Hypertherm XPR300 Instruction Manual
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Hypertherm XPR300 Instruction Manual

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XPR300™
Instruction Manual
809480 – REVISION 6
ENGLISH

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Summary of Contents for Hypertherm XPR300

  • Page 1 XPR300™ Instruction Manual 809480 – REVISION 6 ENGLISH...
  • Page 2 United States and other countries. All other trademarks are the property of their respective holders. Environmental stewardship is one of Hypertherm’s core values, and it is critical to our success and our customers’ success. We are striving to reduce the environmental impact of everything we do. For more information: www.hypertherm.com/environment.
  • Page 3 XPR300 Instruction Manual 809480 REVISION 6 ENGLISH Original instructions November 2020 Hypertherm, Inc. Hanover, NH 03755 USA www.hypertherm.com...
  • Page 4 Mathura Road, New Delhi 110044, India HTJapan.info@hypertherm.com (Main Office Email) 91-11-40521201/ 2/ 3 Tel TechSupportAPAC@hypertherm.com (Technical Service Email) 91-11 40521204 Fax HTIndia.info@hypertherm.com (Main Office Email) TechSupportAPAC@hypertherm.com (Technical Service Email) For training and education resources, go to the Hypertherm Cutting Institute (HCI) online at www.hypertherm.com/hci.
  • Page 5 σε όλες τις γλώσσες που διατίθενται για κάθε εγχειρίδιο από την ψηφιακή βιβλιοθήκη εγγράφων (Documents library) στη διαδικτυακή τοποθεσία www.hypertherm.com. DE (DEUTSCH/GERMAN) WARNUNG! Bevor Sie ein Hypertherm-Gerät in Betrieb nehmen, lesen Sie HU (MAGYAR/HUNGARIAN) bitte die Sicherheitsanweisungen in Ihrer Bedienungsanleitung, das Handbuch für Sicherheit und Übereinstimmung (80669C), das Handbuch für Sicherheit VIGYÁZAT! Mielőtt bármilyen Hypertherm berendezést üzemeltetne,...
  • Page 6 языках, на которые переведено то или иное руководство, можно также KO (한국어 /KOREAN) загрузить в разделе «Библиотека документов» на веб-сайте 경고! Hypertherm 장비를 사용하기 전에 제품 설명서와 안전 및 규정 준수 www.hypertherm.com. 설명서(80669C), 워터젯 안전 및 규정 준수 설명서(80943C) 그리고 무선...
  • Page 7 TH (ภาษาไทย/THAI) ZH-CN (简 体中文/CHINESE SIMPLIFIED) คํ า เตื อ น! ก อ นการใช ง านอุ ป กรณ ข อง Hypertherm ทั ้ ง หมด โปรดอ า นคํ า แนะนํ า ด า น 警告！ 在操作任何海宝设备之前，请阅读产品手册、 《安全和法规遵守手 ความปลอดภั ย ในคู  ม ื อ การใช ส ิ น ค า คู  ม ื อ ด า นความปลอดภั ย และการปฏิ บ ั ต ิ...

  • Page 9: Table Of Contents

    Contents List of Tables..........................21 Electromagnetic Compatibility (EMC)................SC-23 Introduction..............................SC-23 Installation and use ............................SC-23 Assessment of area .............................SC-23 Methods of reducing emissions........................SC-23 Mains supply............................SC-23 Maintenance of cutting equipment......................SC-23 Cutting cables...............................SC-23 Equipotential bonding ........................SC-23 Earthing of the workpiece ......................SC-24 Screening and shielding..........................SC-24 Warranty..........................SC-25 Attention .................................SC-25 General................................SC-25...
  • Page 10 Waterjet product warranty coverage .......................SC-26 Product ...............................SC-26 Parts coverage..........................SC-26 1 Specifications..........................27 Terminology................................27 XPR cutting system description ........................28 General ..............................28 Plasma power supply ..........................28 Gas connect consoles ........................... 28 TorchConnect console........................... 28 Torch................................28 Plasma power supply (part number varies)....................29 Gas connect console (part number varies)....................
  • Page 11 Shield water requirements (VWI and OptiMix) .................... 51 Plumbing and hose requirements for shield water ................52 Additional regulator requirement for shield water (optional) ............52 Torque requirements for gas or water plumbing and hose connections ........52 Requirements for shield water removal for freezing-ambient temperatures ......53 Coolant requirements............................
  • Page 12 Safety instructions related to installation....................... 79 Configuration with Core gas connect console ................82 Configuration with VWI or OptiMix gas connect console ............. 83 Installation steps..............................84 Position the system components......................84 Plasma power supply ......................... 84 Gas connect console ......................... 85 TorchConnect console .......................
  • Page 13 Connect the gas connect console (VWI or OptiMix) to the TorchConnect console ... 113 Connect the pilot arc, coolant hose set, and shield water assembly (VWI or OptiMix) ........................113 Connect the power, CAN, and 5-gas assembly (VWI or OptiMix)....... 116 Install and connect the supply gases ......................
  • Page 14 Set up manually ......................... 174 Access the XPR web interface after setup in network mode ........177 Change the limited AP settings .................... 178 Reset the wireless module......................... 180 How to disable the wireless connection..................182 Web interface screen information ....................184 Plasma power supply ......................
  • Page 15 Ignite State (8) .......................... 211 Pilot arc State (9) ........................212 Rampup State (11) ........................213 Steady State (12)........................213 Rampdown State (13) ......................214 End of cycle State (14)......................214 High-voltage relay stages (closed or opened) in the ohmic circuit.......... 214 Automatic purges ..........................
  • Page 16 Arc Response Technology ..........................234 Automatic torch protection ........................ 234 Automatic rampdown error protection .................... 235 7 Maintenance..........................237 Overview ................................237 How to do daily inspections .......................... 239 Remove the power from the cutting system .................. 240 Examine the gas regulators........................ 241 Examine the shield water regulator (if applicable)................
  • Page 17 Over temp diagnostic codes – Choppers (560 – 561) and Coolant (587)....322 Start switch diagnostic codes (570 – 577) ............... 325 Over temp diagnostic codes – Inductors (580 – 583), Transformers (586) .... 327 Current sensor diagnostic codes (631) ................330 Low inlet pressure for H , Ar, N , and H...
  • Page 18 Rear compartment of the plasma power supply ................371 Gas connect consoles............................ 372 Gas connect console high-voltage side parts ................373 Gas connect console manifold side parts..................374 Core, VWI, and OptiMix gas connect console manifold side......... 374 Core gas connect console manifolds and adapters ............375 VWI gas connect console input and output manifolds and adapters......
  • Page 19 Plasma power supply to cutting table connection ................... 398 Work lead............................... 398 Torch connect console to torch receptacle connection................399 Torch lead............................... 399 Bevel torch lead............................ 399 Supply hoses..............................400 Oxygen hose (blue)..........................400 Nitrogen or Argon hose (black)......................400 Air hose (black).............................
  • Page 20 Discrete multi-system interface (Sheet 18 of 22) ................ 434 EtherCAT connection to EDGE Connect/TC (Sheet 19 of 22) ..........435 Discrete and serial RS-422 CNC connections (Sheet 20 of 22)..........436 Discrete CNC connections (Sheet 21 of 22) ................437 Wireless subsystem block diagram (Sheet 22 of 22) ..............

  • Page 21: List Of Tables

    List of Tables Table 1 – Plasma power supply general specifications................30 Table 2 – Plasma power supply part numbers and specifications............31 Table 3 – Gas connect console part numbers and dimensions ...............32 Table 4 – Length and weight by sleeve type....................34 Table 5 –...
  • Page 22 List of Tables Table 26 – Pinout for J19 on the discrete cable ..................156 Table 27 – Pinout for J2 on the VDC3 board .................... 165 Table 28 – Available non-ferrous processes by gas connect console type and gas type....220 Table 29 –...

  • Page 23: 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 24: Earthing Of The Workpiece

    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 25: 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 26: 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 27: 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 28: Xpr Cutting System Description

    For some cutting systems, a remote on-off switch controls the power that goes to the console. Torch The torch assembly consists of a torch mount sleeve, torch receptacle, torch, and water tube. The torch receptacle contains a solenoid valve. Consumables are installed on the torch. 809480 Instruction Manual XPR300...

  • Page 29: Plasma Power Supply (Part Number Varies)

    (50.11 in.) 590 kg (1,300 lb)  The part number and specifications can differ for your plasma power supply. Refer to Table 1 on page 30 and Table 2 on page 31 for part numbers and specifications. XPR300 Instruction Manual 809480...

  • Page 30: Table 1 - Plasma Power Supply General Specifications

    0.98 at 66.5 kW Cooling Forced air (Class F) Insulation Class H EMC emissions classification (CE models only) Class A Top lift eye Lift points Bottom lift truck slots Lift eye weight rating 680 kg (1,500 lb) 809480 Instruction Manual XPR300...

  • Page 31: Table 2 - Plasma Power Supply Part Numbers And Specifications

    078621 cCSAus 078622 50 – 60 cCSAus 078623 cCSAus 078624 50 – 60 CE, RCM, 078625 50 – 60 EAC, UKr, and 75.4 CE, RCM, 078626 EAC, UKr, and 078627 cCSAus 078628 cCSAus 078629 cCSAus XPR300 Instruction Manual 809480...

  • Page 32: Gas Connect Console (Part Number Varies)

    205.99 mm 078632 (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, refer to Gas connect console on page 85. 809480 Instruction Manual XPR300...

  • Page 33: Torchconnect Console (078618)

    Water or coolant collection inside of the TorchConnect console can damage internal electrical components.  For mounting dimensions, refer to TorchConnect console on page 87. XPR300 Instruction Manual 809480...

  • Page 34: 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) 809480 Instruction Manual XPR300...

  • Page 35: Critical Raw Materials

    Heatsinks, cold plates Natural graphite Pump motor, resistors Phosphorus Sheet metal panels Rare earth elements (heavy and light) Torch breakaway, pump motor Silicon metal Heatsinks, cold plates, transformers, inductors, IGBT modules Tantalum Capacitors Tungsten Power resistors XPR300 Instruction Manual 809480...

  • Page 36: Symbols And Marks

    CE versions of products that include a AAA Serbian mark meet the product safety and EMC requirements for export to Serbia. RoHS mark The RoHS mark indicates that the product meets the requirements of the European Restriction of Hazardous Substances (RoHS) Directive. 809480 Instruction Manual XPR300...

  • Page 37: Iec Symbols

    Direct current (DC) external protective (earth) (PE) conductor Power is ON Alternating current (AC) Power is OFF Plasma torch cutting A 1-phase or 3-phase inverter-based power source Gouging Volt/amperage curve, “drooping” characteristic AC input power connection XPR300 Instruction Manual 809480...
  • Page 38 Specifications 809480 Instruction Manual XPR300...

  • Page 39: Qualifications And Requirements

    If you do not have these documents, technical documentation is available at www.hypertherm.com/docs.  Technical documentation is current as of the date of its release. Subsequent revisions are possible. Refer to www.hypertherm.com/docs for the most recent revisions of released documents. XPR300 Instruction Manual 809480...

  • Page 40: Operator Qualifications

    How to identify and respond to fault conditions.  How to do maintenance.  A copy of the instruction manual.   Additional qualifications apply for personnel who do maintenance and troubleshooting. Refer to Qualifications of service personnel on page 41. 809480 Instruction Manual XPR300...

  • Page 41: 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 42: System Electrical Requirements

    General input power requirements appear in Table 6. For specific requirements for switches, fuses, and cords, refer to Line-disconnect switch requirements on page 43, Circuit breaker and fuse requirements on page 44, and Main power cord requirements on page 44. 809480 Instruction Manual XPR300...

  • Page 43: Plasma Power Supply

    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. XPR300...

  • Page 44: Circuit Breaker And Fuse Requirements

    Local codes and regulations  Always follow the local and national electrical safety requirements for your location, including requirements for correct electrical system design and installation. Contact a licensed electrician for more information about the codes in your location. 809480 Instruction Manual XPR300...

  • Page 45: Input Power Requirements For Ce Units

    A convenient location for a remote on-off switch is near the CNC.  For information about how to do this, refer to How to install a remote on-off switch on page 196. XPR300 Instruction Manual 809480...

  • Page 46: Process Gas Requirements (Core, Vwi, And Optimix Gas Connect Consoles)

    (125 psi) to avoid system alerts. ** Any air compressors that supply air to the cutting system must remove oil prior to air delivery. Hypertherm recommends that air compressors supply air that obey the following requirements of ISO Standard 8573-1:2010 Class 1.4.2: Maximum particle count in 1.0 m...

  • Page 47: Code Conformity

    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 48: Table 8 - Recommended Sizes For Gas Fittings

    Contact a licensed plumber for more information about the codes in your location. Hypertherm recommends an internal diameter of at least 10 mm (0.375 inch) for supply-gas hoses that are 76 m (250 feet) or less.

  • Page 49: Regulators For Supply Gases

    Some air compressors use synthetic lubricants that contain esters. Esters can damage the polycarbonates in the air filter bowl. Add additional gas filtration if necessary. The installer or user must supply the gas regulator (regulators) for the cutting system. XPR300 Instruction Manual 809480...
  • Page 50  Local regulations and the type of gas that is used can influence the recommended inlet gas fittings for your gas connect console. Refer to Table 8 – Recommended sizes for gas fittings on page 48. 809480 Instruction Manual XPR300...

  • Page 51: 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 (Hypertherm Waterjet part number 1-13897) available from Hypertherm. * Water that does not meet minimum purity specifications can cause excessive deposits on the torch nozzle and shield.

  • Page 52: 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 52.  Hoses are available from Hypertherm. Refer to Water (optional shield fluid) (blue) on page 401 of the Parts List.

  • Page 53: Requirements For Shield Water Removal For Freezing-Ambient Temperatures

    Requirements for shield water removal for freezing-ambient temperatures If your XPR cutting system uses shield water and is stored in ambient temperatures at or below 0ºC (32ºF), Hypertherm recommends shield water removal. Follow these steps to remove shield water from the gas connect console (VWI or OptiMix): 1.

  • Page 54: Coolant Requirements

    NOTICE AUTOMOTIVE ANTIFREEZE CAN DAMAGE THE TORCH COOLANT SYSTEM Never use automotive antifreeze in place of Hypertherm coolant. Antifreeze contains chemicals that can damage the torch coolant system. Make sure to read and follow the warning and cautions below. Refer to the Material Safety Data Sheets (MSDS) and Safety Data Sheets (SDS) for safety data and information about how to handle and store coolant, propylene glycol, and benzotriazole.

  • Page 55: 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 and storage is reduced to above 0°C to 40°C (32°F to 104°F).

  • Page 56: Flow Requirements For Coolant

    (gpg of CaCO 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 not 1000 0.001 use.) 809480 Instruction Manual XPR300...

  • Page 57: Requirements To Position System Components

    Bend radius requirements for hoses, cables, and leads on page 61  Distance requirements between high-frequency leads and control cables on page 62  Distance requirements for ventilation and access on page 62  Distance requirements for communications on page 63  XPR300 Instruction Manual 809480...

  • Page 58: Recommended Configuration With The Core Gas Connect Console

    Pilot arc lead in the process gas requirements. b Coolant hose set (1 supply, 1 return) 12 Hoses for supply gases 13 Gases Core: O , and air 809480 Instruction Manual XPR300...

  • Page 59: Recommended Configuration With The Vwi Or Optimix Gas Connect Console

    13 Gases and water c Shield water hose (VWI or OptiMix) VWI: O , air, N , Ar, F5, and water 9 Power, CAN, 5-gas assembly OptiMix: O , air, N , Ar, F5, water, H XPR300 Instruction Manual 809480...

  • Page 60: Site Requirements

    Cables and leads that are too long can cause electromagnetic interference (EMI).   EMI can have a negative effect on cut quality. Contact your cutting machine supplier for recommendations about the best lead lengths for your cutting system. 809480 Instruction Manual XPR300...

  • Page 61: Bend Radius Requirements For Hoses, Cables, And Leads

    * OptiMix assemblies shown as examples. The connectors on all console-to-console assemblies (Core, VWI, and OptiMix) have the same diameter.  For lengths, refer to Gas connect console to torch connect console connections Parts List on page 361. XPR300 Instruction Manual 809480...

  • Page 62: Distance Requirements Between High-Frequency Leads And Control Cables

    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 63: 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 64: Torch Mounting Bracket Requirements

    The XPR torch mounting sleeve is larger than the torch mounting sleeve for HPR torches. Modification or replacement of previous mounting hardware is necessary for XPR torches.  Mounting brackets are available from Hypertherm. Refer to Torch bracket on page 387 of the Parts List.

  • Page 65: 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  Process gas pressures  Fan speeds  XPR300 Instruction Manual 809480...

  • Page 66: Diagnostics And Troubleshooting

    Test preflow gases  Test pierceflow gases  Test cutflow gases  Test for gas system leaks   refer to For more information on CNC commands, the CNC Communication Protocol for the XPR Cutting System (809810). 809480 Instruction Manual XPR300...

  • Page 67: Recommended Grounding And Shielding

    However, due to the variation in equipment and installations, these grounding practices may not succeed in every case to eliminate EMI problems. Hypertherm recommends that you consult your local and national electrical codes to make sure that the grounding and shielding practices that you use satisfy the requirements for your location.

  • Page 68: Grounding Practices

    (047031). Consult an electrician in your location to make sure that your grounding meets all local and national electric codes. 5. For the most effective shielding, use the Hypertherm CNC interface cables for I/O signals, serial communication signals, between plasma systems in multi-drop connections, and for interconnections between all parts of the Hypertherm system.
  • Page 69 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 70 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 71: Example Grounding Diagram With An Xpr Cutting System

     This example is based on practices in North America. Other regions can have different local or national electrical codes. Hypertherm recommends that you consult your local and national electrical codes to make sure that the grounding and shielding practices that you use satisfy the requirements for your location.
  • Page 72 Qualifications and Requirements 809480 Instruction Manual XPR300...

  • Page 73: Installation

    Refer to Noise can damage hearing in the Safety and Compliance Manual (80669C). In addition, you can find an Acoustical Noise Data Sheet for your system at www.hypertherm.com/docs. In the search box, enter data sheet. XPR300 Instruction Manual...

  • Page 74: Installation Checklist

    Make sure that the regulators are the correct type, installed in the correct locations, and correctly installed. Refer to Regulators for supply gases on page 49. As an installer or user, you must supply the gas regulators for your cutting system. Make sure that the plumbing conforms to all applicable codes. 809480 Instruction Manual XPR300...
  • Page 75 Distance requirements for ventilation and access on page 62. 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. Make sure that the surfaces that hold system components are flat, dry, clean, and can support the weight.
  • Page 76 60. Grounding Make sure that the grounding meets requirements. Refer to Recommended grounding and shielding page 67. Plasma power supply Gas connect console Torch connect console Cutting table Torch lead collar 809480 Instruction Manual XPR300...

  • Page 77: Installation Steps

    Make sure that the distance between high-frequency leads and control cables meets requirements. Refer to Distance requirements between high-frequency leads and control cables on page 62. Make sure that the distance for communication meets requirements. Refer to Distance requirements for communications on page 63. XPR300 Instruction Manual 809480...
  • Page 78 Make sure that the consumables are the correct type and correctly installed. A loose or overtightened electrode can cause torch damage. Hypertherm recommends between 2.3 N∙m – 2.8 N∙m (20 in∙lbf – 25 in∙lbf) torque to tighten an electrode. Refer to Install the consumables on page 133.

  • Page 79: Safety Instructions Related To Installation

    Voltages in the cutting system can cause serious electric shock. Electric shock can seriously injure or kill you. Use extreme caution if you do diagnosis or maintenance tasks when the line-disconnect switch is in the ON position. XPR300 Instruction Manual 809480...
  • Page 80 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 81 When you come into contact, flush skin or eyes with water. If swallowed, seek immediate medical attention. NOTICE AUTOMOTIVE ANTIFREEZE CAN DAMAGE THE TORCH COOLANT SYSTEM Never use automotive antifreeze in place of Hypertherm coolant. Antifreeze contains chemicals that can damage the torch coolant system. CAUTION INCORRECT COOLANT CAN DAMAGE THE CUTTING SYSTEM Incorrect coolantcan damage the cutting system.

  • Page 82: Configuration With Core Gas Connect Console

    8 Pilot arc and coolant hose set assembly of the gas connect console or take actions to a Pilot arc lead adjust inlet gas pressures to tolerances specified b Coolant hose set (1 supply, 1 return) in the process gas requirements. 809480 Instruction Manual XPR300...

  • Page 83: Configuration With Vwi Or Optimix Gas Connect Console

    Pilot arc lead adjust inlet gas pressures to tolerances specified b Coolant hose set (1 supply, 1 return) in the process gas requirements. Shield water hose (VWI or OptiMix) XPR300 Instruction Manual 809480...

  • Page 84: Installation Steps

    • Be gentle when you put the plasma power supply into position. Do not drop it from any height. The XPR300 plasma power supply weighs 590 kg (1,300 lbs). You must use lift equipment to put it into position. Refer to Table 16.

  • Page 85: Gas Connect Console

    86. If you have questions about when or how to use the mounting holes, contact your cutting machine supplier or regional Hypertherm Technical Service team. Figure 1 – Mounting dimensions for the Core and VWI gas connect consoles...
  • 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: Torchconnect Console

    15.25 cm (6 in.) bend radius is maintained. If you have questions about console orientation or about when or how to use the mounting brackets, contact your cutting machine supplier or regional Hypertherm Technical Service team. Figure 3 – Recommended orientations for the TorchConnect console...
  • Page 88 Installation Figure 4 – Side-mount orientation and mounting-bracket dimensions for the TorchConnect console 6.35 mm Mounting brackets, side (0.25 in.) orientation 135 mm (5.31 in.) 339.85 mm (13.38 in.) 809480 Instruction Manual XPR300...
  • Page 89 Installation Figure 5 – Bottom-mount orientation and mounting-bracket dimensions for the TorchConnect console Mounting brackets 6.35 mm (0.25 in.) 135 mm (5.31 in.) 339.85 mm 101.60 mm (4.00 in.) (13.38 in.) XPR300 Instruction Manual 809480...

  • Page 90: Ground The System Components

    2. Ground system components after you position them and before you connect the hoses, cables, and leads. Refer to Figure Figure Figure 8, and Figure 9 for grounding details. Figure 6 – Plasma power supply grounding (detail) 809480 Instruction Manual XPR300...
  • Page 91 Installation Figure 7 – Gas connect consoles grounding (detail) Core OptiMix M6 ground stud Figure 8 – TorchConnect console grounding (detail) M6 ground stud XPR300 Instruction Manual 809480...

  • Page 92: Remove The External Panels From The System Components

    All work that requires removal of the plasma power supply outer cover or panels must be done by a qualified technician. Refer to the Safety and Compliance Manual (80669C) for more safety information. 809480 Instruction Manual XPR300...
  • Page 93 Figure 10 – Remove the rear panel from the plasma power supply For installation usually it is necessary to remove only the rear panel. XPR300 Instruction Manual 809480...
  • Page 94 Installation Figure 11 – Remove panels from the gas connect console Move the panel horizontally to remove it. 809480 Instruction Manual XPR300...
  • Page 95 Installation Figure 12 – Remove top and side panels from the TorchConnect console XPR300 Instruction Manual 809480...

  • Page 96: Prepare The Hoses, Cables, And Leads

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

  • Page 97: Pilot Arc And Coolant Hose Set Assembly

    1 return hose with red bands. Power, CAN, and 5-gas assembly (only for VWI and OptiMix)  The 18 meter (59.1 feet) assembly is compatible only with the 2 meter (6.6 feet) or 2.5 meter (8.2 feet) torch lead. XPR300 Instruction Manual 809480...

  • Page 98: Oxygen Hose (Blue)

    As you uncoil them, position the flat portion on the floor. To avoid equipment damage, do not pull from one end of the hose, cable, or lead to uncoil it. Pulling from one end can cause damage. 809480 Instruction Manual XPR300...

  • Page 99: Connect The Plasma Power Supply And Gas Connect Console (Core, Vwi, Or Optimix)

    EtherCAT inside the plasma power supply RS422 Negative RS422 Power Negative Work Work Pilot arc Coolant supply Discrete Pilot Arc Coolant return Coolant Coolant Supply Return (Green) (Red) Pilot Negative Work Power CNC Discrete EtherCAT RS422 XPR300 Instruction Manual 809480...

  • Page 100: Connect The Coolant Hose Set

    If your cutting system previously used the XPR short torch, make sure to interchange the coolant hoses prior to standard-torch operation. Refer to the XPR Short Torch Instruction Manual (810640) for information about how Green to do this. 809480 Instruction Manual XPR300...
  • Page 101 2. Connect the coolant hose set to the gas connect console: a. Connect the coolant return hose (red) to the coolant return fitting (red, bottom) b. Connect the coolant supply hose (green) to the coolant supply fitting (green, top) Green XPR300 Instruction Manual 809480...

  • Page 102: Connect The Power Cable

    For lengths, refer to Power cable on page 394 of the Parts List. Figure 15 – Connect the power cable Use your fingers to tighten these connectors. Do not use tools. Gas connect console Plasma power supply 809480 Instruction Manual XPR300...

  • Page 103: Connect The Can Cable

    For lengths, refer to CAN cable on page 395 of the Parts List. Figure 17 – Connect the CAN cable Use your fingers to tighten these connectors. Do not use tools. Gas connect console Plasma power supply XPR300 Instruction Manual 809480...

  • Page 104: Connect The Work Lead To The Plasma Power Supply And Cutting Table

    To plasma power supply To cutting table  For lengths, refer to Work lead on page 398 of the Parts List. Figure 19 – Connect the work lead to the plasma power supply (shown) and cutting table (not shown) 809480 Instruction Manual XPR300...

  • Page 105: Connect The Negative Lead With Strain Relief

    4. Connect the gas connect console end of the lead to the coolant block, or connect the plasma power supply end of the lead to the negative (-) connector. 5. Tighten the inner nut onto the strain relief nut XPR300 Instruction Manual 809480...
  • Page 106 Installation Figure 21 – Connect the negative lead with strain relief Gas connect console Plasma power supply 809480 Instruction Manual XPR300...

  • Page 107: Connect The Pilot Arc Lead With Strain Relief

    Figure 22 – Pilot arc lead with strain relief  For lengths, refer to Pilot arc lead with strain relief on page 393 of the Parts List. Figure 23 – Connect the pilot arc lead with strain relief to the plasma power supply XPR300 Instruction Manual 809480...
  • Page 108 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. 809480 Instruction Manual XPR300...

  • Page 109: Connect The Gas Connect Console (Core) To The Torchconnect Console

    Pilot arc and coolant hose set assembly (Core) page 395 of the Parts List. 1. Connect the lead assembly to the gas connect console: a. Put the hoses and lead through the hole in the gas connect console. XPR300 Instruction Manual 809480...
  • Page 110 Connect the coolant supply hose (green) to the coolant supply fitting (green). f. Remove the hose clamp from the lead and put it into the groove on the console collar. g. Push the coupler into the console collar and tighten the clamp. 809480 Instruction Manual XPR300...
  • Page 111 Connect the pilot arc lead. e. Remove the hose clamp from the lead and put it into the groove on the console collar. f. Push the coupler into the console collar and tighten the clamp. XPR300 Instruction Manual 809480...

  • Page 112: Connect The Power, Can, And 3-Gas Assembly (Core)

    The 18 meter (59.1 feet) assembly is compatible only with the 2 meter (6.6 feet) or 2.5 meter (8.2 feet) torch lead. For lengths, refer to Power, CAN, and 3-gas assembly (Core) on page 395 of the Parts List. Figure 27 TorchConnect console Core gas connect console 809480 Instruction Manual XPR300...

  • Page 113: Connect The Gas Connect Console (Vwi Or Optimix) To The Torchconnect Console

    Pilot arc, coolant hose set, and shield water assembly (VWI or OptiMix) on page 396 of the Parts List. 1. Connect the lead assembly to the gas connect console: a. Put the hoses and lead through the hole in the gas connect console. XPR300 Instruction Manual 809480...
  • Page 114 Connect the water hose inside of the VWI or OptiMix console. g. Remove the hose clamp from the lead and put it into the groove on the console collar. h. Push the coupler into the console collar and tighten the clamp. 809480 Instruction Manual XPR300...
  • Page 115 Connect the pilot arc lead. f. Remove the hose clamp from the lead and put it into the groove on the console collar. g. Push the coupler into the console collar and tighten the clamp. XPR300 Instruction Manual 809480...

  • Page 116: Connect The Power, Can, And 5-Gas Assembly (Vwi Or Optimix)

    (6.6 feet) or 2.5 meter (8.2 feet) torch lead. For lengths, refer to Power, CAN, and 5-gas assembly (VWI or OptiMix) on page 396 of the Parts List. Figure 30 TorchConnect console VWI or OptiMix gas connect console 809480 Instruction Manual XPR300...

  • Page 117: 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 118: Install Gas Regulators

    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 809480 Instruction Manual XPR300...

  • Page 119: Connect Supply Gases To The Gas Connect Console (Core)

    INCORRECT SUPPLY-GAS FITTINGS CAN CAUSE VALVES TO MALFUNCTION Do not change or replace the supply-gas fittings on the gas connect console. If you alter or replace the fittings, it can cause the internal valves to malfunction if particulates get inside. XPR300 Instruction Manual 809480...
  • Page 120 The following installation steps are for the Core gas connect console.  If you have a VWI or OptiMix gas connect console, refer to Connect supply gases and  shield water to the gas connect console (VWI or OptiMix) on page 122. 809480 Instruction Manual XPR300...

  • Page 121: Table 20 - Recommended Sizes For Gas Fittings

    1. Make sure that you have the correct supply gas hoses before you connect them. Hypertherm recommends an internal diameter of at least 10 mm (0.375 inch) for supply-gas hoses that are 76 m (250 feet) or less.

  • Page 122: Connect Supply Gases And Shield Water To The Gas Connect Console (Vwi Or Optimix)

    NOTICE PTFE TAPE CAN CAUSE CLOGGED VALVES, REGULATORS, AND TORCHES Never use PTFE tape on any joint preparation. Use only a liquid or paste thread sealant on male thread ends. 809480 Instruction Manual XPR300...
  • Page 123 DIRTY, OILY AIR CAN CAUSE DAMAGE TO THE AIR FILTER BOWL Some air compressors use synthetic lubricants that contain esters. Esters can damage the polycarbonates in the air filter bowl. Add additional gas filtration if necessary. XPR300 Instruction Manual 809480...

  • Page 124: Connect The Supply Gases

    Fitting type Size / Ar 5/8 inch – 18 RH, internal (inert gas) “B” 9/16 inch – 19, JIC #6 F5 / H 9/16 inch – 18, LH (fuel gas) “B” 9/16 inch – RH (oxygen) 809480 Instruction Manual XPR300...
  • Page 125 1. Make sure that you have the correct supply gas hoses before you connect them. Hypertherm recommends an internal diameter of at least 10 mm (0.375 inch) for supply-gas hoses that are 76 m (250 feet) or less.

  • Page 126: Connect Optional Shield Water To The Gas Connect Console (Vwi Or Optimix)

    4. Align the color-coded leads in the torch lead assembly with the corresponding connectors in the torch receptacle. 1 Coolant return (red) 5 Coolant supply (green) 2 Plasma valve 6 Shield gas (blue) 3 Pilot arc (yellow) 7 Plasma gas 2 (yellow) 4 Ohmic (orange) 8 Plasma gas 1 (black) 809480 Instruction Manual XPR300...
  • Page 127 Do not use tools. e. Connect the coolant supply hose (green). Push the hose into the connector until it stops, approximately 13 mm (0.5 inch).  This is a push-to-connect Coolant supply hose (green) fitting. XPR300 Instruction Manual 809480...
  • Page 128 7. Reposition the collar on the torch-end of the torch lead: a. Move the collar in the direction of the torch-end of the torch lead assembly. 809480 Instruction Manual XPR300...
  • Page 129 5 Coolant return hose (red)  The 6 meter (20 feet) lead is compatible only with gas assemblies that are 7.5 meters (24.6 feet) or less. For lengths, refer to Torch lead page 399 of the Parts List. XPR300 Instruction Manual 809480...
  • Page 130 Use your hands to tighten the coupler on the torch lead assembly. Do not use tools.  Connect the plasma valve cable to its connector. Use your fingers to tighten this connection. Do not use tools. 809480 Instruction Manual XPR300...

  • Page 131: Install The Torch In The Torch Mounting Bracket

    As the installer or user, you must supply the torch mounting bracket for your cutting system. Choose one that meets the requirements in Torch mounting bracket requirements on page 64. Mounting brackets are available from Hypertherm. Refer to Torch bracket on page 387. of the Parts List.
  • Page 132 For information on bevel cutting, refer to Bevel cutting on page 218. 6. Remove the consumables, including the water tube, from the torch. Figure 35 – Level the torch 7. Tighten the screws on the torch mounting bracket. 809480 Instruction Manual XPR300...

  • Page 133: Install The Consumables

    A tool is necessary to correctly install and tighten the torch electrode. Do not use your hands. Hypertherm recommends tightening the electrode to between 2.3 N∙m – 2.8 N∙m (20 in∙lbf – 25 in∙lbf) torque. If you fail to correctly install and tighten the electrode, torch damage can occur.
  • Page 134 Do not use your hands. If you fail to correctly install or tighten the electrode, torch damage can occur. Hypertherm recommends tightening the electrode to between 2.3 N∙m – 2.8 N∙m (20 in∙lbf – 25 in∙lbf) torque.

  • Page 135: Install The Torch Into The Torch Receptacle

    Turn the torch body with slight upward force until you feel it engage into position in the receptacle.  Use your hands to tighten the torch-coupler nut until the coupler nut no longer rotates. Do not use tools. XPR300 Instruction Manual 809480...

  • Page 136: Connect Electric Power To The Cutting System

    2. Connect the main power cord to the plasma power supply, as shown in Figure a. Connect the ground lead (PE) from the main power cord to the ground terminal ( ) of TB1. 809480 Instruction Manual XPR300...

  • Page 137: Table 22 - 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 XPR300 Instruction Manual 809480...

  • Page 138: Example Configurations For Consumables

    Example 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, refer to Examine the consumable parts page 243 in the Maintenance section of this manual.

  • Page 139: Mild Steel - 80 A, 130 A, 170 A, 220 A, And 300 A - O /Air

    Mild steel – 80 A, 130 A, 170 A, 220 A, and 300 A – O /Air Shield retaining Shield Nozzle retaining Nozzle Swirl ring Electrode Water tube 80 A 420242 420243 420240 420246 420607* 420605* 420368 420365 130 A 420200 420249 420242...

  • Page 140: Non-Ferrous (Stainless Steel And Aluminum) Example Configurations

    Non-ferrous (stainless steel and aluminum) example 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 141: 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 142: Non-Ferrouson-Ferrous - 80 A - F5/Non-Ferrous 2 **, Non-Ferrous

    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 143: 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 144: 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 145: 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* 420368 420356 420359 420365 420200 -Ar-N -Ar-N 420358 420362 420623* 420601* O*** O*** 420323 420475 420604* 420622* * Consumables for mirror cutting only.

  • Page 147: Connect For Communication

    If you use wireless, you must also use discrete to fully operate the cutting system. Refer to Table 23 on page 148. For information on signals and protocols, refer to the CNC Communication Protocol for the XPR Cutting (809810). System XPR300 Instruction Manual 809480...

  • Page 148: Table 23 - Communication Requirements And Options

    192. ** Discrete inputs are ignored when a process ID is set over EtherCAT to a cutting system that uses the factory-default configuration. Contact your cutting machine supplier or Hypertherm Technical Service team with questions. Example: If you use EtherCAT to set the process, the preferred method to monitor is EtherCAT.

  • Page 149: How To Connect To The Plasma Power Supply With Ethercat

    RS-422 and EtherCAT commands in the CNC Communication Protocol for the XPR Cutting System (809810). Figure 38 – EtherCAT cable  Hypertherm sells EtherCAT cables that have been tested with our cutting system. Refer to EtherCAT CNC interface cable on page 397. in the Parts List.
  • Page 150 Connect for Communication Figure 39 – Connect EtherCAT cables to plasma power supply EtherCAT out to the next plasma power supply EtherCAT in from the CNC 809480 Instruction Manual XPR300...

  • Page 151: How To Connect To The Plasma Power Supply With Serial Rs-422

    5. If you are only monitoring with RS-422 serial, you are done. If you want to operate the cutting system, go to step 6. You must connect to the plasma power supply with discrete. Refer to How to connect to the plasma power supply with discrete on page 154. XPR300 Instruction Manual 809480...

  • Page 152: Table 24 - 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 153 Connect for Communication Figure 41 – Connect the serial RS-422 cable to the plasma power supply Serial RS-422 from the CNC Serial RS-422 to the next plasma power supply (if any) XPR300 Instruction Manual 809480...

  • Page 154: How To Connect To The Plasma Power Supply With Discrete

    156 for pinouts. Figure 42 – Discrete cable End A To the plasma power supply End B To the CNC  For lengths, refer to Discrete CNC interface cable on page 397 in the Parts List. 809480 Instruction Manual XPR300...

  • Page 155: Table 25 - Pinout For J14 On The Discrete Cable

    Activate this signal at the same time as the Plasma Pierce complete - Black Start signal. Deactivate this signal when the pierce time is complete. F+24V CNC Available 24 VDC (200 mA maximum) Brown Output- F PWRGND Ground Black XPR300 Instruction Manual 809480...

  • Page 156: Table 26 - Pinout For J19 On The Discrete Cable

    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. Refer to How to use ohmic contact sense on page 193. 809480 Instruction Manual XPR300...
  • Page 157 Connect for Communication Figure 43 – Connect the discrete cable to the plasma power supply Discrete cable to the CNC XPR300 Instruction Manual 809480...

  • Page 158: Vdc3 Board Installation (For Avc With Rs-422 And Discrete-Only)

    Use precautions when handling printed circuit boards (PCBs) to protect them from static electricity. Correct PCB handling includes the following steps: • Store PCBs in anti-static containers. • Wear a grounded wrist strap when handling PCBs. 809480 Instruction Manual XPR300...

  • Page 159: Diagram Of Board, Cable, And Wire Connections

    Part numbers are shown for parts included in the kit.  The wire harness to connect the VDC3 board is located in a clip inside of the plasma power supply. The wiring harness includes the arc voltage wires and the power wires. XPR300 Instruction Manual 809480...

  • Page 160: How To Install The Vdc3 Board (141511)

    Connect for Communication How to install the VDC3 board (141511) Figure 45 – VDC3 board 1 2 3 4 5 6 7 8 J1 120 VAC wires connector J3 Arc voltage wires connector J2 VDC3 board cable connector 809480 Instruction Manual XPR300...
  • Page 161 Connect for Communication 1. Use a 10 mm hex socket wrench or nut driver to remove the rear panel of the plasma power supply. Figure 46 XPR300 Instruction Manual 809480...
  • Page 162 2. Use a #2 Phillips screwdriver to remove the 4 screws from the studs. 3. With J3 on top, use the 4 screws to install the board on the studs. Tighten the screws to 9.2 kg∙cm (8.0 in∙lb). 809480 Instruction Manual XPR300...

  • Page 163: How To Connect The Vdc3 Board (141511)

    How to connect the VDC3 board (141511) 1. Remove the wire bundle from the wire clip in the plasma power supply.  The wire bundle is included in the plasma power supply. The bundle includes the arc voltage wires and power wires. XPR300 Instruction Manual 809480...
  • Page 164 3. Connect the other end of the VDC3 120 VAC harness to the 120 VAC connector. Figure 47 4. Attach the spade connector of the yellow wire (WORK) to the J3-WORK terminal, as shown Figure 5. Attach the spade connector of the yellow/black wire (NEG) to the J3-ELECTRODE terminal. Figure 48 809480 Instruction Manual XPR300...

  • Page 165: Table 27 - Pinout For J2 On The Vdc3 Board

    +24 VDC (out) Nozzle contact sense (output) Nozzle contact enable (input) 24 VDC common + Analog out (40:1) - Analog out (analog common) EMI chassis ground (cable shield) 9. Install the rear panel of the plasma power supply. XPR300 Instruction Manual 809480...

  • Page 166: How To Connect To The Plasma Power Supply With The Xpr Web Interface

    WEAK NETWORK SECURITY INCREASES THE RISK FOR UNAUTHORIZED CUTTING SYSTEM OPERATION OR MISUSE 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 167: Use Ap Mode To Connect

    184.  If you want to change the connection name, refer to Configure on page 191. 4. Enter the password, “hypertherm”.  If you want to change your password, refer to Configure on page 191. 5. Open an Internet browser.
  • Page 168 184 for more information on the  interface menus. 7. To fully operate the cutting system, you must also use discrete. Refer to How to connect to the plasma power supply with discrete on page 154. 809480 Instruction Manual XPR300...

  • Page 169: Use Network Mode To Connect

    2. Choose Connect on the Other screen to open the Device Setup page.  The XPR web interface shows different fields for different XPR models. The screen shown is for reference only. XPR300 Instruction Manual 809480...
  • Page 170 Connect for Communication 3. Choose Client Settings. 4. Choose an option to connect to wireless networks: Select an existing network  page 171. Set up manually on page 174.  809480 Instruction Manual XPR300...

  • Page 171: Select An Existing Network

    2. Type the required credentials for the router in Passphrase. 3. If needed, select the Advanced Options check box and select a method to get the IP address. If not, go to step a. Dynamic Host Configuration Protocol (DHCP) XPR300 Instruction Manual 809480...
  • Page 172 Connect for Communication b. Static IP (advanced users only.) 4. Choose Next to go to the Wireless Configuration Summary screen.  This page shows information about the SSID, Channel, and Security type. 809480 Instruction Manual XPR300...
  • Page 173 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. You must connect to the plasma power supply with discrete. Refer to How to connect to the plasma power supply with discrete on page 154. XPR300 Instruction Manual 809480...

  • Page 174: Set Up Manually

    1. Select or type the wireless related settings such as SSID, Channel, Security, and Passphrase. 2. If needed, select the Advanced Options check box and select a method to get the IP address. If not, go to step a. Dynamic Host Configuration Protocol (DHCP) 809480 Instruction Manual XPR300...
  • Page 175 Static IP (advanced users only.) 3. Choose Next to go to the Wireless Configuration Summary screen.  This page shows information about the SSID, Channel, Security type, IP Address, Subnet Mask, Gateway, and DNS Server. XPR300 Instruction Manual 809480...
  • Page 176 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. You must connect to the plasma power supply with discrete. Refer to How to connect to the plasma power supply with discrete on page 154. 809480 Instruction Manual XPR300...

  • Page 177: Access The Xpr Web Interface After Setup In Network Mode

    Use the IP address of the plasma power supply.  Hypertherm recommends that you use DHCP reservation if it is available on your router. This allows the plasma power supply to keep the same IP address through power cycles without having to set up the wireless module with the static IP address.

  • Page 178: Change The Limited Ap Settings

    You can change the limited AP SSID, channel, network address, and DHCP settings in the Connect screen. 1. Choose Other > Connect > Limited AP Settings. 2. On the Limited AP Settings screen, select the AP mode settings 809480 Instruction Manual XPR300...
  • Page 179 Connect for Communication 3. Choose Advance Options, then Next. 4. Verify that the settings are correct. Adjust if necessary, otherwise, choose Save. 5. Choose Apply Settings.  The change takes effect after you cycle the power. XPR300 Instruction Manual 809480...

  • Page 180: 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 power-indicator LED is not illuminated on the plasma power supply. 2. Remove the side panel of the plasma power supply. 809480 Instruction Manual XPR300...
  • Page 181 Make sure that the power-indicator LED is not illuminated on the plasma power supply. 7. Set position 4 on DIP switch S3, located on the main control board, to the OFF position. This enables the wireless. XPR300 Instruction Manual 809480...

  • Page 182: How To Disable The Wireless Connection

    1. Remove the power from the cutting system: a. Set the line-disconnect switch to the OFF position. b. Make sure that the power-indicator LED is not illuminated on the plasma power supply. 2. Remove the side panel of the plasma power supply. 809480 Instruction Manual XPR300...
  • Page 183 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 power-indicator LED is illuminated on the plasma power supply. XPR300 Instruction Manual 809480...

  • Page 184: 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 185: 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.  The XPR web interface shows different fields for different XPR models. The screen shown is for reference only. XPR300 Instruction Manual 809480...

  • Page 186: Gas System

    The active valves are indicated with a gray highlight. 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 187 Connect for Communication Figure 51 – Example text-view screen that describes the gas system status XPR300 Instruction Manual 809480...
  • Page 188 Connect for Communication Figure 52 – Example diagram-view screen that shows the gas system status 809480 Instruction Manual XPR300...

  • Page 189: Log

    Connect for Communication On this screen you can monitor active diagnostic codes and view diagnostic code history. There are 4 categories of codes: information, alert, error, and failure. Refer to Table 36 on page 269 for definitions. XPR300 Instruction Manual 809480...

  • Page 190: 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 191: Other

    Connect – On this screen you can change your client settings and connect to other networks. For more information on how to do this, refer to Use network mode to connect on page 169. Update – On this screen you can update the web interface and firmware. XPR300 Instruction Manual 809480...

  • Page 192: How To Change The Device That Has Control

    Make sure that the power-indicator LED is not illuminated on the plasma power supply. 2. Supply power to the cutting system: a. Set the line-disconnect switch to the ON position. b. Make sure that the power-indicator LED is illuminated on the plasma power supply. 809480 Instruction Manual XPR300...

  • Page 193: 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 XPR300 Instruction Manual 809480...

  • Page 194: External Ohmic Contact Sense

    Otherwise, skip to step  The plug is located below the torch lead connection (Figure 54). Figure 54 – Remove plug to access the ohmic wire if you use a third-party ohmic circuit 809480 Instruction Manual XPR300...
  • Page 195 9 Torch lifter or third party ohmic circuit 4 Ohmic wire, torch receptacle to ohmic relay 10 Pin 1 and pin 2 on J4 are connected in the 5 Ohmic relay ohmic PCB 6 Ohmic wire, ohmic relay to J4 XPR300 Instruction Manual 809480...

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

  • Page 197: 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 XPR300 Instruction Manual 809480...

  • Page 198: 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 809480 Instruction Manual XPR300...

  • Page 199: Coolant Installation

    254.  The plasma power supply ships with the coolant filter (027005) and coolant pump screen (127559) installed. Additional coolant filters and screens are available from Hypertherm. Refer to Coolant system page 364.  For information about how to install a replacement coolant filter or coolant pump screen, refer to the XPR Preventative Maintenance Program (PMP) Instruction Manual (809490).

  • Page 200: How To Fill The Cutting System With Coolant

    If your coolant pump is damaged, pump replacement can be necessary. NOTICE AUTOMOTIVE ANTIFREEZE CAN DAMAGE THE TORCH COOLANT SYSTEM Never use automotive antifreeze in place of Hypertherm coolant. Antifreeze contains chemicals that can damage the torch coolant system. NOTICE If you use the wrong coolant, it can cause damage to the cutting system.
  • Page 201 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 202 Coolant Installation 809480 Instruction Manual XPR300...

  • Page 203: 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 204: 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  CNC Communication Protocol for the XPR Cutting System (809810) ...

  • Page 205: Indicators

    The LED illuminates green when the plasma power supply is receiving electric power and  the remote on-off switch is in the ON position. The plasma power supply that came with early XPR300 cutting systems has a green-only  power-indicator. A power-indicator LED upgrade kit (428893) is available from Hypertherm if you want a 2-color LED for your plasma power supply.

  • Page 206: Cnc Display

    Except for the power-indicator LEDs that show power status, all other visual indications of cutting system performance appear on the CNC or XPR web interface.  For CNC screen descriptions, see the instruction manual that came with your CNC. 809480 Instruction Manual XPR300...

  • Page 207: Sequence Of Operation

    Diagnose and troubleshoot the problem. Refer to Is Powerup State (1) complete and successful? Diagnostics and Troubleshooting on page 259. Then, start the Powerup State (1) again. Continue to Initial checks State (2) on page 208 XPR300 Instruction Manual 809480...

  • Page 208: Initial Checks State (2)

    Are the measurements within the acceptable Diagnose and troubleshoot the problem. Refer to range? Diagnostics and Troubleshooting on page 259. Wait for process selection by the operator. Select a process ID. Continue to Gas purge/pump on State (3) page 209. 809480 Instruction Manual XPR300...

  • Page 209: 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 wireless device sends to the cutting system, 2) if this is the first process sent after the Powerup State (1) starts, and 3) the type of previous operator-selected process. XPR300 Instruction Manual 809480...

  • Page 210: Wait For Start State (5)

    259. Then, start Preflow/charge DC State (7) again. Continue to Ignite State (8) on page 211. * To conserve energy, the coolant pump and fans stop after the time limit expires without a command. 809480 Instruction Manual XPR300...

  • Page 211: Ignite State (8)

    Is the Chopper 1 current above the minimum current? Does Ignite State (8) complete within Diagnose and troubleshoot the problem. Refer to 500 milliseconds? Diagnostics and Troubleshooting on page 259. Continue to Pilot arc State (9) on page 212. XPR300 Instruction Manual 809480...

  • Page 212: Pilot Arc State (9)

    Chopper 2 becomes active during this time. Does the Pilot arc State (9) complete within 500 Diagnose and troubleshoot the problem. Refer to milliseconds? Diagnostics and Troubleshooting on page 259. Continue to Rampup State (11) on page 213. 809480 Instruction Manual XPR300...

  • Page 213: Rampup State (11)

    30 A, only Chopper 1 is active). Note: If the operator-selected process is equal to or greater than 30 A, monitor both choppers. Is the Plasma Start signal removed? Continue to Rampdown State (13) on page 214. XPR300 Instruction Manual 809480...

  • Page 214: Rampdown State (13)

    L or later. Stall force is required when the N O process is used underwater. During a dry process, the cutting system closes the high-voltage relay and enables the ohmic-sense circuit (except during high-frequency starts). 809480 Instruction Manual XPR300...

  • Page 215: Automatic Purges

    If a process changes from a wet process to a dry process, a shield-fluid purge is used. During a shield-fluid purge, N purges residual water from the shield gas/fluid hose.  A wet process uses water as a shield fluid. A dry process does not use water as a shield fluid. XPR300 Instruction Manual 809480...

  • Page 216: 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 217: 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 218: Bevel Cutting

    52°, you can raise the torch to increase the clearance.  Arc voltage settings for bevel cutting depend on the torch position, metal thickness, cut speed, and effective cut height. For this reason, cut charts only include arc voltages for perpendicular-position cutting. 809480 Instruction Manual XPR300...

  • Page 219: Bevel Compensation Tables

    Arc Response Technology™ to extend the life of consumables by detecting and reacting to rampdown errors before they occur. 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 220: Non-Ferrous (Stainless Steel And Aluminum) Processes

    0.250 80 A F5/N 80 A N 0.375 0.500 130 A H -mix/N 130 A N 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 221: 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 222: 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 good non-vented cut quality at fast cutting speeds. processes 809480 Instruction Manual XPR300...

  • Page 223: 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 224: Mirror Cutting

    Mirror-cutting consumables are commonly used to cut a “left-handed” version of a “right-handed” part. Mirror-cutting consumables use the same settings as standard consumables.  For part numbers for mirror-cutting consumables, refer to Example configurations for consumables on page 138. 809480 Instruction Manual XPR300...

  • Page 225: Process Selection

    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 226: Process Id Offsets / Overrides

    226.  If you have an unusual process requirement, contact your cutting machine supplier or regional Hypertherm Technical Service team for guidance. Process ID offsets / overrides You can adjust some pre-programmed settings with an offset or override command. An offset/override command is a type of serial RS-422 or EtherCAT signal that lets you change the default value of a setting, within an allowable limit.

  • Page 227: How To Use Cut Charts

    The process category number for the process that you choose changes the quality-speed balance. For best results, Hypertherm recommends that you select process category number 1 whenever possible. Category 1 represents an optimized thickness (or PCT) for that cut process with the overall best balance of cut quality and cut speed.

  • Page 228: Table 30 - 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 229: Table 31 - 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 29 –...

  • Page 230: How To Select Consumables

    This section of the manual gives general recommendations for how to get the best results for many processes.  For instructions on how to troubleshoot specific performance problems, refer to Diagnostics and Troubleshooting on page 259. 809480 Instruction Manual XPR300...

  • Page 231: General Recommendations For All Processes

    Decrease the cutting speed when the end of the cut is near.  Stop the plasma arc before the part is completely cut (allow completion of the cut during  rampdown). Program the path of the torch into the scrap area for rampdown.  XPR300 Instruction Manual 809480...

  • Page 232: Recommendations For Piercing Processes

    Do not attempt this technique unless you are an experienced operator. Damage to the torch, lifter, or other system components is possible. Choose an argon-assist process to pierce thicker than 45 mm (1.75 inch) for mild steel.  809480 Instruction Manual XPR300...

  • Page 233: 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 234: How To Maximize The Life Of Consumable Parts

    Gas and current flow automatically ramp-up at the start of a cut  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. Refer to Arc Response Technology on page 234.

  • Page 235: 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 236 Operation 809480 Instruction Manual XPR300...

  • Page 237: 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 238: Table 32 - Inspection, Preventive Maintenance, And Cleaning Tasks

    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 and coolant check valve 809480 Instruction Manual XPR300...

  • Page 239: How To Do Daily Inspections

    Examine the shield water regulator (if applicable) on page 241  Examine the connections and fittings on page 241  Examine the consumable parts, torch, and torch receptacle on page 242  Examine the torch lead on page 247  XPR300 Instruction Manual 809480...

  • Page 240: Remove The Power From The Cutting System

    The end-use customer and the cutting machine supplier are responsible for providing protection against the hazardous moving parts of this cutting system. Read and follow the instruction manual provided by the cutting machine supplier. See the Safety and Compliance Manual (80669C) for more safety information. 809480 Instruction Manual XPR300...

  • Page 241: Examine The Gas Regulators

    Remove the power from the cutting system on page 240. 2. Examine all of the hoses, cables, and leads that connect system components. Look for: Kinks  Cracks  Cuts  Frays  Bulges or bubbles  XPR300 Instruction Manual 809480...

  • Page 242: Examine The Consumable Parts, Torch, And Torch Receptacle

    52 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 243: Examine The Consumable Parts

    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 244 Use a clean, lint-free cloth to wipe the internal and external surfaces. b. Use compressed air to remove debris from internal and external surfaces.  The nozzle retaining cap can retain debris. Make sure to clean it thoroughly. 809480 Instruction Manual XPR300...

  • Page 245: Examine The Torch

    Cracks in the torch insulator  3. Replace any O-rings that have damage or excess Internal O-rings (4) at rear of torch wear.  Torch rebuild kits are available from Hypertherm. Refer to Preventive maintenance kits on page 401 of the Parts List.

  • Page 246: Examine The Torch Receptacle

    Cracks in the torch receptacle  body 3. Replace the O-ring if it has damage or excess wear.  Torch rebuild kits are available from Hypertherm. Refer to Preventive maintenance kits on page 401 of the Parts List. 809480...

  • Page 247: Examine The Torch Lead

    Look for evidence that the hoses, cables, and leads are exceeding bend radius requirements during cutting system operation. Refer to Bend radius requirements for hoses, cables, and leads on page 61. Make adjustments if you find evidence of kinking, bending, or twisting.  XPR300 Instruction Manual 809480...

  • Page 248: How To Replace The Water Tube

    3. Examine the O-ring on the end of the water tube: a. Replace the O-ring if you find damage or excess wear.  Torch rebuild kits are available from Hypertherm. Refer to Preventive maintenance kits on page 401 of the Parts List.

  • Page 249: How To Identify Emitter Wear

    If an electrode needs replacement because of emitter wear, always replace the nozzle at the same time as the electrode. The following guidelines for how to evaluate emitter wear apply to hafnium-emitter electrodes. The face of a new electrode looks shiny and smooth (Figure 60). XPR300 Instruction Manual 809480...
  • Page 250 Figure 60 – Face of a new electrode (note hafnium emitter and electrode pit) Electrode face Hafnium emitter Electrode pit If the electrode pit diameter extends beyond the hafnium (Figure 61), replace the electrode and nozzle. Figure 61 – Wide electrode pit that extends beyond the hafnium 809480 Instruction Manual XPR300...
  • Page 251 Figure 62 – Non-symmetrical, rough-edged pit and rough-surfaced electrode face  If an electrode needs replacement because of emitter wear, always replace the nozzle at the same time as the electrode. XPR300 Instruction Manual 809480...

  • Page 252: How To Measure The Pit Depth Of An Electrode

    2. Use an electrode pit-depth gauge to measure the pit depth on the electrode. Refer to Figure 63 on page 252.  A pit-depth gauge (004630) is available from Hypertherm. Refer to Other consumable and torch parts on page 392 of the Parts List.

  • Page 253: How To Do Coolant Maintenance

    If your coolant pump is damaged, pump replacement can be necessary. NOTICE AUTOMOTIVE ANTIFREEZE CAN DAMAGE THE TORCH COOLANT SYSTEM Never use automotive antifreeze in place of Hypertherm coolant. Antifreeze contains chemicals that can damage the torch coolant system. NOTICE INCORRECT COOLANT CAN DAMAGE THE CUTTING SYSTEM Incorrect coolant can damage the cutting system.

  • Page 254: 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 255: 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 256 Close the valve at the bottom of the reservoir and remove the 3/8-inch inner diameter tubing from the outlet.  Do not store the 3/8-inch diameter tubing inside of the plasma power supply. 809480 Instruction Manual XPR300...
  • Page 257 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 258 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 259: Diagnostics And Troubleshooting

      If you have questions about how to care for your cutting system, contact your cutting machine supplier or regional Hypertherm Technical Service team. You can find contact information for each regional office at www.hypertherm.com on the “Contact us” page.

  • Page 260: Safety Considerations

    Use extreme caution if you do diagnosis or maintenance tasks when the plasma power supply remains connected to an electric power source and the outer cover or panels are removed. 809480 Instruction Manual XPR300...

  • Page 261: Initial Inspection Steps

    If the line-disconnect switch is not in the OFF position you can get a serious electric shock. Electric shock can seriously injure or kill you. 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. XPR300 Instruction Manual 809480...
  • Page 262 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. 809480 Instruction Manual XPR300...

  • Page 263: Examine The Pcbs

    1. Remove the power from the cutting system. Refer to Remove the power from the cutting system on page 261. 2. Remove the external panel or panels from the system component that has the PCB that you want to examine. Refer to Table XPR300 Instruction Manual 809480...

  • Page 264: Table 34 - Pcb Names And Locations

    Measure the line voltage between the terminals inside the plasma power supply on page 265. 7. 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 XPR300...

  • Page 265: Measure The Line Voltage Between The Terminals Inside The Plasma Power Supply

    3. If any 1 line is equal to or 10% greater than the other 2 lines, examine with the incoming electric supply lines.  If the incoming electric supply lines are good, contact a licensed electrician or the electric company that supplies electricity for more information. XPR300 Instruction Manual 809480...
  • Page 266 Examine the fuses at the line-disconnect switch. Look for continuity. d. Repair or replace any damaged or defective parts if found. 5. Repeat these steps until the line voltage between any 2 of the 3 lines is equal to the supply voltage. Figure 64 809480 Instruction Manual XPR300...

  • Page 267: 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 XPR300 Instruction Manual 809480...

  • Page 268: Table 35 - Diagnostic Codes In The Web Interface

     If you cannot find or resolve the problem with the corrective actions in Table 36, contact your cutting machine supplier or regional Hypertherm Technical Service team listed in the front of this manual. 809480 Instruction Manual...

  • Page 269: Can Codes

    Table 36 – Diagnostic codes Diagnostic code Diagnostic code Code cancels number and Description Corrective action XPR action name with category GCC->Main CAN The gas connect console Refer to CAN codes (500 – 503, 510 – 513 for gas Shut down Remote on-off (Core, VWI, or OptiMix) connect console, 504 –...
  • Page 270 Diagnostic code Diagnostic code Code cancels number and Description Corrective action XPR action name with category Main no CAN There is a problem with the Refer to CAN codes (500 – 503, 510 – 513 for gas None Remote on-off CAN network when power is connect console, 504 –...
  • Page 271 Diagnostic code Diagnostic code Code cancels number and Description Corrective action XPR action name with category Main->Ch2 CAN The main control PCB cannot Refer to CAN codes (500 – 503, 510 – 513 for gas None Remote on-off receive communications (at connect console, 504 –...
  • Page 272 Diagnostic code Diagnostic code Code cancels number and Description Corrective action XPR action name with category Pilot arc t/o (no arc No current detected on the End of cycle Start or set transfer) work lead for 500 process; Alert 1. Make sure that the transfer height is correct. milliseconds after the pilot arc remote on-off 2.
  • Page 273 Diagnostic code Diagnostic code Code cancels number and Description Corrective action XPR action name with category Low psi-Line A • The Line A pressure (P5) 1. Review the diagnostic code history for previous Ramp down Set process; is less than 75% of the pressure-related codes.
  • Page 274 Diagnostic code Diagnostic code Code cancels number and Description Corrective action XPR action name with category Low psi-Line B For a minimum of 1. Review the diagnostic code history for previous Ramp down Set process; 200 milliseconds, Line B pressure-related codes. Previous codes can remote on-off Alert pressure is less than 75% of...
  • Page 275 Diagnostic code Diagnostic code Code cancels number and Description Corrective action XPR action name with category Low psi-F5 For a minimum of 1. Review the diagnostic code history for previous Ramp down Set process; 200 milliseconds, the F5 pressure-related codes. Previous codes can remote on-off Alert pressure sensor (P7) is less...
  • Page 276 Diagnostic code Diagnostic code Code cancels number and Description Corrective action XPR action name with category Low flow For a minimum of 10 seconds Refer to Low coolant flow codes (540 – 542) Shut down Remote on-off 2-Coolant after the coolant flow rate page 319.
  • Page 277 10 A. • Inductors 7. Replace the damaged choppers or inductors if found. 8. Make sure that the arc remains on the workpiece during cutting. 9. If the code continues, contact your cutting machine supplier or regional Hypertherm Technical Service team.
  • Page 278 7. Replace the damaged choppers or inductors if found. 8. Make sure that the arc remains on the workpiece during XPR cutting system operation. 9. If the code continues, contact your cutting machine supplier or regional Hypertherm Technical Service team.
  • Page 279 7. Replace the damaged choppers or inductors if found. 8. Make sure that the arc remains on the workpiece during XPR cutting system operation. 9. If the code continues, contact your cutting machine supplier or regional Hypertherm Technical Service team.
  • Page 280 8. Make sure that the arc remains on the workpiece during XPR cutting system operation. 9. If the code continues, contact your cutting machine supplier or regional Hypertherm Technical Service team. Over temp-Ch1 The insulated-gate bipolar Refer to Over temp diagnostic codes – Choppers Ramp down –...
  • Page 281 Diagnostic code Diagnostic code Code cancels number and Description Corrective action XPR action name with category Start on Powerup The Plasma Start switch is in Refer to Start switch diagnostic codes (570 – 577) None Start or set the ON position before the on page 325.
  • Page 282 Diagnostic code Diagnostic code Code cancels number and Description Corrective action XPR action name with category Over temp-Ind1 The temperature of Refer to Over temp diagnostic codes – Inductors Ramp down — Inductor 1 (1A) or 2 (1B) is (580 – 583), Transformers (586) on page 327.
  • Page 283 Diagnostic code Diagnostic code Code cancels number and Description Corrective action XPR action name with category Fan timeout Fan timeout codes can occur Shut down — when cooling takes more Failure 1. Identify the over-temp diagnostic codes that than 1 hour. appear on the XPR web interface.
  • Page 284 Diagnostic code Diagnostic code Code cancels number and Description Corrective action XPR action name with category No Chopper 2 The inductor thermocouples 1. Make sure that the connector (J8) on None Start or set found for Chopper 2 were detected, Chopper 2 is fully engaged.
  • Page 285 1. Confirm the input-line voltage is within+/-14% Shut down Remote on-off than 414 V. of nominal. Refer to Input power requirements Failure on page 42. 2. If the code continues, contact your cutting machine supplier or regional Hypertherm Technical Service team.
  • Page 286 J4 and K1 relay connections for damage. 11. If K1 is bad, replace either the power distribution board (141425) or the K1 relay (003257). 12. If the code continues, contact your cutting machine supplier or regional Hypertherm Technical Service team.
  • Page 287 133. current. 3. If the code continues, contact your cutting This code is applicable only machine supplier or regional Hypertherm for processes that start with Technical Service team. argon (Ar) gas. No DC output-Ch2 No current produced within 1.
  • Page 288 Alert 2. Restore electrical power to the cutting system. State for at least 100 3. Send a process command to the cutting milliseconds. system. 4. If the code continues, contact your cutting system supplier or regional Hypertherm Technical Service team.
  • Page 289 Diagnostic code Diagnostic code Code cancels number and Description Corrective action XPR action name with category Current (DC) During Preflow State, a 1. Inspect the consumable parts for damage and Shut down Start or set preflow chopper finds current. excess wear. process;...
  • Page 290 Diagnostic code Diagnostic code Code cancels number and Description Corrective action XPR action name with category Thermistor The main control PCB finds a Use a digital multimeter to measure the resistance Shut down Remote on-off Fault-Coolant shorted coolant temperature from the thermistor. Refer to How to measure Error sensor.
  • Page 291 ON position (enabled) (D89 illuminated). Re-set the switch if necessary. 5. Contact your cutting machine supplier or regional Hypertherm Technical Service team. Make sure that you have the Record ID associated with the error.
  • Page 292 Diagnostic code Diagnostic code Code cancels number and Description Corrective action XPR action name with category Low Inlet H -Mix The hydrogen (H ) inlet Refer to Low inlet pressure for H , Ar, N , and H None Set process; pressure (P10) for the mixing diagnostic codes (695 –...
  • Page 293 Diagnostic code Diagnostic code Code cancels number and Description Corrective action XPR action name with category Shield Gas Inlet N For a minimum of If you have a cutting system equipped with a Core None Set process; 200 milliseconds, the or VWI gas connect console, refer to Gas inlet remote on-off...
  • Page 294 Diagnostic code Diagnostic code Code cancels number and Description Corrective action XPR action name with category No sensor P2-TCC The P2 pressure sensor in Refer to Pressure transducer diagnostic codes Ramp down Set process; the torch connect console is (706 – 715) on page 336.
  • Page 295 Diagnostic code Diagnostic code Code cancels number and Description Corrective action XPR action name with category Process Invalid The operator-selected Refer to the smart-fault data value (number) that None Set process; process is not supported by accompanies the diagnostic code in the XPR web remote on-off Error this XPR cutting system.
  • Page 296 The cutting system is not ready for a new process ID. If the code continues, contact your cutting machine supplier or regional Hypertherm Technical Service It can only accept a process Team. ID during the following states: “Initial Checks (2), ”...
  • Page 297 3. Make sure that you have the most recent XPR Because the mixer tries to firmware. You can log into the Xnet at deliver a flow, the outlet www.hypertherm.com to download it. pressure can continue to rise. Mix Pout>Pin Pressure out (P21) is more...
  • Page 298 Diagnostic code Diagnostic code Code cancels number and Description Corrective action XPR action name with category Mix I2C1 There is a mixing 1. Examine the cable used to ground the gas Ramp down Set process; communication error on connect console. Connect a disconnected remote on-off Error I2C1.
  • Page 299 Diagnostic code Diagnostic code Code cancels number and Description Corrective action XPR action name with category Solenoid error V4 There is an over-current Ramp down Set process; condition for valve V4 at the remote on-off Alert PCB in the torch connect console.
  • Page 300 Diagnostic code Diagnostic code Code cancels number and Description Corrective action XPR action name with category Solenoid error V10 There is an over-current Ramp down Set process; condition for valve V10 at the remote on-off Alert 1. Examine the wiring for the valve. PCB in the torch connect 2.
  • Page 301 Diagnostic code Diagnostic code Code cancels number and Description Corrective action XPR action name with category Low Speed- The fan tachometer feedback 1. Examine the fan. Make sure that the following None Set process; MagFan 2 is below the minimum. fan connections are good and tighten loose remote on-off Alert...
  • Page 302 Diagnostic code Diagnostic code Code cancels number and Description Corrective action XPR action name with category Low speed CAB Fan speed is below the 1. Examine the fan. Make sure that the following None Set process; FAN1 (Control minimum acceptable RPM fan connections are good: remote on-off Alert...
  • Page 303 5. Inspect the following contactor components for loose connections: • Contactor • Input to chopper • Power cord 6. Tighten loose connections if found. Otherwise, continue with the following steps. 7. If the code continues, contact your cutting machine supplier or regional Hypertherm Technical Service team.
  • Page 304 • Power cord 6. Tighten loose connections if found. Otherwise, continue with the following steps. 7. If the code continues, contact your cutting machine supplier or regional Hypertherm Technical Service team. Low level-Coolant The coolant level is low. Fill the coolant reservoir with coolant. Refer to None Set process;...
  • Page 305 If the code continues, contact your cutting machine to less than 20 V on the main remote on-off Alert supplier or regional Hypertherm Technical Service control PCB. team. Main 24 V bus low The 24 V bus decreases to Ramp down Set process;...
  • Page 306 You can log in into the Xnet at www.hypertherm.com to download it. 3. If the code continues, contact your cutting machine supplier or regional Hypertherm Technical Service team. Main contactor The main contactor driver 1. Inspect the main contactor and wiring. Replace None Set process;...
  • Page 307 You can log into the Xnet at www.hypertherm.com to download it. 3. If the code continues, contact your cutting machine supplier or regional Hypertherm Technical Service team. Remote relay fault The remote on-off relay driver 1. Inspect the pump solid state relay for damage.
  • Page 308 7. If the ohms value is more than 10% above or below 280 ohms, replace the pilot arc relay. 8. If the ohms value is within acceptable range, make sure that you have the most recent XPR firmware. You can log into the Xnet at www.hypertherm.com to download it.
  • Page 309 (Hv relay). 7. If the ohms value is within acceptable range, make sure that you have the most recent XPR firmware. Log into the Xnet at www.hypertherm.com to download it. Ch1 15V bus The Chopper 1 15 V bus is 1.
  • Page 310 Diagnostic code Diagnostic code Code cancels number and Description Corrective action XPR action name with category Mix low psi-P2 The Air inlet pressure (P2) in Increase air pressure. None Start or set the torch connect console is process; Alert less than 7.58 bar (110 psi) remote on-off (OptiMix only) during a mix gas process.

  • Page 311: For Can Cable And Jumper Block, 507 - 508 For Can Network And Bus, 600 - 602 For No Can Communication)

    If the CAN cable connections are good, examine the PCB for Chopper 1/PCB 2 and Chopper 2/PCB 3. Make sure that the following green LEDS are illuminated on each PCB: D22 (+18/-5 VDC)  D14 (+5 VDC)  D21 (+3.3 VDC)  XPR300 Instruction Manual 809480...
  • Page 312 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 4.
  • Page 313 If D24 is not illuminated and D25 is flickering, examine the control board for shorts. Look for a shorting block across pins 1 and 2 of J16. k. If there is a shorting block, remove it and restart the cutting system. l. If J16 is open, replace the control board (141375). XPR300 Instruction Manual 809480...
  • Page 314 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 315  flickering), the mixer in the gas connect console can be the problem. Contact your cutting machine supplier or regional Hypertherm Technical Service team. Technical Service can help you decide if it is necessary to replace the gas connect console.
  • Page 316 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. e. If the power LEDs are good, examine CAN TX LED (D35) and RX LED (D34). Flickering indicates the microprocessor on the PCB is functional.

  • Page 317: Low Shield Water Pressure Code (532)

    8. Adjust the inlet water pressures to at least 2.77 bar (40 psi) when cutting, if necessary.  The Hypertherm-supplied regulator that is connected to the gas connect console is pre-set at the factory. Do not adjust this regulator. 9. If you cannot find or fix the problem with these corrective actions, contact your cutting machine supplier or regional Hypertherm Technical Service team.

  • Page 318: Low Shield Gas Pressure Code (534)

    410 to identify if V11 is enabled. Look for voltage between 5 VDC – 24 VDC. c. If B2 and V11 do not have the correct voltage, examine the connections between the control board (141334) and the valves. Make sure that the connections are fully engaged. 809480 Instruction Manual XPR300...

  • Page 319: Low Coolant Flow Codes (540 - 542)

    If yes, replace B2 or P14, as needed. 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 320 If the value differs more than 0.8 L/min (0.2 gal/min), or if there are no pulses (0 Hz), replace the flow sensor. 7. If 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 321: 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 322 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 323 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 1250 1000 XPR300 Instruction Manual 809480...

  • Page 324: Table 37 - Minimum And Maximum Ohmic Resistance Values For Thermistors

    Table 37 on page 324, 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. e. If the resistance value is at or very near 0 ohms: Inspect the wiring between each thermistor and its connector pins.
  • Page 325 If the thermistor resistance is within range when the thermistor is disconnected from the control PCB and the code continues when the thermistor is reconnected to the control PCB, contact your cutting machine supplier or regional Hypertherm Technical Service team. They can help you decide if control PCB replacement is necessary. Refer to...
  • Page 326 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 327 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 328 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 329: Table 38 - Minimum And Maximum Ohmic Resistance Values For Thermistors

    9. If the thermistor resistance is within range when the thermistor is disconnected from the control PCB and the code continues when the thermistor is reconnected to the control PCB, contact your cutting machine supplier or regional Hypertherm Technical Service team. They can help you decide if control PCB replacement is necessary. Refer to...
  • Page 330 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. 809480 Instruction Manual...
  • Page 331 Do not exceed the recommended pressures. 5. If the pressure remains too low, examine the gas hoses and gas inlet fittings. Look for: Damage or kinks that can restrict flow.  Leaks that can decrease pressure.  XPR300 Instruction Manual 809480...
  • Page 332 11. 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 333 7. Replace any fitting that has damage. 8. Tighten loose connections if found. 9. If you cannot find or resolve the problem with these corrective actions, contact your cutting machine supplier or regional Hypertherm Technical Service team. XPR300 Instruction Manual...
  • Page 334 Ar gas regulators inside the OptiMix gas connect console (078633) are set at Hypertherm. They are set when the process gas is flowing with 7.9 bar – 8.6 bar (115 psi – 125 psi) pressure on the gas inlet and 6.9 bar (100 psi) on the gas outlet. A downstream 1.6 mm (0.063 inch) orifice is part of both regulator configurations.
  • Page 335 /Air (Ar pierce assist) mild steel  3. Remove the cover for OptiMix gas connect console. 4. Pull up the Ar regulator knob so the orange indicator is visible. 5. Go to Gas System in the XPR web interface. XPR300 Instruction Manual 809480...
  • Page 336 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. 809480 Instruction Manual...
  • Page 337 3. If the gas inlet pressure is not within the acceptable range, adjust it a. Use a 2-stage regulator that can delivery the necessary gas flow and can maintain consistent gas pressure with high-pressure gas cylinders. XPR300 Instruction Manual 809480...
  • Page 338 5. If you have a Core or VWI gas connect console, or if the code continues, or if you cannot find or resolve the problem with these corrective actions, contact your cutting machine supplier or regional Hypertherm Technical Service team. How to do a gas leak test (VWI and OptiMix)
  • Page 339 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 340 1. Obtain an empty container that has a capacity of at least 3.79 liters (1 US gallon) and volume measurements, if possible. 2. Remove the power from the cutting system. Refer to Remove the power from the cutting system on page 240. 809480 Instruction Manual XPR300...
  • Page 341 Replace all of the coolant on page 254.  Hypertherm recommends coolant replacement every 6 months. For complete preventive maintenance information, refer to the XPR Preventive Maintenance Program (PMP) Instruction Manual (809490). 12. If coolant flow remains slow after replacement, verify that the following function and components...
  • Page 342  13. If you cannot find or resolve the problem with these corrective actions, contact your cutting machine supplier or regional Hypertherm Technical Service team. How to test continuity between the nozzle and workpiece 1. Remove the power from the cutting system. Refer to Remove the power from the cutting system on page 240.
  • Page 343 3. Install a temporary jumper wire between J5 (nozzle) and J1 (work) on the start circuit PCB 4 (141360). NOTICE Never fire an arc when a temporary jumper wire is installed on the PCB. Sparking and damage to the PCB can occur. XPR300 Instruction Manual 809480...
  • Page 344 6. Measure the ohms between the nozzle and the workpiece. Less than 3 ohms is good. A value greater than 3 ohms indicates a faulty connection between the torch and ignition console, or between the ignition console and the power supply, or between the power supply work lead and workpiece. 809480 Instruction Manual XPR300...
  • Page 345 Chopper 2 PCB 3 J9 pin 1 J9 pin 2 Coolant temperature PCB 1 J1.2 pin 7 J1.2 pin 8 2. Look for a resistance value that is outside of the minimum or maximum in Table XPR300 Instruction Manual 809480...

  • Page 346: Table 39 - Minimum And Maximum Ohmic Resistance Values For Thermistors

    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 347 3. Disconnect the ohmic relay connector to access the bullet connector on the torch receptacle block-side located inside the torch connect console. 4. Use a digital multimeter to measure the resistance from the torch tip to the ohmic relay. Refer to Figure 65 on page 348. XPR300 Instruction Manual 809480...
  • Page 348 J4 connector is not clamped onto the wire insulation and that the connection between the J2 or J2A connector and the relay coil is good.  If the connections are good but there is no 24 VDC, contact your cutting machine supplier or regional Hypertherm Technical Service Team. 809480 Instruction Manual XPR300...
  • Page 349 If LED D2 is not illuminated, replace the ohmic contact board (141368). h. If LED D2 is illuminated and D15 is not, examine the wiring harness between both boards. Look for loose wiring. 12. If the code continues, contact your cutting machine supplier or regional Hypertherm Technical Service Team. XPR300...
  • Page 350 Diagnostics and Troubleshooting PCB information Plasma power supply power distribution PCB (141425) Signal 120 VAC 809480 Instruction Manual XPR300...
  • Page 351 Diagnostics and Troubleshooting Plasma power supply control PCB (141322) PROG WIFI MODE SEL D104 D105 D108 ENABLE CNC +24V OUT DISABLE D103 D100 XPR300 Instruction Manual 809480...
  • Page 352 COOLANT SOLENOID MAG FAN 2 FEEDBACK D100 PUMP ENABLE MAG FAN 1 FEEDBACK +15 V +3.3 V -15 V MAGNETIC FANS ENABLE +5 V HEAT EXCHANGER FAN ENABLE +24 V COOLANT FLOW D103 COOLANT LEVEL REMOTE ON-OFF 809480 Instruction Manual XPR300...
  • Page 353 Wireless module transmit: Default is ON OFF = Disabled ON = From J20 programming connector Wireless module transmit Default is OFF OFF = Disabled ON = Wireless disabled Wireless enable Default is OFF OFF = Wireless enabled XPR300 Instruction Manual 809480...
  • Page 354 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 355 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 356 Diagnostics and Troubleshooting Plasma power supply fan power distribution PCB (141384) 809480 Instruction Manual XPR300...
  • Page 357 Diagnostics and Troubleshooting Gas connect console control PCB (141375) Signal Signal +24 V CAN RX Status Activity USBFLAG +3.3 V +5 V CAN TX A3.3 XPR300 Instruction Manual 809480...
  • Page 358 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 359 +3.3 V USB FLAG +5 V CAN RX +24 V CAN TX V1 TORCH VALVE V2 (NOT USED IN THIS SYSTEM) V3 (NOT USED IN THIS SYSTEM) HV RELAY (NOT USED IN THIS SYSTEM) OHMIC CONTACT XPR300 Instruction Manual 809480...
  • Page 360 Diagnostics and Troubleshooting 809480 Instruction Manual XPR300...
  • Page 361 Parts List Plasma power supply Part number Voltage (AC) 078620 078621 078622 078623 078624 078625 078626 078627 078628 078629 XPR300 Instruction Manual 809480...
  • Page 362 Side panel with labels and handles 101300 Base 428725 Front panel with “H” (not shown) and power-indicator 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 363 CAB FAN4 HX FAN1, Fan: 890 cfm, 48 VDC, 254 mm (10 inch) HX FAN2, 229822 diameter MAG FAN1, MAG FAN2 229717 Heat-exchanger only – 003266 Solid state relay – 141384 Fan power distribution PCB PCB6 XPR300 Instruction Manual 809480...
  • Page 364 Parts List Coolant system Part number Description Quantity 127014 Coolant reservoir cap 229741 Coolant flow meter 229775 Coolant level sensor 101281 Coolant filter bracket 809480 Instruction Manual XPR300...
  • Page 365 Coolant solenoid valve assembly 229654 Thermistor: Copper pipe clip with electrical connector 127559 Coolant pump screen (coarse) 229843 Plug and O-ring 002561 Coolant reservoir 006113 Coolant check valve 428330 Kit: Tubing (1 inch hose not included) XPR300 Instruction Manual 809480...
  • Page 366 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 809480 Instruction Manual XPR300...
  • Page 367 Elbow fitting: 1/2 inch tube X 1/2 inch on the back of the choppers (4) 015815 tube, 90° and the heat-exchanger inlet (1) 015820 Fitting: 1/2 inch tube X 1/2 inch tube heat-exchanger outlet XPR300 Instruction Manual 809480...
  • Page 368 400 V, 50 Hz – 415 V, 50 Hz – 440 V, 50 Hz – 60 Hz – 480 V, 60 Hz – 600 V, 60 Hz * You cannot purchase this part. Shown for reference only. 809480 Instruction Manual XPR300...
  • Page 369 380 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 370 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 371 Parts List Part number Description Designator Quantity 229711 XPR300 wire harness – CAN cable 0.5 m (1.6 ft) (not shown) Located between the control PCB and 223399 – Chopper 2. CAN cable 1 m (3.3 ft) (not shown) 223400 –...
  • Page 372 VDC3 PCB (Optional, for use with RS-422 141511 – and discrete cutting systems) Gas connect consoles Core OptiMix Part number Description 078631 Core gas connect console 078632 VWI gas connect console 078633 OptiMix gas connect console 809480 Instruction Manual XPR300...
  • Page 373 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 XPR300 Instruction Manual 809480...
  • Page 374 #8 male Green ring: 0.87 inches 015898 Core, VWI, OptiMix – inner diameter Red ring: 0.87 inches inner 015899 Core, VWI, OptiMix – diameter 075218 Washer Core, VWI, OptiMix – 075140 Bolt Core, VWI, OptiMix – 809480 Instruction Manual XPR300...
  • Page 375 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) XPR300 Instruction Manual 809480...
  • Page 376 Parts List VWI gas connect console input and output manifolds and adapters 809480 Instruction Manual XPR300...
  • Page 377 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 378 Parts List OptiMix gas connect console input and output manifolds and adapters 809480 Instruction Manual XPR300...
  • Page 379 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’ 20 015197 1/8 inch NPT X #5 XPR300 Instruction Manual 809480...
  • Page 380 Quantity 229703 Mixer module OptiMix – Kit: Mixer module and cable 528057 OptiMix – ties 011101 Regulator OptiMix – 223398 Pressure transducer VWI and OptiMix P6 – P9 006167 Solenoid valve VWI and OptiMix B4, B5 809480 Instruction Manual XPR300...
  • Page 381 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 382 Torch lead connector – Machine screw: M6 X 10 mm 075544 – 4 (3 shown) Phillips, pan head Torch connect console – top Part number Description Designator Quantity 428338 Kit: Tubing – 006152 Check valve – 809480 Instruction Manual XPR300...
  • Page 383 Ohmic contact PCB PCB2 Green power-indicator LED 229825 – 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 384 Adapter: 1/8 inch NPT O-ring seal X – 1/4 inch tube 428756 Bottom manifold assembly: – • Bottom manifold • Adapter • Critical orifice • Solenoid valve 015811 Adapter: 1/4 inch NPT O-ring seal X 8 mm – tube 809480 Instruction Manual XPR300...
  • Page 385 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 386 Preventive maintenance 044028 kits on page 401.) 006155 Torch solenoid valve (V1) 229918 Torch solenoid valve (V1) tool 006169 Torch solenoid valve connector 428488 Torch assembly, 300 A mild steel consumables 104879 2.25 inch spanner wrench 809480 Instruction Manual XPR300...
  • Page 387 Parts List Torch bracket Part number Description 428646 Torch lifter bracket: 2.25 inch diameter sleeve XPR300 Instruction Manual 809480...
  • Page 388 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 389 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 390 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 391 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 392 Parts List Other consumable and torch parts Part number Description 004630 Pit depth gauge 004629 Gauge point 027055 Silicone lubricant, 1/4 ounce 104119 Consumable tool 428764 XPR robotic torch teach accessory 429013 XPR electrode torque tool 809480 Instruction Manual XPR300...
  • Page 393 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 36. XPR300 Instruction Manual 809480...
  • Page 394 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 395 6 m (19.7 feet) 428983 18 m (59.1 feet)* 428467 7.5 m (24.6 feet) – – * The 18 meter (59.1 feet) assembly is compatible only with the 2 meter (6.6 feet) or 2.5 meter (8.2 feet) torch lead. XPR300 Instruction Manual 809480...
  • Page 396 6 m (19.7 feet) 428980 18 m (59.1 feet)* 428366 7.5 m (24.6 feet) – – * The 18 meter (59.1 feet) assembly is compatible only with the 2 meter (6.6 feet) or 2.5 meter (8.2 feet) torch lead. 809480 Instruction Manual XPR300...
  • Page 397 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 398 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 36. 809480 Instruction Manual XPR300...
  • Page 399 428836 4.5 m (14.8 feet) 428978 6 m (20 feet)* 428979 6 m (20 feet)* * The 6 meter (20 feet) lead is compatible only with gas assemblies that are 7.5 meters (24.6 feet) or less. XPR300 Instruction Manual 809480...
  • Page 400 7.5 m (24.6 feet) 124032 35 m (114.8 feet) 124028 10 m (32.8 feet) 124033 45 m (147.6 feet) 124029 15 m (49.2 feet) 124034 60 m (196.9 feet) 124030 20 m (65.6 feet) 124035 75 m (246.1 feet) 809480 Instruction Manual XPR300...
  • Page 401 Part number Description 428639 Kit: Filter, torch rebuild without coolant 428640 Kit: Filter, torch rebuild with coolant 428920 Kit: Shield-fluid treatment 428641 Kit: Electronics (200 V – 240 V) 428642 Kit: Electronics (380 V – 600 V) XPR300 Instruction Manual 809480...
  • Page 402 Parts List Tools Part number Description 229917 Torch connect console solenoid valve tool 229918 Torch solenoid valve tool 104879 2.25 inch spanner wrench 004629 Pit depth gauge 104119 Consumable tool 1-13897 (Hypertherm Waterjet part number) TDS meter 809480 Instruction Manual XPR300...
  • Page 403 Part number Description Designator Quantity 011110 Air filter element – 223398 Pressure transducer (VWI and OptiMix only) P6 – P9 006167 Solenoid valve (VWI and OptiMix only) B4 – B5 141354 High-frequency, high-voltage ignition PCB PCB2 XPR300 Instruction Manual 809480...
  • Page 404 B1 – B3 229965 Solenoid valve V4 – V12 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 – 809480 Instruction Manual XPR300...
  • Page 405 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. XPR300 Instruction Manual 809480...
  • Page 406 Parts List 809480 Instruction Manual XPR300...
  • Page 407 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 408 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 409 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 410 Process IDs: 1001, 1002, 1003, 1152, 1153, 1155, 1004, 1005, 1151, 1156 Block type Preflow /Air Cutflow /Air Piercing /Air Process IDs: 7001, 7004, 7005, 7007, 7008, 7009, 7010, 7011, 7012, 7013, 7018 Block type Preflow /Air Cutflow /Air Piercing 809480 Instruction Manual XPR300...
  • Page 411 Block type Preflow Cutflow Piercing Process IDs: 2010, 2011, 2028, 2052, 2055, 2058 Block type Preflow Cutflow Piercing Process IDs: 2053, 2056, 2059, 2060, 2061, 2062, 2063, 2064, 2065, 2066 Block type Preflow Mix/N Cutflow Mix/N Piercing XPR300 Instruction Manual 809480...
  • Page 412 Process IDs: 1102, 1101 Block type /Air Preflow /Air Cutflow /Air Piercing Process IDs: 1103, 1104, 1105, 1106, 1107 Block type /Air Preflow /Air Cutflow Piercing /Air Process IDs: 1207 Block type Preflow /Air Cutflow /Air Piercing 809480 Instruction Manual XPR300...
  • Page 413 Process IDs: 2001, 2002, 2003, 2004, 2005 Block type Preflow F5/N Cutflow F5/N Piercing Process IDs: 2006, 2007, 2012, 2013, 2014, 2015, 2024, 2025, 2026 Block type Preflow Cutflow Piercing Process IDs: 2008, 2009 Block type Preflow /Air Cutflow Air/Air Piercing Air/N XPR300 Instruction Manual 809480...
  • Page 414 Process IDs: 9004, 9005, 9006, 9014, 9015, 9016, 9017 Block type Preflow Ar/N Ar/N Cutflow Ar/N Piercing Process ID: 8007 Block type /Air Preflow /Air Cutflow /Air Piercing Process ID: 9007 Block type Preflow Ar/Air Cutflow Ar/Air Piercing Ar/Air 809480 Instruction Manual XPR300...
  • Page 415 Preflow Ar/N Cutflow Ar/N Ar/N Piercing Process IDs: 1202, 1204, 1207 Block type Preflow Cutflow Piercing Process IDs: 2027, 2101 Block type /Air Preflow Cutflow Air/Air Piercing Air/Air Process ID: 8002 Block type Preflow Cutflow Piercing XPR300 Instruction Manual 809480...
  • Page 416 Process IDs: 9011, 9012, 9013 Block type Ar/N Preflow Ar/N Cutflow Ar/N Piercing Process IDs: 1060, 1061, 7016, 7017 Block type /Air Preflow /Air Cutflow /Air Piercing Process ID: 1157 Block type /Air Preflow /Air Cutflow Piercing 809480 Instruction Manual XPR300...
  • Page 417 Overview (Sheet 1 of 22) 013403 013403...
  • Page 418 Plasma power supply 1 (Sheet 2 of 22) 013403...
  • Page 419 Plasma power supply 2 (Sheet 3 of 22) 013403...
  • Page 420 Plasma power supply 3 (Sheet 4 of 22) 013403...
  • Page 421 Plasma power supply 4 (Sheet 5 of 22) 013403...
  • Page 422 Plasma power supply 5 (Sheet 6 of 22) 013403...
  • Page 423 Plasma power supply 6 (Sheet 7 of 22) 013403...
  • Page 424 Plasma power supply 7 (Sheet 8 of 22) 013403...
  • Page 425 Gas connect console 1 (Sheet 9 of 22) 013403...
  • Page 426 Gas connect console 2 (Sheet 10 of 22) 013403...
  • Page 427 Torch connect console (Sheet 11 of 22) 013403...
  • Page 428 Coolant system (Sheet 12 of 22) 013408...
  • Page 429 Gas system 1 (Sheet 13 of 22) 013403...
  • Page 430 Gas system 2 (Sheet 14 of 22) 013403...
  • Page 431 Gas system 3 (Sheet 15 of 22) 013403...
  • Page 432 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 433 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 434 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 435 EtherCAT connection to EDGE Connect/TC (Sheet 19 of 22) Notes: 1. Hypertherm EDGE Connect/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 436 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 437 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 438 Wireless subsystem block diagram (Sheet 22 of 22) 013403...

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