, CAN, and 3-gas assembly (Core only). See Connect the power, CAN, and 3-gas assembly (Core) on page 113. XPR300 Instruction Manual 809480...
  • Page 74 Make sure that the distance between high-frequency leads and control cables meets requirements. See Distance requirements between high-frequency leads and control cables on page 56. Make sure that the distance for communication meets requirements. See Distance requirements for communications on page 57. 809480 Instruction Manual XPR300...
  • Page 75 Coolant – Make sure that the coolant is installed correctly. See Coolant Installation on page 189. Make sure that the coolant type is correct. See Coolant requirements on page 49. Make sure that the coolant reservoir is full. See How to fill the cutting system with coolant on page 190. XPR300 Instruction Manual 809480...

  • Page 76: Safety Instructions Related To Installation

    Use extreme caution if you do diagnosis or maintenance tasks when the plasma power supply remains plugged in and the panels on the plasma power supply are removed. 809480 Instruction Manual XPR300...
  • Page 77 If you use oxygen as the plasma gas for cutting, it can cause a potential fire hazard due to the oxygen-enriched atmosphere that collects. Hypertherm recommends that you install an exhaust ventilation system to remove the oxygen-enriched atmosphere that can collect when oxygen is used as the plasma gas for cutting.
  • Page 78 If you use the wrong coolant, it can cause damage to the cutting system. See Coolant requirements on page 49. Never use automotive antifreeze in place of Hypertherm coolant. Antifreeze contains chemicals that damage the torch coolant system. Always use purified water with 0.2% benzotriazole in the coolant mixture to prevent damage to the pump, torch, and other components in the coolant system.
  • Page 79 • 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 pressures and flow rates. XPR300 Instruction Manual 809480...

  • Page 80: Configuration With Core Gas Connect Console

    * Regulator (For the best results, position a gas regulator within 3 meters (10 feet) of the gas 8 Pilot arc and coolant hose set assembly connect console) a Pilot arc lead b Coolant hose set (1 supply, 1 return) 809480 Instruction Manual XPR300...

  • Page 81: Configuration With Vwi Or Optimix Gas Connect Console

    8 Pilot arc, coolant hose set, shield water assembly * Regulator (For the best results, position a gas regulator within 3 meters (10 feet) of the gas a Pilot arc lead connect console) b Coolant hose set (1 supply, 1 return) XPR300 Instruction Manual 809480...

  • Page 82: How To Position The System Components

    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 page 57  809480 Instruction Manual XPR300...

  • Page 83: Position System Components

    • Set the plasma power supply down gently. Do not drop it from any height. The XPR300 plasma power supply weighs 590 kg (1,300 lbs). You must use a lift truck or other lift equipment to position the plasma power supply. See Table 16.

  • Page 84: Position And Mount The Gas Connect Consoles

    For mounting dimensions, see Figure 1 on page 85 and Figure 2 on page 86.  If you have questions about when or how to use the mounting holes to mount your gas connect console, contact your cutting machine supplier or regional Hypertherm Technical Service team. 809480 Instruction Manual XPR300...
  • Page 85 Gas inlet side of gas connect console (Core) Gas outlet side of gas connect console 26.98 cm (10.63 in.) Gas inlet side of gas connect console 1.27 cm (0.50 in.) 6.48 mm 19.69 cm (0.26 in.) (7.75 in.) XPR300 Instruction Manual 809480...
  • Page 86 Gas inlet side of gas connect console (OptiMix) Gas outlet side of gas connect console 32.05 cm (12.62 in.) Gas inlet side of gas connect console 1.27 cm (0.50 in.) 6.48 mm 19.69 cm (0.26 in.) (7.75 in.) 809480 Instruction Manual XPR300...

  • Page 87: Position And Mount The Torch Connect Console

    For mounting dimensions, see Figure 3 on page 88 and Figure 4 on page 89.  If you have questions about when or how to use the mounting brackets to mount your torch connect console, contact your cutting machine supplier or regional Hypertherm Technical Service team. XPR300 Instruction Manual 809480...
  • Page 88 Installation Figure 3 – Side mount orientation and mounting dimensions for the torch connect console 6.35 mm (0.25 in.) 135 mm (5.31 in.) 339.85 mm (13.38 in.) 809480 Instruction Manual XPR300...
  • Page 89 Installation Figure 4 – Bottom mounting for the torch connect console 6.35 mm (0.25 in.) 135 mm (5.31 in.) 339.85 mm (13.38 in.) XPR300 Instruction Manual 809480...

  • Page 90: How To Ground The System 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) 809480 Instruction Manual XPR300...
  • Page 91 Installation Figure 6 – Gas connect consoles grounding (detail) Core OptiMix M6 ground stud Figure 7 – Torch connect console grounding (detail) M6 ground stud XPR300 Instruction Manual 809480...
  • Page 92 Installation Figure 8 – Torch lead collar grounding (detail) Ground connection – 6.36 mm (1/4 in.) flat terminal 809480 Instruction Manual XPR300...

  • Page 93: How To Remove The External Panels From The System Components

    Even if power is removed from the plasma power supply, you can still get a serious electric shock if the cutting system remains connected to an electric power source. Make sure that all electric power is removed before you start installation. XPR300 Instruction Manual 809480...
  • Page 94 Installation 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. 809480 Instruction Manual XPR300...
  • Page 95 Installation Figure 10 – Remove panels from the gas connect console Move the panel horizontally to remove XPR300 Instruction Manual 809480...
  • Page 96 Installation Figure 11 – Remove top and side panel from the torch connect console 809480 Instruction Manual XPR300...

  • Page 97: How To Identify And Ready The Hoses, Cables, And Leads

    Coolant hose set  The coolant hose set includes 1 supply hose with green bands and 1 return hose with red bands. Negative lead with strain relief Pilot arc lead with strain relief Power cable CAN cable XPR300 Instruction Manual 809480...

  • Page 98: Work Lead

    Pilot arc, coolant hose set, and shield water assembly (only for VWI and OptiMix)  The coolant hose set includes 1 supply hose with green bands and 1 return hose with red bands. Power, CAN, and 5-gas assembly (only for VWI and OptiMix) 809480 Instruction Manual XPR300...

  • Page 99: Oxygen Hose (Blue)

    Installation 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) XPR300 Instruction Manual 809480...

  • Page 100: How To Connect The Plasma Power Supply And Gas Connect Console (Core, Vwi, Or Optimix)

    How to connect the plasma power supply and gas connect console (Core, VWI, or OptiMix) Label in the plasma power supply Power RS422 Negative RS422 Work Discrete Pilot Arc Coolant Coolant Supply Return (Green) (Red) Pilot Negative Work Power EtherCAT RS422 CNC Discrete 210566 REVB 809480 Instruction Manual XPR300...

  • Page 101: Connect The Coolant Hose Set

    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). Green XPR300 Instruction Manual 809480...
  • Page 102 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). Green 809480 Instruction Manual XPR300...

  • Page 103: Connect The Power Cable

    To plasma power supply (male cable connector) To gas connect console (female cable connector)  For lengths, see Power cable on page 362 of the Parts List. Figure 14 – Connect the power cable Gas connect console Plasma power supply XPR300 Instruction Manual 809480...

  • Page 104: Connect The Can Cable

    To plasma power supply (male cable connector) To gas connect console (female cable connector)  For lengths, see CAN cable on page 363 of the Parts List. Figure 16 – Connect the CAN cable and finger-tighten Gas connect console Plasma power supply 809480 Instruction Manual XPR300...

  • Page 105: How To Connect The Work Lead To The Plasma Power Supply And Cutting Table

    To plasma power supply To cutting table  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 XPR300 Instruction Manual 809480...

  • Page 106: Connect The Negative Lead With Strain Relief

    (-) 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. 809480 Instruction Manual XPR300...
  • Page 107 Installation Figure 20 – Connect the negative lead with strain relief Gas connect console Plasma power supply XPR300 Instruction Manual 809480...

  • 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 809480 Instruction Manual XPR300...
  • Page 109 Move the panel horizontally to remove it.  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. XPR300 Instruction Manual 809480...

  • Page 110: How To Connect The Gas Connect Console To The Torch Connect Console

    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. 809480 Instruction Manual XPR300...
  • Page 111 (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. XPR300 Instruction Manual 809480...
  • Page 112 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. 809480 Instruction Manual XPR300...

  • Page 113: Connect The Power, Can, And 3-Gas Assembly (Core)

    2 CAN cable 5 Air hose (black) 3 Oxygen hose (blue)  For lengths, see Power, CAN, and 3-gas assembly (Core) on page 363 of the Parts List. Figure 26 Torch connect console Core gas connect console XPR300 Instruction Manual 809480...

  • Page 114: Connect The Gas Connect Console (Vwi Or Optimix) To The Torch Connect Console

    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. 809480 Instruction Manual XPR300...
  • Page 115 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. XPR300 Instruction Manual 809480...
  • Page 116 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. 809480 Instruction Manual XPR300...

  • Page 117: Connect The Power, Can, And 5-Gas Assembly

    -mix or F5 hose (red) 4 Air hose (black)  For lengths, see Power, CAN, and 5-gas assembly (VWI or OptiMix) on page 364 of the Parts List. Figure 29 Torch connect console VWI or OptiMix gas connect console XPR300 Instruction Manual 809480...

  • Page 118: How To Install And Connect The Supply Gases

    If you use oxygen as the plasma gas for cutting, it can cause a potential fire hazard due to the oxygen-enriched atmosphere that collects. Hypertherm recommends that you install an exhaust ventilation system to remove the oxygen-enriched atmosphere that can collect when oxygen is used as the plasma gas for cutting.

  • Page 119: Table 17 - Torque Specifications

    Up to 10 mm (3/8 inch) 8.5 – 9.5 75 – 84 6.25 – 7 12 mm (1/2 inch) 16.3 – 19.0 144 – 168 12 – 14 25 mm (1 inch) 54.2 – 88.1 480 – 780 40 – 65 XPR300 Instruction Manual 809480...

  • Page 120: Install Gas Regulators

    For the best results, 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.

  • Page 121: Connect Supply Gases To The Gas Connect Console (Core)

    • 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 pressures and flow rates. XPR300 Instruction Manual 809480...

  • Page 122: Table 18 - Recommended Sizes For Gas Fittings

    (VWI or OptiMix) on page 124. Hypertherm recommends an internal diameter of 10 mm (0.375 inch) for supply gas hoses that are 76 m (250 feet) or less. Make sure that you have the correct supply gas hoses before you connect them.
  • Page 123 * For the best results, 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) away from the 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.

  • Page 124: Connect Supply Gases And Shield Water To The Gas Connect Console (Vwi Or Optimix)

    • 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 pressures and flow rates. 809480 Instruction Manual XPR300...

  • Page 125: Table 19 - Recommended Sizes For Gas Fitting

    (Core) on page 121. Hypertherm recommends an internal diameter of 10 mm (0.375 inch) for supply gas hoses that are 76 m (250 feet) or less. Make sure that you have the correct supply gas hoses before you connect them.
  • Page 126 * For the best results, 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) away from the 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.

  • Page 127: Connect Shield Water To The Gas Connect Console (Vwi Or Optimix)

    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 40°C (32°F to 104°F). XPR300 Instruction Manual 809480...

  • Page 128: How To Connect The Torch Receptacle To The Torch Connect Console

    4. Align the color-coded leads in the torch lead assembly with the corresponding connectors in the torch receptacle.  Good alignment minimizes twisted leads. Twisted leads can cause gas or coolant restrictions that shorten the life of consumables or result in bad cut quality. 809480 Instruction Manual XPR300...

  • Page 129: Table 20 - Torque Specifications

    Plasma valve connector c. Connect the pilot arc lead (yellow) and finger-tighten.  Do not use tools. Pilot arc lead (yellow) d. Connect the ohmic lead Ohmic lead (yellow) (yellow) and finger-tighten.  Do not use tools. XPR300 Instruction Manual 809480...
  • Page 130 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 Plasma gas hose 1 (black) fitting. 809480 Instruction Manual XPR300...
  • Page 131 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 the collar toward the torch XPR300 Instruction Manual 809480...

  • Page 132: Connect The Easyconnect™ Torch Lead Assembly To The Torch Connect Console

    7 Shield gas hose 3 Ohmic lead 8 Plasma gas hose A 4 Pilot arc lead 9 Plasma gas hose B 5 Coolant return hose (red)  For lengths, see Torch lead on page 367 of the Parts List. 809480 Instruction Manual XPR300...
  • Page 133 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. XPR300 Instruction Manual 809480...

  • Page 134: How To Install The Torch In The Torch Mounting Bracket

    You must supply the torch mounting bracket for your cutting system. Choose one that meets the requirements in Torch mounting bracket requirements on page 58. Mounting brackets are available from Hypertherm. (See Torch bracket on page 355 of the Parts List). ...
  • Page 135 The torch position for XPR torches can range from 0° – 52°. For information on bevel cutting, see Bevel cutting on page 210. Figure 35 – Level the torch 6. Tighten the screws on the torch mounting bracket. XPR300 Instruction Manual 809480...

  • Page 136: 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. ...
  • Page 137 Install the electrode . Use a tightening tool (104119) to tighten the electrode.  A loose electrode can cause torch damage. Hypertherm recommends between 2.3 N∙m – 2.8 N∙m (20 in∙lb – 25 in∙lb ) torque to tighten an electrode.

  • Page 138: How To Install The Torch Into The Torch Receptacle

     Hand tighten only. Do not use tools. 3. Make sure that the torch body is fully inserted into the torch receptacle. There should be no space between the torch body and torch receptacle. Correct Incorrect 809480 Instruction Manual XPR300...

  • Page 139: How To Connect Electric Power To The Cutting System

    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. XPR300 Instruction Manual 809480...

  • Page 140: Table 21 - Color Codes For Main Power Cord Wires

    Wire color codes for North America 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 809480 Instruction Manual XPR300...

  • Page 141: Sample Configurations For Consumables

    Sample configurations for consumables  Worn or damaged consumables can have a negative effect on cut quality. Examine the installed consumables at least once 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.

  • Page 142: Mild Steel - 80 A, 130 A, 170 A, And 300 A - O /Air

    Mild steel – 80 A, 130 A, 170 A, and 300 A – O /Air Shield retaining Shield Nozzle retaining Nozzle Swirl ring Electrode Water tube 80 A 420242 420240 420243 420246 420607* 420605* 420368 130 A 420365 420200 420242 420249 420252 420255...

  • Page 143: Non-Ferrous (Stainless Steel And Aluminum) Sample Configurations

    Non-ferrous (stainless steel and aluminum) sample configurations Non-ferrous – 40 A – N and Air/Air Shield retaining Shield Nozzle retaining Nozzle Swirl ring Electrode Water tube 420303 420368 420288 420314 420291 420365 420598* 420200 420624* 420294 Air/Air * Consumables for mirror cutting only.

  • Page 144: Non-Ferrouson-Ferrous - 60 A - F5/Non-Ferrous 2 **, Non-Ferrous

    Non-ferrous – 60 A – F5/N **, N O**, and Air/Air Shield retaining Shield Nozzle retaining Nozzle Swirl ring Electrode Water tube F5/N F5/N F5/N 420303 420297 420309 420603* 420368 420323 420604* 420365 420200 420303 420296 420300 420593* Air/Air Air/Air 420294 Air/Air 420297...

  • Page 145: Non-Ferrous - 80 A - F5/N 2 **, N

    Non-ferrous – 80 A – F5/N **, N O**, Air/Air Shield retaining Shield Nozzle retaining Nozzle Swirl ring Electrode Water tube F5/N F5/N F5/N 420303 420306 420309 420603* 420368 420323 420604* 420365 420200 420303 420290 420300 420593* Air/Air Air/Air 420294 Air/Air 420306 420309...

  • Page 146: Non-Ferrous - 130 A - N

    Non-ferrous – 130 A – N -Ar-N **, N O*** Shield retaining Shield Nozzle retaining Nozzle Swirl ring Electrode Water tube 420314 420318 420598* 420597* 420368 420356 420315 420365 420200 -Ar-N -Ar-N 420323 420318 420604* 420597* O*** O*** 420314 420469 420598* 420595* * Consumables for mirror cutting only.

  • Page 147: Non-Ferrous - 170 A - N

    Non-ferrous – 170 A – N -Ar-N **, N O***, Air/Air Shield retaining Shield Nozzle retaining Nozzle Swirl ring Electrode Water tube 420324 420314 420356 420327 420598* 420613* 420368 420365 420200 -Ar-N -Ar-N -Ar-N -Ar-N 420324 420323 420356 420327 420604* 420613* O*** O***...

  • Page 148: N , H /N **, N /H /N , H /N **, N /H O

    Non-ferrous – 300 A – N -Ar-N **, N O*** Shield retaining Shield Nozzle retaining Nozzle Swirl ring Electrode Water tube 420323 420362 420604* 420601* 420356 420368 420359 420365 420200 -Ar-N -Ar-N 420358 420362 420623* 420601* O*** O*** 420323 420475 420604* 420622* * Consumables for mirror cutting only.

  • Page 149: Connect For Communication

     If you use serial RS-422, you must also use discrete to fully operate the cutting system. See Table 22 on page 150. For information on signals and protocols, see the (809810). XPR300 CNC Communication Protocol XPR300 Instruction Manual 809480...

  • Page 150: Table 22 - Communication Requirements And Options

    How 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. 809480 Instruction Manual XPR300...

  • Page 151: How To Connect To The Plasma Power Supply With Ethercat

    XPR300 CNC Communication Protocol Figure 38 – EtherCAT cable  Hypertherm sells EtherCAT cables that have been tested with our cutting system. See EtherCAT CNC interface cable on page 365 in the Parts List. If you supply your own cables, choose EtherCAT cables that follow the Beckhoff specification.You...
  • Page 152 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.  809480 Instruction Manual XPR300...

  • Page 153: How To Connect To The Plasma Power Supply With The Xpr Web Interface

    How to connect to the plasma power supply with the XPR web interface CAUTION If you use a wireless (Wi-Fi™) network to communicate with your cutting system, Hypertherm recommends the use of a secure Wi-Fi network to minimize the risk of unauthorized cutting system operation or misuse.

  • Page 154: Use Ap Mode To Connect

    166.  If you want to change the connection name, see Configure on page 172. 4. Enter the password, “hypertherm”.  If you want to change your password, see Configure on page 172. 5. Open an Internet browser.
  • Page 155 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 on page 176. XPR300 Instruction Manual 809480...

  • Page 156: Use Network Mode To Connect

    2. Choose Connect on the Other screen to open the Device Setup page. 3. Choose Client Settings. 4. Choose an option to connect to wireless networks: Select an existing network on  page 157. Set up manually on page 159.  809480 Instruction Manual XPR300...

  • Page 157: Select An Existing Network

    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 Security type. 5. Choose Save. XPR300 Instruction Manual 809480...
  • Page 158 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 power supply with discrete on page 176. 809480 Instruction Manual XPR300...

  • Page 159: Set Up Manually

    Advanced users only.) 3. Choose Next to go to the Wireless Configuration Summary screen.  This page shows information about the SSID, Channel, Security type, IP Address, Subnet Mask, Gateway, and DNS Server. 4. Choose Save. XPR300 Instruction Manual 809480...
  • Page 160 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 power supply with discrete on page 176. 809480 Instruction Manual XPR300...

  • Page 161: Access The Xpr Web Interface After Setup In Network Mode

    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 address to access the XPR web interface. In the example in Figure 40 you navigate to http://192.168.1.133/index.html. XPR300 Instruction Manual 809480...

  • Page 162: Change The 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. 809480 Instruction Manual XPR300...

  • Page 163: Reset The Wireless Module

    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. 2. Remove the side panel of the plasma power supply. XPR300 Instruction Manual 809480...
  • Page 164 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. 809480 Instruction Manual XPR300...
  • Page 165 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. XPR300 Instruction Manual 809480...

  • Page 166: Web Interface Screen Information

    If the Client ID and the Operator ID are the same on your device, you are in control of the plasma power supply. Connection – This is the status of the communication between the device and the plasma  power supply. (Good or Error.) 809480 Instruction Manual XPR300...

  • Page 167: Plasma Power Supply

    Connect for Communication 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. XPR300 Instruction Manual 809480...

  • Page 168: Gas System

    The gases shown on Line A, Line B, and shield are different depending on the process ID that you selected. The gases flow for 60 seconds unless you choose the same button or choose another button that interrupts the test. 809480 Instruction Manual XPR300...

  • Page 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. XPR300 Instruction Manual 809480...

  • Page 170: Operate

    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. 809480 Instruction Manual XPR300...

  • Page 171: Other

    Connect for Communication 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. XPR300 Instruction Manual 809480...
  • Page 172 The connection  name must be less than 32 characters long. Passwords must  be between 8 and 20 characters long. Passwords are  case sensitive. 809480 Instruction Manual XPR300...

  • Page 173: How To Connect To The Plasma Power Supply With Serial Rs-422

    To use arc voltage control (AVC) with a serial RS-422 cutting system, you must install an additional PCB inside the plasma power supply. For information on how to install this board, see the XPR300 VDC3 Board Installation Field Service Bulletin (809700).

  • Page 174: Table 23 - Pinout For Serial Rs-422 Interface Cable

    Wire color Wire type Signal Pin number Pin number Signal TxD + RxD + Pair TxD - Black RxD - RxD + White TxD + Pair RxD - Black TxD - Green Pair – Black – 809480 Instruction Manual XPR300...
  • Page 175 Connect for Communication Figure 42 – Connect the serial RS-422 cable to the plasma power supply Serial RS-422 from the Serial RS-422 to the next plasma power supply (if any) XPR300 Instruction Manual 809480...

  • Page 176: How To Connect To The Plasma Power Supply With Discrete

    To use arc voltage control (AVC) with a discrete cutting system, you must install an additional PCB inside the plasma power supply. For information on how to install this board, see the XPR300 VDC3 Board Installation Field Service Bulletin (809700).

  • Page 177: Table 24 - Pinout For J14 On The Discrete Cable

    Output Notifies the CNC that an error has occurred. Error - Black Ready for start + White Notifies the CNC that the plasma power supply is Output ready for the plasma start. Ready for start - XPR300 Instruction Manual 809480...
  • Page 178 4 CNC +24 VDC provides 24 VDC at 200 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.) 809480 Instruction Manual XPR300...
  • Page 179 Connect for Communication Figure 44 – Connect the discrete cable to the plasma power supply Discrete cable to the CNC XPR300 Instruction Manual 809480...

  • Page 180: How To Change The Device That Has Control

    Use extreme caution if you do diagnosis or maintenance tasks when the plasma power supply remains plugged in and the panels on the plasma power supply are removed. 809480 Instruction Manual XPR300...
  • Page 181 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. XPR300 Instruction Manual 809480...

  • Page 182: How To Use Ohmic Contact Sense

    8 J1 to J27 wires 3 Torch connect console 9 Control PCB 4 Ohmic wire, torch receptacle to ohmic relay 10 CAN connection 5 Ohmic relay 11 2 ground connections (required) 6 Ohmic wire, ohmic relay to J3 809480 Instruction Manual XPR300...

  • Page 183: External Ohmic Contact Sense

    Otherwise, skip to step 5.  The plug is located below the torch lead connection (Figure 47). Figure 47 – Remove plug to access the ohmic wire if you use a third-party ohmic circuit XPR300 Instruction Manual 809480...
  • Page 184 7 Ohmic PCB 3 Torch connect console 8 Ohmic wire, J4 to lifter or third party ohmic circuit 4 Ohmic wire, torch receptacle to ohmic relay 9 Torch lifter or third party ohmic circuit 5 Ohmic relay 809480 Instruction Manual XPR300...

  • Page 185: How To Install A Remote On-Off Switch

    When the remote on-off switch is set to OFF (disabled), power is removed from the following parts: Gas connect console  Torch connect console  Contactor enable  Pump relay enable  Fan enable  CNC outputs  XPR300 Instruction Manual 809480...

  • Page 186: Examples Of Output Circuits

    24 VDC low-power coil ≤ 10 mA or ≥ 2400 Ω Wire ground All relay coils require a freewheeling diode across the relay coil. This circuit VOIDS the warranty. Do NOT use. Any voltage Power ground 809480 Instruction Manual XPR300...

  • Page 187: Examples Of Input Circuits

    +24 VDC Output from CNC/PLC External relay (AC or DC) Power ground Optocoupler interface +24 VDC CNC/PLC Transistor-output optocoupler Power ground Amplified-output interface +24 VDC CNC/PLC 12 VDC – 24 VDC Power ground Active-high drive Power ground XPR300 Instruction Manual 809480...
  • Page 188 Connect for Communication 809480 Instruction Manual XPR300...

  • Page 189: Coolant Installation

    The cutting system ships without coolant in the reservoir. Before you operate the cutting system, you must fill it with coolant. The coolant capacity for the XPR300 cutting system is between 22.7 liters – 45.42 liters (6 US gallons – 12 US gallons).

  • Page 190: How To Fill The Cutting System With Coolant

    If your coolant pump is damaged, it may need to be replaced. Never use automotive antifreeze in place of Hypertherm coolant. Antifreeze contains chemicals that damage the torch coolant system.
  • Page 191 If you put too much coolant in the reservoir, coolant flows out of the front of the plasma power supply onto the floor. 9. After installation of the coolant, use the CNC or XPR web interface to deselect the process. XPR300 Instruction Manual 809480...
  • Page 192 Coolant Installation 809480 Instruction Manual XPR300...

  • Page 193: Operation

      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 at www.hypertherm.com on the “Contact us” page.

  • Page 194: Controls And Indicators

     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) ...

  • Page 195: Indicators

    (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.  XPR300 Instruction Manual 809480...

  • Page 196: 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. 809480 Instruction Manual XPR300...

  • Page 197: Sequence Of Operation

    CNC or wireless device. Diagnose and troubleshoot the problem. (See Is Powerup State (1) complete and successful? Diagnostics and Troubleshooting on page 251.) Then, start the Powerup State (1) again. Continue to Initial checks State (2) on page 198 XPR300 Instruction Manual 809480...

  • Page 198: Initial Checks State (2)

    Are the measurements within the acceptable Diagnose and troubleshoot the problem. (See range? Diagnostics and Troubleshooting on page 251.) Wait for process selection by the operator. Select a process ID. Continue to Gas purge/pump on State (3) on page 199. 809480 Instruction Manual XPR300...

  • Page 199: Gas Purge/Pump On State (3)

    ** The length of time 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. XPR300 Instruction Manual 809480...

  • Page 200: Wait For Start State (5)

    Diagnostics and Troubleshooting on page 251.) Then, start Preflow/charge DC State (7) again. Continue to Ignite State (8) on page 201. * To conserve energy, the coolant pump and fans stop after the time limit expires without a command. 809480 Instruction Manual XPR300...

  • Page 201: Ignite State (8)

    Chopper 1 current above the minimum current? Continuously monitor Chopper 1 current. Diagnose and troubleshoot the problem. (See Is Ignite State (8) complete and successful? Diagnostics and Troubleshooting on page 251.) Continue to Pilot arc State (9) on page 202. XPR300 Instruction Manual 809480...

  • Page 202: Pilot Arc State (9)

    Chopper 2 becomes active during this time. Diagnose and troubleshoot the problem. (See Is the Pilot arc State (9) complete and successful? Diagnostics and Troubleshooting on page 251.) Continue to Rampup State (11) on page 203. 809480 Instruction Manual XPR300...

  • Page 203: Rampup State (11)

    (Both Chopper 1 and Chopper 2 become active.) Is the Rampup State (11) complete and Diagnose and troubleshoot the problem. (See successful? Diagnostics and Troubleshooting on page 251.) Continue to Steady State (12) on page 204. XPR300 Instruction Manual 809480...

  • Page 204: Steady State (12)

    50 A, only Chopper 1 is active). Note: If the operator-selected process is equal to or greater than 50 A, monitor both choppers. Is the Plasma Start signal removed? Continue to Rampdown State (13) on page 205. 809480 Instruction Manual XPR300...

  • Page 205: Rampdown State (13)

    Decrease gas flow to the final setpoint. Is Rampdown State (13) complete and Diagnose and troubleshoot the problem. (See successful? Diagnostics and Troubleshooting on page 251.) Continue to End of cycle State (14) on page 206. XPR300 Instruction Manual 809480...

  • Page 206: End Of Cycle State (14)

    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-voltage relay and enables the ohmic-sense circuit (except during high-frequency starts). 809480 Instruction Manual XPR300...

  • Page 207: Automatic Purges

    -mix) or F5 drains from the XPR cutting system through the torch. 2. If you have an OptiMix XPR cutting system, N purges any residual mixed-fuel gas. 3. If you have a VWI XPR cutting system, air purges any residual F5 gas from the torch lead. XPR300 Instruction Manual 809480...

  • Page 208: Process-Setup Purges For All Xpr Cutting Systems

    If you have a Core XPR cutting system, the gas-change purge is skipped, and only the process-setup purge occurs. The type of process gas used for a process-setup purge is based on the operator-selected process. 809480 Instruction Manual XPR300...

  • Page 209: How To Choose The Torch Positions And Process Settings You Need

    You can minimize unwanted results, increase the number of pierces, and maximize the life of consumable parts when you use the piercing settings that Hypertherm recommends. ...

  • Page 210: Bevel Cutting

    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. 809480 Instruction Manual XPR300...
  • Page 211 This value is equal to the nominal thickness, divided by the cosine of the bevel angle. 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...

  • Page 212: Bevel Compensation Tables

    The consumable parts for 300 A processes are non-vented and use a liquid-cooled nozzle (in place of a vented, air-cooled nozzle). The XPR300 cutting system offers HyDefinition vented consumables for 30 A – 170 A processes. The processes enable the operator to achieve the following results: HyDefinition vented •...

  • Page 213: Non-Ferrous (Stainless Steel And Aluminum) Processes

    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 , Air/Air O, F5/N O, Air/Air OptiMix O, H -mix/N , F5/N O, H -mix/N , Air/Air XPR300 Instruction Manual 809480...

  • Page 214: Table 27 - Process Recommendations For Cut Quality, Based On Metal Thickness And Type

    0.250 80 A F5/N 80 A N 0.375 130 A H -mix/N 130 A N 0.500 0.625 170 A H -mix/N 170 A N 0.750 1.000 300 A H -mix/N 300 A N 2.000 3.000 – 809480 Instruction Manual XPR300...

  • Page 215: Stainless Steel

    Operation Stainless steel The XPR300 cutting system offers HDi vented cutting for all processes that cut stainless steel (up to170 A). HyDefinition vented processes produce high-quality cuts with minimal dross and can be used with either N , F5, or mixed-fuel gases.

  • Page 216: Aluminum

    • A sharp top edge of the cut • A smooth cut edge • Excellent cut-edge angularity HyDefinition The 300 A processes (N , mixed-fuel/N , and N O) are non-vented and deliver non-vented good cut quality at fast cutting speeds. processes 809480 Instruction Manual XPR300...

  • Page 217: Processes For Special Applications

    25 mm (1 inch) below the bottom surface of the workpiece. For information about True Hole processes, contact your cutting machine supplier or regional Hypertherm Technical Service team. Make sure that the torch is perpendicular (at a 90° angle) to the workpiece.

  • Page 218: Mirror Cutting

    CNC. Underwater cut charts are listed by amperage. They appear with the ferrous and stainless steel cut charts. (See the XPR300 Cut Charts Instruction Manual (809830).) Underwater cut chart settings are provided for: Ferrous processes 80 A and above ...

  • Page 219: Process Selection

    Operate screen in the XPR web interface. Manual selection of settings is not necessary in most cases. However, you can adjust some pre-programmed settings with override or offset commands, within limits. (See Process ID offsets / overrides on page 220.) XPR300 Instruction Manual 809480...

  • Page 220: How To Use Process Ids To Access Optimal Settings

    When you select a process ID from the CNC or XPR web interface, you automatically get the optimized settings that Hypertherm recommends for that process. The pre-programmed settings come from Hypertherm’s extensive laboratory tests. Because of differences in cutting systems, metals, and consumables, it is sometimes necessary to adjust the settings.

  • Page 221: How To Use Cut Charts

    For information about how to find electronic cut charts, see the instruction manual that came with your CNC. Cut charts are available in the XPR300 Cut Charts Instruction Manual (809830).  The cut charts are for reference purposes. Always use the electronic cut charts that appear on your CNC or XPR web interface for the most complete and accurate process-selection information.

  • Page 222: Table 28 - Process Category Options And Expected Quality-Speed Results For Ferrous (Mild Steel) Processes

    • Cut-edge quality can be rough. • Expect significant dross.  In general, Hypertherm recommends lower amperage processes for the best cut-edge quality, and higher amperage processes for the best dross-free cutting. When speed is more important than quality, you can use a higher-amperage process.

  • Page 223: Table 29 - Process Category Options And Expected Quality-Speed Results For Non-Ferrous Processes

    • Thick-metal cutting techniques can be necessary.  In general, Hypertherm recommends dross-free processes. Non-ferrous dross is very difficult to remove. Depending on the gas-connect console, the XPR300 cutting system offers the following non-ferrous cutting processes: Air/Air, N O, F5/N and mixed-fuel gas/N . For guidance about process selection, refer to Table 27 –...

  • Page 224: How To Select 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 Manual (809830)  How to install the consumables on page 136 ...

  • Page 225: Factors Of Cut Quality

     See the instruction manual that came with your cutting machine or table for information on how to do this. Do all cutting system maintenance tasks as scheduled. (See Maintenance on page 231.)  XPR300 Instruction Manual 809480...

  • Page 226: Recommendations For Perpendicular-Position Cutting Processes

    Puddle avoidance minimizes shield damage. Make sure to follow transfer height and pierce height recommendations during piercing  processes. (See the XPR300 Cut Charts Instruction Manual (809830.) If it is difficult to pierce the workpiece (because of metal type or thickness): ...

  • Page 227: Recommendations For Marking Processes

    Operation Hypertherm’s pierce control and assist technology can minimize timing and torch height issues that can have a negative effect on piercing processes. 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.

  • Page 228: How To Maximize The Life Of Consumable Parts

    Gas and current flow automatically ramp-down at the end of a cut  To achieve the full benefits of Hypertherm’s LongLife and Arc Response Technology™, avoid  firing the torch into the air. (See Arc Response Technology on page 228.) ...

  • Page 229: Automatic Rampdown Error Protection

    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 pressure. This can significantly increase the electrode life, especially when cut speeds are less than 3,560 mm/min (140 in/min). XPR300 Instruction Manual 809480...
  • Page 230 Operation 809480 Instruction Manual XPR300...

  • Page 231: Maintenance

    Maintenance Overview Hypertherm cutting systems can operate in harsh conditions for many years. To maintain cutting system performance, minimize operating costs, and lengthen cutting system life, it is important to follow all maintenance procedures and schedules.  If you have questions about how to maintain your cutting system, contact your cutting machine supplier or regional Hypertherm Technical Service team.

  • Page 232: Table 30 - Inspection, Preventive Maintenance, And Cleaning Tasks

    Do the coolant flow test Examine the gas line connections Examine the hoses Examine the cables Examine the ground connections Examine the table-to-workpiece connection Replace the coolant and coolant filter, and clean and examine the pump screen 809480 Instruction Manual XPR300...

  • Page 233: How To Do Daily Inspections

    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  XPR300 Instruction Manual 809480...

  • Page 234: Remove The Power From The Cutting System

    This provides easier access to the torch and consumable parts. 1. Set the line-disconnect switch to the OFF position. 809480 Instruction Manual XPR300...

  • Page 235: Examine The Gas Regulators

     Cuts  Frays  Bulges or bubbles  3. Replace any hose, cable, or lead if you find damage or excessive wear.  See Installation on page 67 for information about how to do this. XPR300 Instruction Manual 809480...

  • Page 236: Examine The Consumable Parts, Torch, And Torch Receptacle

    See Table 11 on page 48 for torque specifications. b. Order a replacement hose, cable, or lead set if you find its fitting has damage or excess wear. Replacement sets are available from Hypertherm.  Individual fittings for external hoses, cables, and leads are not replaceable.

  • Page 237: Examine The Consumable Parts

    (027055) to O-rings that appear dry. Nozzle retaining cap Damage Replace the nozzle retaining cap. Poor cut quality after replacing other consumables Damaged O-rings Dry O-rings Apply a thin film of silicone lubricant (027055) to O-rings that appear dry. XPR300 Instruction Manual 809480...
  • Page 238 Damaged O-rings Replace the electrode. Over-lubricated O-rings Use a clean, lint-free cloth to remove excess lubricant. Dry O-rings Apply a thin film of silicone lubricant (027055) to O-rings that appear dry. 809480 Instruction Manual XPR300...
  • Page 239 6. Before you supply power to the cutting system, install the following components: Consumables in the torch. (See How to install the consumables on page 136.)  Torch in the torch receptacle. (See How to install the torch into the torch receptacle on  page 138.) XPR300 Instruction Manual 809480...

  • Page 240: Examine The Torch

    Internal O-rings (4) at rear of torch 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.

  • Page 241: Examine The Torch Receptacle

     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 receptacle.

  • Page 242: Examine The Torch Lead

    Look for evidence that the hoses, cables, and leads are exceeding bend radius requirements during cutting system operation. (See Bend radius requirements for hoses, cables, and leads on page 56.) Make adjustments if you find evidence of kinking, bending, or twisting.  809480 Instruction Manual XPR300...

  • Page 243: How To Replace The Water Tube

    Replace the O-ring if you find damage 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.

  • Page 244: How To Measure The Pit Depth Of An Electrode

    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 from Hypertherm. (See Other consumable and torch parts on page 360 of the Parts List.) Figure 53 – Use a pit-depth gauge to measure electrode depth...

  • Page 245: How To Do Coolant Maintenance

    If your coolant pump is damaged, it may need to be replaced. Never use automotive antifreeze in place of Hypertherm coolant. Antifreeze contains chemicals that damage the torch coolant system.

  • Page 246: Estimate The Total Coolant Volume For Your Cutting System

    The use of old coolant can decrease coolant flow, which can cause higher torch temperatures that shorten the life of consumable parts. Hypertherm recommends that you replace all of the coolant at least once every 6 months, as part of routine preventive maintenance. More frequent replacement can be necessary because of environmental conditions including but not limited to contaminants in your coolant or diagnostic codes that indicate coolant problems.

  • Page 247: Remove Old Coolant From The Coolant System

    Use a container that holds the approximate total coolant volume for your cutting system. c. Open the valve located on the bottom of the reservoir. d. Remove the cap on the reservoir inlet to allow the coolant to flow out of the reservoir. XPR300 Instruction Manual 809480...
  • Page 248 Do not store the 3/8-inch diameter tubing inside of the plasma power supply. f. Leave the coolant return hose (red band) disconnected from the rear of the plasma power supply. g. Put a container under the pump plug. 809480 Instruction Manual XPR300...
  • Page 249 If you find damage on the coolant pump screen, replace it (127559). d. Install the coolant pump screen. e. Wipe the O-ring on the plug. Make sure that the O-ring is free of debris, cracks, and nicks. f. Install the plug on the coolant pump housing. XPR300 Instruction Manual 809480...
  • Page 250 After 3 minutes, look for coolant flow out of the coolant return hose (red band). Repeat this process until coolant flow from the coolant return hose (red band) stops. e. When coolant flow from coolant return hose (red band) stops, connect both hoses to the rear of the plasma power supply. 809480 Instruction Manual XPR300...

  • Page 251: Diagnostics And Troubleshooting

    For information about daily inspections and preventive maintenance, see the following: How to do daily inspections on page 233 of this manual.  XPR300 Preventative Maintenance Program (PMP) Instruction Manual (809490).   If you have questions about how to care for your cutting system, contact your cutting machine supplier or regional Hypertherm Technical Service team.

  • Page 252: Safety Considerations

    Use extreme caution if you do diagnosis or maintenance tasks when the plasma power supply remains plugged in and the panels on the plasma power supply are removed. 809480 Instruction Manual XPR300...

  • Page 253: Initial Inspection Steps

    Make sure that the line-disconnect switch is set to ON. (See Line-disconnect switch  requirements on page 40.) Examine the PCBs. (See page 256.)  Measure the line voltage between the terminals that are inside of the plasma power supply.  (See page 258.) XPR300 Instruction Manual 809480...

  • Page 254: Remove The Power From 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. 809480 Instruction Manual XPR300...
  • Page 255 Before you remove the power from the cutting system, it can be helpful to move the torch to the edge of the cutting table and raise the torch lifter to its highest point. This provides easier access to the torch and consumable parts. XPR300 Instruction Manual 809480...

  • Page 256: Examine The Pcbs

    See Control side – view 2 on page 336. Start-circuit assembly Plasma power supply See Control side – view 1 on page 334. I/O PCB Plasma power supply See Control side – view 2 on page 336. 809480 Instruction Manual XPR300...
  • Page 257 (See Measure the line voltage between the terminals 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. XPR300 Instruction Manual...

  • Page 258: Measure The Line Voltage Between The Terminals Inside The Plasma Power Supply

    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. 809480 Instruction Manual XPR300...
  • Page 259 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 XPR300 Instruction Manual 809480...

  • Page 260: Diagnostic Codes

    – 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 809480 Instruction Manual XPR300...

  • Page 261: Table 33 - Diagnostic Codes In The Xpr Web Interface

    You cannot start the arc until an Failure condition is resolved.  If you cannot find or resolve the problem with the corrective actions in Table 34, contact your cutting machine supplier or regional Hypertherm Technical Service team listed in the front of this manual. XPR300...

  • Page 262: Table 34 - Diagnostic Codes

    (Core, VWI, or OptiMix) through the CAN. Main->Mix CAN The main control is unable to receive communications (at least Failure once-per-second) from the gas connect console’s mix module through the CAN. 809480 Instruction Manual XPR300...
  • Page 263 4. Inspect the main contactor and pilot arc relay. Replace if you find damage or excess wear. 5. Do a torch lead test. (See How to do a torch lead test on page 313.) XPR300 Instruction Manual 809480...
  • Page 264 Replace them if you find damage The process does not get or excess wear. selected. Inert gas purge The XPR cutting system is unable to complete the N purge within Error 45 seconds. The process did not get selected. 809480 Instruction Manual XPR300...
  • Page 265 • Make sure that there is no damage or excess wear. 5. Replace incorrect consumables or consumables that have damage or excess wear. 6. Use the gas volume monitors located near the pressure transducers to look for gas leaks. XPR300 Instruction Manual 809480...
  • Page 266 See Low shield water pressure code Low psi-H For at least 200 milliseconds, the shield water pressure (P9) is less (532) on page 290. Alert than 50% of the setpoint and the setpoint is greater than 0. 809480 Instruction Manual XPR300...
  • Page 267 After the flow rate gets to See Low coolant flow codes (540 – 2-Coolant 1.89 L/min (0.5 gal/min), the 542) on page 292. Error cutting system has 50 seconds to get to 3.03 L/min (0.8 gal/min). XPR300 Instruction Manual 809480...
  • Page 268 170 A. limit-Ch2 Failure 7. Make sure that the arc remains on workpiece during XPR cutting system operation. 8. If the code continues, contact your cutting machine supplier or regional Hypertherm Technical Service team. 809480 Instruction Manual XPR300...
  • Page 269 Over-temp error codes can occur when cooling takes more than 10 Error minutes. A high ambient temperature can Over temp-Ind4 have an effect on cooling time. Error Over temp-Xfmr The temperature for the transformer is more than 160°C Error (320°F). XPR300 Instruction Manual 809480...
  • Page 270 505, 514 – 515 for CAN cable and PCB for at least 30 seconds. jumper block, 507 – 508 for CAN network and bus, 600 – 602 for no CAN communication) on page 285. 809480 Instruction Manual XPR300...
  • Page 271 Failure the consumables on page 136. the Channel A Chopper 2 current signature. Ch2 Torch A catastrophic failure of a Protect ChB consumable part is detected on Failure the Channel B Chopper 2 current signature. XPR300 Instruction Manual 809480...
  • Page 272 136. No DC No current produced within 3. If error continues, contact your output-Ch2 250 milliseconds after Arc-On Error cutting machine supplier or State initiates. regional Hypertherm Technical Service team. 809480 Instruction Manual XPR300...
  • Page 273 Alert Preflow/charge DC State. 2. If any consumable part needs replacement, see How to install the consumables on page 136. 3. Examine the torch lead. Look for a short or open line condition. XPR300 Instruction Manual 809480...
  • Page 274 Inductor 2B Error The main control detects an open Use a digital multimeter to measure Thermistor-Xfmr circuit in the transformer. the resistance from the thermistor. Error (See How to measure resistance from thermistors on page 315.) 809480 Instruction Manual XPR300...
  • Page 275 Drops in voltage can reset the CAN node. 5. Look for loose or poorly connected CAN cables. 6. Contact your cutting machine supplier or regional Hypertherm Technical Service team. Make sure that you have the Record ID associated with the error. XPR300...
  • Page 276 5.52 bar (80 psi) or greater than 8.61 bar (105 psi). Low Inlet H The water (H O) inlet pressure for P8 in the gas connect console Alert (for VWI and OptiMix only) is less than 2.07 bar (30 psi). 809480 Instruction Manual XPR300...
  • Page 277 (706 – 715) on page 307. Error detected. No sensor The P2 pressure sensor in the P2-TCC torch connect console is not Error detected. No sensor The P3 pressure sensor in the P3-TCC torch connect console is not Error detected. XPR300 Instruction Manual 809480...
  • Page 278 XPR about how to select a process ID Error cutting system. 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 a process ID.
  • Page 279 Install loose or missing panels if found. 3. Make sure that all hardware that holds the external panels is in position and is tight. Tighten loose connections if found. XPR300 Instruction Manual 809480...
  • Page 280 PCB in the torch connect away, the valve is bad. console. 3. Replace the bad valve. Solenoid error There is an over-current condition for receptacle valve V6 at the Alert PCB in the torch connect console. 809480 Instruction Manual XPR300...
  • Page 281 2. Make sure that all external panels for all system components are correctly installed. Install loose or missing panels if found. 3. Make sure that all hardware that holds the external panels is in position and is tight. XPR300 Instruction Manual 809480...
  • Page 282 Chopper 2. page 258.) Error 2. If the code continues, contact your cutting machine supplier or regional Hypertherm Technical Service team. The coolant level is low. Fill the coolant reservoir with coolant. level-Coolant (See Coolant Installation on Alert page 189.)
  • Page 283 DC work The work lead current exceeds Contact your cutting machine exceeds limits the setpoint by 5 A. supplier or regional Hypertherm Error Technical Service team. Main 24 V dip The 24 V DC bus drops below 20 V on the main control.
  • Page 284 Increase air inlet pressure. Line B inlet pressure while V10 is Alert active. The system will automatically stop XPR cutting system operation.  See Sequence of operation on page 197 for descriptions of XPR cutting system operation. 809480 Instruction Manual XPR300...

  • Page 285: Can Codes

    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.  XPR300 Instruction Manual 809480...
  • Page 286 Hypertherm Technical Service team. i. If the CAN cable connectors and microprocessor are good and the LEDs appear functional, but the code continues, contact your cutting machine supplier or regional Hypertherm Technical Service team. 3. If the code is for the Core or VWI gas connect console (GCC), go to step 6.
  • Page 287 If you find a bent pin, try to straighten it. If this does not work, order a new cable.  i. If D24 and D25 are not illuminated and not flickering, the CAN cable to the plasma power supply is disconnected. Reconnect the CAN cable if necessary. XPR300 Instruction Manual 809480...
  • Page 288 There is a bad connection between the small CAN jumper cable for the gas connect  console control board (141375) and the sheet metal (located inside of the gas connect console). Reconnect or replace the CAN cable if necessary. 809480 Instruction Manual XPR300...
  • Page 289 (D87) are blinking. Look for once-per-second blinking (indicates the microprocessor on the PCB is functional). If the LEDs are not blinking once-per-second, replace the control board. If replacement  is necessary, contact your cutting machine supplier or Hypertherm Technical Service team. XPR300 Instruction Manual...

  • Page 290: Low Shield Water Pressure Code (532)

    If the RX LED is flickering and the CAN TX LED (D35) is not flickering, replace the control board (141334) inside of the torch connect console. If replacement is necessary, contact your cutting machine supplier or regional Hypertherm Technical Service team. 9. If you cannot find or resolve the problem with these corrective actions, contact your cutting machine supplier or regional Hypertherm Technical Service team.

  • Page 291: Low Shield Gas Pressure Code (534)

    Diagnostics and Troubleshooting 8. Adjust the pressures for any external water regulators, if necessary. The Hypertherm-supplied cutting system regulator is not adjustable. 9. If you cannot find or fix the problem with these corrective actions, contact your cutting machine supplier or regional Hypertherm Technical Service team.

  • Page 292: Low Coolant Flow Codes (540 - 542)

    B2 or the pressure transducer P14. 7. If you cannot find or resolve the problem with these corrective actions, contact your cutting machine supplier or regional Hypertherm Technical Service team. Low coolant flow codes (540 – 542)

  • Page 293: High Coolant Flow Codes (543 - 544)

    1. Look at the CNC or XPR web interface to make sure that the coolant pump is operational. 2. For diagnostic code 543, examine the coolant hoses. Make sure that you have Hypertherm-supplied coolant hoses. Replace the bad hoses with Hypertherm-supplied coolant hoses, if necessary.
  • Page 294 Examine the hoses and hose fittings. Look for damage or loose connections.  4. If you cannot find or resolve the problem with these corrective actions, contact your cutting machine supplier or regional Hypertherm Technical Service team. 809480 Instruction Manual...

  • Page 295: Over-Temp Diagnostic Codes - Choppers (560 - 561) And Coolant (587)

    Keep your hands away from moving parts. 1. Make sure that the clearance around the plasma power supply is adequate.  For adequate ventilation, Hypertherm recommends a minimum separation distance of 1 meter (3.3 feet) between the plasma power supply and any other objects or equipment.
  • Page 296 J9 pin 2 561, 668, 679 Chopper 2 (cold plate) PCB 3 J9 pin 1 J9 pin 2 c. Look for a resistance value that is outside of the minimum or maximum in Table 35:. 1250 1000 809480 Instruction Manual XPR300...

  • Page 297: Table 35 - Minimum And Maximum Ohmic Resistance Values For Thermistors

    10,000 ohms. d. If the resistance value is above the maximum, contact your cutting machine supplier or regional Hypertherm Technical Service team. They can help you to decide if there is a wiring fault or if thermistor replacement is necessary.
  • Page 298 PCB and the code continues when the thermistor is reconnected to the control PCB, contact your cutting machine supplier or regional Hypertherm Technical Service team. They can help you decide if control PCB replacement is necessary. (See Plasma power supply control PCB (141322) on page 318 or Plasma power supply chopper PCB (141319) on page 320.)

  • Page 299: Start Switch Diagnostic Codes (570 - 577)

    9. If LED D50 is still illuminated after the wire is removed, there is a problem with the board. Contact your cutting machine supplier. 10. If the LED is not illuminated, skip to step 12. XPR300 Instruction Manual 809480...
  • Page 300 A closed circuit can indicate that the CNC sent a plasma-start signal or damage on the discrete cable. 15. If you cannot find or resolve the issue with these corrective actions, contact your cutting machine supplier or regional Hypertherm Technical Service team. 809480 Instruction Manual...

  • Page 301: Over Temp Diagnostic Codes - Inductors (580 - 583), Transformers (586)

    Keep your hands away from moving parts. 1. Make sure that the clearance around the plasma power supply is adequate.  For adequate ventilation, Hypertherm recommends a minimum separation distance of 1 meter (3.3 feet) between the plasma power supply and any other objects or equipment.
  • Page 302 J1.4 pin 7 J1.4 pin 8 583, 663, 674 Inductor 2B PCB 1 J1.2 pin 1 J1.2 pin 2 586, 666, 677 Transformer PCB 1 J1.4 pin 1 J1.4 pin 2  Thermistors are located on the magnetics. 809480 Instruction Manual XPR300...

  • Page 303: Table 36 - Minimum And Maximum Ohmic Resistance Values For Thermistors

    10,000 ohms. d. If the ohmic resistance is above the maximum value, contact your cutting machine supplier or regional Hypertherm Technical Service team. They can help you to decide if there is a wiring fault or if thermistor replacement is necessary.

  • Page 304: Current Sensor Diagnostic Codes (631)

    PCB and the code continues when the thermistor is reconnected to the control PCB, contact your cutting machine supplier or regional Hypertherm Technical Service team. They can help you decide if control PCB replacement is necessary. (See Plasma power supply control PCB (141322) on page 318.)

  • Page 305: Low Inlet Pressure For H , Ar, N , And H O Diagnostic Codes (695 - 697, 700, 701)

    4. If the connections are good and the code continues, replace PCB5 (I/O PCB). 5. If you cannot find or resolve the problem with these corrective actions, contact your cutting machine supplier or regional Hypertherm Technical Service team. Low inlet pressure for H...

  • Page 306: Shield Gas Inlet Pressure In The Torch Connect Console Diagnostic Codes (702 - 705)

    9. Tighten loose connections if found. 10. If you cannot find or resolve the problem with these corrective actions, contact your cutting machine supplier or regional Hypertherm Technical Service team. Shield gas inlet pressure in the torch connect console diagnostic codes (702 – 705)

  • Page 307: Pressure Transducer Diagnostic Codes (706 - 715)

    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 supplier or regional Hypertherm Technical Service team. XPR300 Instruction Manual...

  • Page 308: Gas Inlet Pressure Codes (768 - 771)

    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. 809480 Instruction Manual XPR300...

  • Page 309: How To Do A Gas Leak Test (Vwi And Optimix)

    See if the code follows the transducer. Replace the bad transducer if necessary. For information about how to do this, refer to “Replace a pressure transducer” 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.
  • Page 310 If you use oxygen as the plasma gas for cutting, it can cause a potential fire hazard due to the oxygen-enriched atmosphere that collects. Hypertherm recommends that you install an exhaust ventilation system to remove the oxygen-enriched atmosphere that can collect when oxygen is used as the plasma gas for cutting.

  • Page 311: How To Measure Coolant Flow

    Coolant flow measurements from different parts of the cooling system, can identify the location of an obstruction or restriction. You can use an in-line flow meter to do this. In-line flow meters (128933) are available from Hypertherm. XPR300 Instruction Manual...
  • Page 312 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 XPR300 complete preventative maintenance information, see the Preventative Maintenance Program (PMP) Instruction Manual (809490).

  • Page 313: How 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. XPR300 Instruction Manual 809480...
  • Page 314 Diagnostics and Troubleshooting 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. 809480 Instruction Manual XPR300...

  • Page 315: How To Measure Resistance From Thermistors

    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 75ºC (167ºF) 1,000 2,000 85ºC (185ºF) 1,250 95ºC (203ºF) 1,000 105ºC (221ºF) 115ºC (239ºF) XPR300 Instruction Manual 809480...
  • Page 316 10,000 ohms. 3. If the resistance is above the maximum value, contact your cutting machine supplier or regional Hypertherm Technical Service team. They can help you to decide if there is a wiring fault or if thermistor replacement is necessary.

  • Page 317: Pcb Information

    Diagnostics and Troubleshooting PCB information Plasma power supply power distribution PCB (141425) Signal 120 VAC XPR300 Instruction Manual 809480...

  • Page 318: Plasma Power Supply Control Pcb (141322)

    Diagnostics and Troubleshooting Plasma power supply control PCB (141322) D104 D105 D108 D103 D100 809480 Instruction Manual XPR300...
  • Page 319 MAG FAN 3 FEEDBACK D100 PUMP ENABLE MAG FAN 2 FEEDBACK +15 V MAG FAN 1 FEEDBACK -15 V +3.3 V +5 V MAGNETIC FANS ENABLE +24 V HEAT EXCHANGER FAN ENABLE D103 COOLANT LEVEL COOLANT FLOW XPR300 Instruction Manual 809480...

  • Page 320: Plasma Power Supply Chopper Pcb (141319)

    D3 D4 D33D34 D21 D32 D31 Signal Signal +15V AND -15V POWER +5 V +3.3 V STATUS OVER CURRENT CHANNEL B ACTIVITY OVER CURRENT CHANNEL A +5VB USBFLAG CAN TX +18V AND -5V POWER CAN RX 809480 Instruction Manual XPR300...

  • Page 321: Plasma Power Supply Start Circuit Pcb (141360)

    Diagnostics and Troubleshooting Plasma power supply start circuit PCB (141360) Signal Signal PILOT ARC ENABLE +18V AND -5V POWER Plasma power supply I/O PCB (141371) XPR300 Instruction Manual 809480...

  • Page 322: Plasma Power Supply Fan Power Distribution Pcb (141384)

    Diagnostics and Troubleshooting Plasma power supply fan power distribution PCB (141384) 809480 Instruction Manual XPR300...

  • Page 323: Gas Connect Console Control Pcb (141375)

    Diagnostics and Troubleshooting Gas connect console control PCB (141375) Signal Signal +24 V CAN RX Status Activity USBFLAG +3.3V +5 V CAN TX A3.3 XPR300 Instruction Manual 809480...

  • Page 324: Gas Connect Console High Frequency Pcb (141354)

    Diagnostics and Troubleshooting Gas connect console high frequency PCB (141354) Signal HIGH FREQUENCY ENABLE Torch connect console ohmic PCB (141368) Signal Ohmic contact 809480 Instruction Manual XPR300...

  • Page 325: Torch Connect Console Control Pcb (141334)

    Diagnostics and Troubleshooting Torch connect console control PCB (141334) Signal Signal STATUS LED ACTIVITY LED A3.3 V +3.3 V USB FLAG +5 V CAN RX +24 V CAN TX V1 TORCH VALVE XPR300 Instruction Manual 809480...
  • Page 326 Diagnostics and Troubleshooting Signal Signal V2 (NOT USED IN THIS SYSTEM) V3 (NOT USED IN THIS SYSTEM) HV RELAY (NOT USED IN THIS SYSTEM) OHMIC CONTACT 809480 Instruction Manual XPR300...

  • Page 327: Parts List

    Parts List Plasma power supply Part number Voltage (AC) 078620 078621 078622 078623 078624 078625 078626 078627 078628 078629 XPR300 Instruction Manual 809480...

  • Page 328: Outer Panels

    Side panel with labels and handles 101300 Base 428725 Front panel with “H” (not shown) and power LED label 101314 Lower right (liquid-cooling) rear corner panel 101307 Lower left (control) rear corner panel 428726 Rear panel with label and handles 809480 Instruction Manual XPR300...

  • Page 329: Fans

    CAB FAN4 HX FAN1, Fan assembly: 890 cfm, 48 VDC, 254 mm HX FAN2, 229822 (10 inch) diameter MAG FAN1, MAG FAN2 229717 Heat-exchanger assembly – 003266 Solid state relay – 141384 Fan power distribution PCB PCB6 XPR300 Instruction Manual 809480...

  • Page 330: Coolant System

    Adapter: 1 inch MNPT X 3/8 inch FNPT X 1/4 inch FNPT Adapter: 3/8 inch hexagonal Coolant solenoid valve assembly 006132 Coolant bypass check valve 229721 Coolant solenoid valve assembly 229654 Thermistor: Copper pipe clip with electrical connector 809480 Instruction Manual XPR300...

  • Page 331: Coolant Adapters In The Rear Compartment

    Adapter: 1/2 inch FNPT X 1-1/2 inch length bulkhead 015899 Red ring: 0.87 inch inner diameter (not shown) 015029 Adapter: 1/2 inch NPT X #8 male 015898 Green ring: 0.87 inch inner diameter (not shown) 015902 Green ring: 1.13 inch inner diameter XPR300 Instruction Manual 809480...

  • Page 332: Other Adapters Not Shown

    Elbow fitting: 1/2 inch tube X 1/2 inch 015815 (4) and the heat-exchanger tube, 90° inlet (1) 015820 Fitting: 1/2 inch tube X 1/2 inch tube heat-exchanger outlet 809480 Instruction Manual XPR300...

  • Page 333: Transformers And Inductors

    – 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 XPR300 Instruction Manual 809480...

  • Page 334: Control Side - View 1

    Part number Description Designator Quantity Power source: 88 VAC – 264 VAC to 229671 48 VDC, 600 W 141425 Power distribution PCB PCB7 Fuse: 10 A, 250 VAC, time delay (on 108709 F3, F4, F5 PCB7) 809480 Instruction Manual XPR300...
  • Page 335 380 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 229678 Start circuit assembly PCB4 XPR300 Instruction Manual 809480...

  • Page 336: Control Side - View 2

    208397 208 V, 220 V, 240 V) 141371 I/O PCB PCB5 Pilot arc relay: 24 VDC, coil, 60 A 28 VDC 003277 contacts 101316 Pilot arc relay cover – Chopper 1, 229679 Chopper assembly Chopper 2 809480 Instruction Manual XPR300...
  • Page 337 Parts List XPR300 Instruction Manual 809480...

  • Page 338: Rear Compartment Of The Plasma Power Supply

    Terminal block 600 V, 140 A (380 V, 415 V, 029316 440 V, 480 V, 600 V) Main contactor (200 V, 208 V, 220 V, 003276 240 V) M_CON Main contactor (380 V, 400 V, 415 V, 003268 440 V, 480 V, 600 V) 809480 Instruction Manual XPR300...

  • Page 339: Gas Connect Consoles

    0.7 m (26 inches) Black EtherCAT CNC interface cable 0.7 m 223727 – (26 inches) Gas connect consoles Core OptiMix Part number Description 078631 Core gas connect console 078632 VWI gas connect console 078633 OptiMix gas connect console XPR300 Instruction Manual 809480...

  • Page 340: Gas Connect Console High-Voltage Side Parts

    Core, VWI, OptiMix high-voltage transformer 009045 EMI filter Core, VWI, OptiMix – High-frequency, 141354 Core, VWI, OptiMix PCB2 high-voltage ignition PCB Socket head cap screw: 075678 M5 – 0.8 X 10 mm Core, VWI, OptiMix – hexagonal 809480 Instruction Manual XPR300...

  • Page 341: Gas Connect Console Manifold Side Parts

    #8 male Green ring: 0.87 inches 015898 Core, VWI, OptiMix – inner diameter Red ring: 0.87 inches 015899 Core, VWI, OptiMix – inner diameter 075218 Washer Core, VWI, OptiMix – 075140 Bolt Core, VWI, OptiMix – XPR300 Instruction Manual 809480...

  • Page 342: Core Gas Connect Console Manifolds And Adapters

    1/4 inch NPT X #6 male (air output and input) 015103 1/4 inch NPT X RH ‘B’ inert female (nitrogen output and input) 015116 1/8 inch NPT X RH ‘A’ male (oxygen output) 015009 1/4 inch NPT X RH ‘B’ male (oxygen input) 809480 Instruction Manual XPR300...
  • Page 343 Parts List XPR300 Instruction Manual 809480...

  • Page 344: Vwi Gas Connect Console Input And Output Manifolds And Adapters

    Parts List VWI gas connect console input and output manifolds and adapters 809480 Instruction Manual XPR300...
  • Page 345 1/4 inch NPT X LH ‘B’ 015116 Adapter: 1/8 inch NPT X RH ‘A’ (oxygen outlet) 015210 Adapter: 1/8 inch NPT X LH ‘A’ male (hydrogen mix outlet) 015197 Adapter: 1/8 inch NPT X #5 male (argon outlet) XPR300 Instruction Manual 809480...

  • Page 346: Optimix Gas Connect Console Input And Output Manifolds And Adapters

    Parts List OptiMix gas connect console input and output manifolds and adapters 809480 Instruction Manual XPR300...
  • Page 347 1/4 inch NPT X RH ‘B’ male 015922 1/4 inch X hexagonal collar 015230 1/4 inch NPT X LH ‘B’ 015116 1/8 inch NPT X RH ‘A’ 015210 1/8 inch NPT X LH ‘A’ 015197 1/8 inch NPT X #5 XPR300 Instruction Manual 809480...

  • Page 348: Vwi And Optimix Gas Connect Console Mixer, Transducers, And Valves

    Part number Description Console Designator Quantity Mixer (You cannot purchase – this part. Shown for OptiMix – reference only.) 223398 Pressure transducer VWI and OptiMix P6 – P9 006167 Solenoid valve VWI and OptiMix B4, B5 809480 Instruction Manual XPR300...

  • Page 349: Gas Connect Console Wires Harness, Hose Kit, And Can Cables

    CAN cable 0.48 m (1.6 ft) male-female Core, VWI 223711 CAN cable 0.5 m (1.6 ft) male-female OptiMix 223712 CAN cable 0.39 m (1.3 ft) male-female OptiMix Torch connect console Part number Description 078618 Torch connect console XPR300 Instruction Manual 809480...

  • Page 350: Torch Connect Console Easy Connect Side

    Torch receptacle block – 229882 Ohmic relay and bracket – 420376 Torch lead connector – Machine screw: M6 X 10 mm 075544 – 4 (3 shown) Phillips, pan head 428338 Kit: Tubing – 006152 Check valve – 809480 Instruction Manual XPR300...

  • Page 351: Torch Connect Console Manifold Side - View 1

    Ohmic contact PCB PCB2 229825 Green power LED assembly – 101366 Bracket – 2 (1 shown) 229780 Valve cable 40 mm (1.6 inches) – 229800 Valve cable 279.4 mm (11 inches) – 229655 Wire harness – XPR300 Instruction Manual 809480...

  • Page 352: Torch Connect Console Manifold Side - View 2

    9 (8 shown) 229917 Solenoid valve (229965) tool – 015905 Adapter: 1/8 inch NPT O-ring seal X – 1/4 inch tube 428756 Bottom manifold assembly: – • Bottom manifold • Adapter • Critical orifice • Solenoid valve 809480 Instruction Manual XPR300...

  • Page 353: Front Adapters And Valves

    1/8 inch NPT X #6 male – 015103 1/4 inch NPT X RH ‘B’ inert female – 015007 1/4 inch NPT X #5 male – 015922 1/4 inch hexagonal collar – 015210 1/8 inch NPT X LH ‘A’ male – XPR300 Instruction Manual 809480...

  • Page 354: Torch Assembly

    Quick-disconnect/torch receptacle 420221 Quick-disconnect torch 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 809480 Instruction Manual XPR300...

  • Page 355: Torch Bracket

    Parts List Torch bracket Part number Description 428646 Torch lifter bracket: 2.25 inch diameter sleeve XPR300 Instruction Manual 809480...

  • Page 356: Consumable Starter Kits

    Parts List Consumable starter kits  See Sample configurations for consumables on page 141 or the XPR300 Cut Charts Instruction Manual (809830) for specific applications. Mild steel consumable starter kit (428616) Part number Description Quantity 420240 Electrode: 80 A 420243...

  • Page 357: Stainless Steel And Aluminum Consumable Starter Kit (428617)

    Swirl ring: 40 A – 170 A multiple processes 420323 Swirl ring: 60 A – 300 A multiple processes 420368 Water tube 420200 Shield retaining cap 420365 Nozzle retaining cap 104879 2.25 inch spanner wrench 104119 Consumable tool 027055 Silicone lubricant, 1/4 ounce XPR300 Instruction Manual 809480...

  • Page 358: Mild Steel Consumable Starter Kit With Torch (428618)

    Nozzle: 300 A 420491 Shield: 300 A 420406 Swirl ring: 300 A 420368 Water tube 420200 Shield retaining cap 420365 Nozzle retaining cap 104879 2.25 inch spanner wrench 104119 Consumable tool 027055 Silicone lubricant, 1/4 ounce 809480 Instruction Manual XPR300...

  • Page 359: Stainless Steel And Aluminum Consumable Starter Kit With Torch (428619)

    Swirl ring: 40 A – 170 A multiple processes 420323 Swirl ring: 60 A – 300 A multiple processes 420368 Water tube 420200 Shield retaining cap 420365 Nozzle retaining cap 104879 2.25 inch spanner wrench 104119 Consumable tool 027055 Silicone lubricant, 1/4 ounce XPR300 Instruction Manual 809480...

  • Page 360: Other Consumable And Torch Parts

    Parts List Other consumable and torch parts Part number Description 004629 Pit depth gauge 027055 Silicone lubricant, 1/4 ounce 104119 Consumable tool 809480 Instruction Manual XPR300...

  • Page 361: Plasma Power Supply To Gas Connect Console Connections

    35 m (114.8 feet) 223556* 20 m (65.6 feet) 223526 45 m (147.6 feet) 223557* 25 m (82 feet) * Leads labeled with CCC mark only. CCC is defined in Symbols and marks on page 32. XPR300 Instruction Manual 809480...

  • Page 362: Power Cable

    7.5 m (24.6 feet) 428483 45 m (147.6 feet) 428478 10 m (32.8 feet) 428484 60 m (196.9 feet) 428479 15 m (49.2 feet) 428485 75 m (246.1 feet) 428480 20 m (65.6 feet) – – 809480 Instruction Manual XPR300...

  • Page 363: Can Cable

    Part number Length Part number Length 428464 3 m (9.8 feet) 428467 7.5 m (24.6 feet) 428465 4.5 m (14.8 feet) 428468 10 m (32.8 feet) 428466 6 m (19.7 feet) 428469 15 m (49.2 feet) XPR300 Instruction Manual 809480...

  • Page 364: Pilot Arc, Coolant Hose Set, And Shield Water Assembly (Vwi Or Optimix)

    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) 809480 Instruction Manual XPR300...

  • Page 365: Plasma Power Supply To Cnc Connections

    12 m (39.4 feet) 223705 37.5 m (123 feet) 223697 13.5 m (44.3 feet) 223706 45 m (147.6 feet) 223698 15 m (49.2 feet) 223707 60 m (196.9 feet) 223699 16.5 m (54.1 feet) 223708 75 m (246.1 feet) XPR300 Instruction Manual 809480...

  • Page 366: Serial Cnc Interface Cable

    35 m (114.8 feet) 223666* 20 m (65.6 feet) 223647 45 m (147.6 feet) 223667* 25 m (82 feet) * Leads labeled with CCC mark only. CCC is defined in Symbols and marks on page 32. 809480 Instruction Manual XPR300...

  • Page 367: Torch Connect Console To Torch Receptacle Connection

    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) – – XPR300 Instruction Manual 809480...

  • Page 368: Nitrogen Or Argon Hose (Black)

    7.5 m (24.6 feet) 124044 45 m (147.6 feet) 124039 10 m (32.8 feet) 124045 60 m (196.9 feet) 124040 15 m (49.2 feet) 124046 75 m (246.1 feet) 124041 20 m (65.6 feet) – – 809480 Instruction Manual XPR300...

  • Page 369: Water (Optional Shield Fluid) (Blue)

    428642 Kit: Electronics (380 V – 600 V) Tools Part number Length 229917 Torch connect console solenoid valve tool 229918 Torch solenoid valve tool 104879 2.25 inch spanner wrench 004629 Pit depth gauge 104119 Consumable tool XPR300 Instruction Manual 809480...

  • Page 370: Recommended Spare Parts

    3-phase, 120 VAC 003276* Main contactor (200 V, 208 V, 220 V, 240 V) M_CON Main contactor (380 V, 400 V, 415 V, 440 V, 003268* 480 V, 600 V) * Voltage dependent - Select accordingly 809480 Instruction Manual XPR300...

  • Page 371: Gas Connect Consoles - Recommended Spare Parts

    Pressure transducer with wire and connector P1 – P5, P14 Torch – recommended spare parts Part number Description Designator Quantity 420220 Quick-disconnect/torch receptacle – 420221 Quick-disconnect torch – 420368 Water tube – 006155 Torch solenoid valve – XPR300 Instruction Manual 809480...

  • Page 372: Ce/Ccc Warning Label

    Become trained. Only qualified personnel should operate this equipment. Use torches specified in the manual. Keep non-qualified personnel and children away. Do not remove, destroy, or cover this label. Replace if it is missing, damaged, or worn. 809480 Instruction Manual XPR300...

  • Page 373: Wiring Diagrams

    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). XPR300 Instruction Manual...

  • Page 374: Wiring Diagram Symbols

    DC supply Diode Socket Shield Door interlock Plug Shunt PNP transistor Spark gap Feed-through LC Potentiometer Switch, flow Push button, Switch, level, Filter, AC normally closed normally closed Push button, Switch, pressure, Fuse normally closed normally open 809480 Instruction Manual XPR300...
  • Page 375 Switch, 1 pole, 2 throw, Transformer center off Switch, temperature, Transformer, air core normally closed Switch, temperature, Transformer, coil normally open Terminal block Triac Time delay closed, VAC source NC/off Torch symbols Electrode Nozzle Shield Torch Torch, HyDefinition ® XPR300 Instruction Manual 809480...

  • Page 376: Valve States By Process Type

    See the tables below to see the ON-OFF state for each valve by process type.  If a valve does not activate or deactivate as described in the tables below, contact your cutting machine supplier 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*) –...
  • Page 377 (Core, VWI, and OptiMix) Valve Stage Preflow /Air Pierce flow Air/Air Cutflow Air/Air Aluminum Cutting (80 A) – Air Plasma / Air Shield (Core, VWI, and OptiMix) Valve Stage Preflow /Air Pierce flow Air/N Cutflow Air/Air XPR300 Instruction Manual 809480...
  • Page 378 Stage Gas – Water Preflow Pierce flow Cutflow Stainless Steel and Aluminum Cutting (130 A, 170 A, 300 A) – H -Ar-N Plasma / N Shield (OptiMix only) Valve Stage Preflow Pierce flow -Ar-N -Ar-N Cutflow 809480 Instruction Manual XPR300...

  • Page 379: Valve States During Marking

    Wiring Diagrams Valve states during marking Mild Steel, Stainless Steel, and Aluminum Marking – N Plasma / N Shield (Core, VWI, and OptiMix) Valve Stage Preflow Cutflow Marking XPR300 Instruction Manual 809480...
  • Page 380 Wiring Diagrams 809480 Instruction Manual XPR300...

  • Page 381: Overview (Sheet 1 Of 22)

    Overview (Sheet 1 of 22) 013403 013403...

  • Page 382: Plasma Power Supply 1 (Sheet 2 Of 22)

    Plasma power supply 1 (Sheet 2 of 22) 013403...

  • Page 383: Plasma Power Supply 2 (Sheet 3 Of 22)

    Plasma power supply 2 (Sheet 3 of 22) 013403...

  • Page 384: Plasma Power Supply 3 (Sheet 4 Of 22)

    Plasma power supply 3 (Sheet 4 of 22) 013403...

  • Page 385: Plasma Power Supply 4 (Sheet 5 Of 22)

    Plasma power supply 4 (Sheet 5 of 22) 013403...

  • Page 386: Plasma Power Supply 5 (Sheet 6 Of 22)

    Plasma power supply 5 (Sheet 6 of 22) 013403...

  • Page 387: Plasma Power Supply 6 (Sheet 7 Of 22)

    Plasma power supply 6 (Sheet 7 of 22) 013403...

  • Page 388: Plasma Power Supply 7 (Sheet 8 Of 22)

    Plasma power supply 7 (Sheet 8 of 22) 013403...

  • Page 389: Gas Connect Console 1 (Sheet 9 Of 22)

    Gas connect console 1 (Sheet 9 of 22) 013403...

  • Page 390: Gas Connect Console 2 (Sheet 10 Of 22)

    Gas connect console 2 (Sheet 10 of 22) 013403...

  • Page 391: Torch Connect Console (Sheet 11 Of 22)

    Torch connect console (Sheet 11 of 22) 013403...

  • Page 392: Coolant System (Sheet 12 Of 22)

    Coolant system (Sheet 12 of 22) 013403...

  • Page 393: Gas System 1 (Sheet 13 Of 22)

    Gas system 1 (Sheet 13 of 22) 013403...

  • Page 394: Gas System 2 (Sheet 14 Of 22)

    Gas system 2 (Sheet 14 of 22) 013403...

  • Page 395: Gas System 3 (Sheet 15 Of 22)

    Gas system 3 (Sheet 15 of 22) 013403...

  • Page 396: Ethercat Multi-System Interface (Sheet 16 Of 22)

    EtherCAT multi-system interface (Sheet 16 of 22) Unit 1 Unit 2 Unit 3 Unit 4 Plasma power supply Plasma power supply Plasma power supply Plasma power supply 141322 141322 141322 141322 Control board Control board Control board Control board 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4...

  • Page 397: Serial Rs-422 And Discrete Multi-System Interface (Sheet 17 Of 22)

    Termination resistors (120 Ω) or termination jumpers must be installed and set at the CNC for each of the RS-422 RX and TX signal pairs. 3. If a Hypertherm CNC is used and there are intermittent communication failures (PS Link Failure), Serial RS-422 CNC interface...

  • Page 398: Discrete Multi-System Interface (Sheet 18 Of 22)

    Discrete multi-system interface (Sheet 18 of 22) Unit 1 Unit 2 Unit 3 Unit 4 Plasma power supply Plasma power supply Plasma power supply Plasma power supply 141322 141322 141322 141322 Control board Control board Control board Control board 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4...

  • Page 399: Ethercat Connection To Edge Connect/T/Tc (Sheet 19 Of 22)

    EtherCAT connection to EDGE Connect/T/TC (Sheet 19 of 22) Notes: 1. Hypertherm EDGE Connect/T/TC CNC examples shown with EtherCAT drives. Please see the CNC documentation for installation and connection details. EtherCAT cable 2. Torch height controller not shown. See the THC documentation for voltage divider installation and connection details.

  • Page 400: Discrete And Serial Rs-422 Cnc Connections (Sheet 20 Of 22)

    Discrete and serial RS-422 CNC connections (Sheet 20 of 22) Serial RS-422 cable Notes: 1. See the CNC documentation for installation and connection details. Discrete cable 2. Torch height controller not shown. See the THC documentation for voltage divider installation and connection details.

  • Page 401: Discrete Cnc Connections (Sheet 21 Of 22)

    Discrete CNC connections (Sheet 21 of 22) Notes: Discrete cable 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: Wireless Subsystem Block Diagram (Sheet 22 Of 22)

    Wireless subsystem block diagram (Sheet 22 of 22) 013403...

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