Hypertherm XPR300 Replacement Part Procedures
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Hypertherm XPR300 Replacement Part Procedures

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XPR300™
Replacement Part Procedures
Field Service Bulletin
809970 | Revision 1 | January 2019

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Summary of Contents for Hypertherm XPR300

  • Page 1 XPR300™ Replacement Part Procedures Field Service Bulletin 809970 | Revision 1 | January 2019...
  • Page 2 One of Hypertherm’s long-standing core values is a focus on minimizing our impact on the environment. Doing so is critical to our, and our customers’, success. We are always striving to become better environmental stewards; it is a process we care deeply about.
  • Page 3 한국어 / KOREAN product worden meegeleverd. De handleidingen, elke handleiding 경고! Hypertherm 장비를 사용하기 전에 제품 설명서와 안전 및 규정 beschikbaar in alle talen, zijn ook verkrijgbaar via de “Documentenbibliotheek” 준수 설명서 (80669C)에 나와 있는 안전 지침을 읽으십시오. 안전 지침을...
  • Page 4 Kópia návodu, ktorá je dodávaná s produktom, môže mať elektronickú alebo tlačenú podobu. Kópie návodov, vo všetkých dostupných jazykoch, sú k dispozícii aj v sekcii z „knižnice Dokumenty“ na www.hypertherm.com.

  • Page 5: Table Of Contents

    Replace the coolant pump and motor assembly ................27 Remove the coolant pump and motor assembly..............27 Install the coolant pump and motor assembly ..............28 Left-side (control-side) parts..........................30 Replace the chopper ..........................30 Remove the chopper ........................30 XPR300 Field Service Bulletin 809970...
  • Page 6 Replace the coil assembly ..........................71 Remove the coil assembly........................71 Install the coil assembly ......................... 73 Replace the EMI filter............................74 Replace the control PCB ..........................75 Replace the 24 V power source........................76 809970 Field Service Bulletin XPR300...
  • Page 7 Replace the bottom manifold assembly...................... 111 Remove the bottom manifold assembly ..................111 Install the bottom manifold assembly ....................113 Torch connect console top panel and side panels................... 114 4 Torch............................115 Replace the solenoid valve ..........................116 XPR300 Field Service Bulletin 809970...
  • Page 8 Pilot arc lead with strain relief ......................150 Negative lead with strain relief ......................150 Power cable............................151 Coolant hose set ..........................151 CAN cable ............................. 152 Gas connect console to torch connect console connections............... 152 809970 Field Service Bulletin XPR300...
  • Page 9 Plasma power supply – recommended spare parts ..............159 Gas connect consoles – recommended spare parts ..............160 Torch connect console – recommended spare parts..............160 Torch – recommended spare parts....................160 Descriptions of warning label icons....................161 XPR300 Field Service Bulletin 809970...
  • Page 10 Contents 809970 Field Service Bulletin XPR300...

  • Page 11: Plasma Power Supply

    Disconnect electrical power before doing any installation or maintenance. All work requiring removal of the plasma power supply outer cover or panels must be done by a qualified technician. See the Safety and Compliance Manual (80669C) for more safety precautions. XPR300 Field Service Bulletin 809970...

  • Page 12: How To Use Push-To-Connect Fittings

    Replace any tubing that is damaged. If you reuse damaged tubing, it can result in leaks.  Used tubing can have an indentation on the end that can cause leaks. To prevent leaks, trim the tubing to remove the indentation. 809970 Field Service Bulletin XPR300...

  • Page 13: Front Parts

    4. Disconnect the fan wire connector. 5. Remove the fan and bracket assembly. 6. Use a 4 mm, hexagonal-socket wrench to remove the 3 nuts from the fan. 7. Remove the fan from the bracket. XPR300 Field Service Bulletin 809970...

  • Page 14: Install The Magnetics Fans

    3. Put the bottom of the fan and bracket assembly into the sheet metal tab. 4. Connect the fan wire connector. 5. Use a 10 mm, hexagonal-socket wrench to install the nut. 6. Install the front panel. 809970 Field Service Bulletin XPR300...

  • Page 15: Right-Side (Liquid-Cooling-Side) Parts

    5. Use a 13/16-inch, open-ended wrench to remove the fitting from the flow meter. 6. Apply liquid thread sealant to the fitting threads. NOTICE Never use PTFE tape on any joint preparation. Use only a liquid or paste thread sealant on male thread ends. XPR300 Field Service Bulletin 809970...
  • Page 16 10. Connect the tube to the push-to-connect fitting in the flow meter. See How to use push-to-connect fittings on page 12. 11. Install all of the panels. 12. Add coolant to fill the tank. 809970 Field Service Bulletin XPR300...

  • Page 17: Replace The Coolant Level Sensor

    9. Use the XPR web interface to make sure that the coolant sensor operates correctly.  For more information on the XPR web interface, see the Connect for Communication in the XPR300 Instruction Manual (809480). XPR300 Field Service Bulletin 809970...

  • Page 18: Replace A Heat-Exchanger Fan

    3. Remove the push-to-connect fittings from the inlet and the outlet of the heat-exchanger assembly, and immediately put the ends of the hoses in a container. 4. Disconnect the wire connector for the coolant thermistor. 809970 Field Service Bulletin XPR300...
  • Page 19 7. Pull the heat-exchanger panel away from the center panel. 8. Remove the 4 screws that connect the fan to the heat-exchanger assembly.  Repeat this step for both fans, if applicable. 9. Remove the fan. XPR300 Field Service Bulletin 809970...

  • Page 20: Install A Heat-Exchanger Fan

    6. Pull back on the fittings to make sure the connection is tight. 7. Remove the tape and protective material from the rear panel of the heat-exchanger assembly. 8. Add coolant to fill the tank. 9. Install all of the panels. 809970 Field Service Bulletin XPR300...

  • Page 21: Replace The Heat-Exchanger Assembly

    2. Remove the push-to-connect fittings from the inlet and the outlet of the heat-exchanger assembly, and immediately put the ends of the hoses in a container. 3. Carefully remove the copper clip and thermistor from the pipe.  Do not deform the copper clip. XPR300 Field Service Bulletin 809970...

  • Page 22: Install The Heat-Exchanger Assembly

    2. Use 4 screws to install each fan onto the new heat-exchanger assembly. 3. Use the nuts to install the new heat-exchanger assembly onto the heat-exchanger panel in the plasma power supply. 4. Push the heat-exchanger panel back into position. 809970 Field Service Bulletin XPR300...
  • Page 23 8. Connect the coolant hose fittings to the heat-exchanger assembly. 9. Remove the tape and protective material from the rear panel of the heat-exchanger assembly. 10. Add coolant to fill the tank. 11. Install all of the panels. XPR300 Field Service Bulletin 809970...

  • Page 24: Replace The Coolant Thermistor

    8. Use the XPR web interface to make sure that there are no coolant temperature errors.  For more information on the XPR web interface, see the Connect for Communication in the XPR300 Instruction Manual (809480). 809970 Field Service Bulletin...

  • Page 25: Replace The Solid State Relay

    5. Use the 2 mounting screws to install the solid state relay with T1, 2 in the upper-left corner, as shown. 6. Install the wires as shown and tighten the wire screws. 7. Install the right side panel. XPR300 Field Service Bulletin 809970...

  • Page 26: Replace The Fan Power Distribution Pcb

    J4 for the bottom heat-exchanger fan  J5 for the magnetics fan  J6 for the control PCB  J7 for the top control-side fan  J8 for the bottom control-side fan  8. Install the right-side (liquid-cooling-side) panel. 809970 Field Service Bulletin XPR300...

  • Page 27: Replace The Coolant Pump And Motor Assembly

    See Remove the right-side (liquid-cooling-side) panel on page 60. c. Drain the coolant. See Remove old coolant from the coolant system in the Maintenance section in the XPR300 Instruction Manual (809480).  Keep all nuts and screws that you remove.

  • Page 28: Install The Coolant Pump And Motor Assembly

    9. Use a 1-1/2 inch, open-ended wrench to install the 1 inch hose to the pump fitting. Tighten the fitting to 47 N∙m (416 in∙lb). 10. Connect the solenoid valve connector (J7) to the wire harness. 809970 Field Service Bulletin XPR300...
  • Page 29 11. Connect the power connector (J21) to the motor. 12. Install the liquid-cooling-side panel. 13. Install the coolant. See the Coolant Installation section in the XPR300 Instruction Manual (809480). 14. Use the XPR web interface to make sure that the coolant pump and motor assembly operates correctly.

  • Page 30: Left-Side (Control-Side) Parts

    See Remove the left-side (control-side) panel on page 61. d. Drain the coolant. See Remove old coolant from the coolant system in the Maintenance section in the XPR300 Instruction Manual (809480).  Keep all nuts and screws that you remove.
  • Page 31 3. Remove the push-to-connect fittings and retaining nuts from the rear of the chopper that you want to replace. See How to use push-to-connect fittings on page 12. 1 Chopper 1 fittings and retaining nuts 2 Chopper 2 fittings and retaining nuts XPR300 Field Service Bulletin 809970...
  • Page 32 Inductor leads (J4, J5). Use a 16 mm wrench. 5. Use a 10 mm, hexagonal-socket wrench to remove the 2 nuts 6. Lift the chopper up and out of the tabs , then remove the chopper from the plasma power supply. 809970 Field Service Bulletin XPR300...

  • Page 33: Install The Chopper

    5. If you spilled any coolant inside the plasma power supply, clean inside the plasma power supply. 6. Remove the tape and protective material from the rear panel of the heat-exchanger assembly. 7. Install the side panels. 8. Install the coolant. See the Coolant Installation section in the XPR300 Instruction Manual (809480). XPR300...

  • Page 34: Replace The Control-Side Fans

    See Remove the left-side (control-side) panel on page 61.  Keep all nuts and screws that you remove. 2. On the liquid-cooling side of the plasma power supply, remove J7 and J8 from the fan power distribution PCB. 809970 Field Service Bulletin XPR300...
  • Page 35 2 nuts from the bracket assembly. 4. Remove the bracket assembly from the plasma power supply. 5. Remove the 2 screws from the control-side fan that you want to replace. XPR300 Field Service Bulletin 809970...

  • Page 36: Install The Control-Side Fans

    5. Route the fan wires through the center panel of the plasma power supply. 6. Connect the control-side fans to the fan power distribution PCB: J7 for the top fan  J8 for the bottom fan  7. Install the side panels. 809970 Field Service Bulletin XPR300...

  • Page 37: Replace The 48 V Power Source

    2. On the liquid-cooling side of the plasma power supply, remove J7 and J8 from the fan power distribution PCB. 3. On the control side, remove the connector covers from the power source. 4. Loosen the 4 screws to remove the wires. XPR300 Field Service Bulletin 809970...

  • Page 38: Install The 48 V Power Source

     The wire connections must point to the top of the plasma power supply. 2. Align the bracket assembly with the studs in the front sheet metal panel and the slots in the center panel. 809970 Field Service Bulletin XPR300...
  • Page 39 6. Route the fan wires through the center panel of the plasma power supply. 7. Connect the control-side fans to the fan power distribution PCB: J7 for the top fan  J8 for the bottom fan  8. Install the control-side panel. XPR300 Field Service Bulletin 809970...

  • Page 40: Replace The 24 V Power Source

    7. Install the wires L, N, +, -. Tighten the screws. 8. Install the unlabeled wires. Connect the red wire to + and white wire to -. Tighten the screws. 9. Install the control-side panel. 809970 Field Service Bulletin XPR300...

  • Page 41: Replace The Control Transformer

    4. Remove J1 from the power distribution PCB. 5. Use a 10 mm, hexagonal-socket wrench to remove the nuts and screws from the bracket on the control transformer. 6. Remove the control transformer XPR300 Field Service Bulletin 809970...

  • Page 42: Install The Control Transformer

    3. Connect J1 to the power distribution PCB. 4. Connect L1 to the front fuse and L2 to the back fuse and tighten the screws. Tighten to hand-tight. 5. Install the fuse covers. 6. Install the control-side panel. 809970 Field Service Bulletin XPR300...

  • Page 43: Replace The Power Distribution Pcb

    2. Disconnect the wire connectors from the PCB. 3. Remove the 4 screws 4. Align the new PCB with the studs. 5. Install the 4 screws. 6. Connect the wire connectors. 7. Install the control-side panel. XPR300 Field Service Bulletin 809970...

  • Page 44: Replace The Control Pcb

    9. Make sure that J21 is in the OFF position. 10. Connect all of the wire connectors. 11. Connect the communication interface cables.  Make sure that you connect the in and out cables to the correct locations. 809970 Field Service Bulletin XPR300...
  • Page 45 This includes the MAC address that is on the new MAC address label. 13. Install the control-side panel. 14. Install the rear panel. 15. If necessary, update the firmware in the system. See the XPR Firmware Updates Field Service Bulletin (809820). XPR300 Field Service Bulletin 809970...

  • Page 46: Replace The I/O Pcb

    8. Use a 17 mm, hexagonal-socket wrench to install J1.1, J1.4, and J1.5. Tighten to 13 N∙m (115 in∙lb). 9. Use an 17 mm, hexagonal-socket wrench to install J2.1, J39.2, and J39.3. Tighten to 13 N∙m (115 in∙lb). 10. Connect HRS39, HRS40, HRS3, and J5. 11. Install the control-side panel. 809970 Field Service Bulletin XPR300...

  • Page 47: Replace The Pilot Arc Relay

    Tighten the screws to 1 N∙m (10 in∙lb). 8. Use the 2 screws on the top to install the + and - wires as shown. Tighten the screws to 1 N∙m (10 in∙lb). 9. Install the cover. 10. Install the control-side panel. XPR300 Field Service Bulletin 809970...

  • Page 48: Replace Start Circuit Assembly

    6. Align the new PCB with the mounting studs. 7. Install the 3 nuts. Tighten to 9 N∙m (80 in∙lb). 8. Connect J4, J6, J7, and J8. 9. Install the control-side panel. 809970 Field Service Bulletin XPR300...

  • Page 49: Bottom-Compartment Parts

    2. Use a 10 mm, hexagonal-socket wrench to remove the nut from the top of the fan bracket. 3. Tilt the top of the bracket towards you until you get access to the fan-wire connector. 4. Disconnect the fan-wire connector. 5. Remove the fan and bracket assembly. XPR300 Field Service Bulletin 809970...
  • Page 50 2 Inductor 2 (L2) 7. Move the inductor towards the fan opening. 8. Carefully remove the black heatshrink from the 3 terminals of the inductor. 9. Remove the 3 inductor wires from the cable holder. 809970 Field Service Bulletin XPR300...
  • Page 51 12. Press the 2 side bars and then push the connector through the hole in the sheet metal to disconnect the connector for the thermal switches on the inductor. J1 for Inductor 1 (L1)  J3 for Inductor 2 (L2)  XPR300 Field Service Bulletin 809970...
  • Page 52 13. After you disconnect all of the wires, rotate the inductor 90 degrees so that the bracket points towards the fan opening. 14. Lift the inductor slightly so that the bracket goes through the bottom of the fan opening. 809970 Field Service Bulletin XPR300...

  • Page 53: Install An Inductor

    9. Put the bottom of the fan and bracket assembly into the sheet metal tab. 10. Connect the fan-wire connector. 11. Use a 10 mm, hexagonal-socket wrench to install the nut. 12. Install the liquid-cooling-side panel. 13. Install the front panel. XPR300 Field Service Bulletin 809970...

  • Page 54: Rear-Compartment Parts

    Tighten the nut and screw to 9 N∙m (80 in∙lb). 9. Connect J6. 10. Install A1 and A2. Tighten the screws to 1 N∙m (10 in∙lb). 809970 Field Service Bulletin XPR300...
  • Page 55 The wires labeled L1, L2, and L3 on the right side of the main contactor must align with the wires labeled L1, L2, and L3 on the left side of the main contactor. 12. Install the rear panel. XPR300 Field Service Bulletin 809970...

  • Page 56: Replace The Inrush Contactor

    The wires labeled L1, L2, and L3 on To inrush resistor the top of the inrush contactor must align with the wires labeled L1, L2, and L3 on the bottom of the inrush contactor. 7. Install the rear panel. 809970 Field Service Bulletin XPR300...

  • Page 57: Replace The Inrush Resistor Assembly

    Sharp cooling fins can cause cuts. Use caution when you work near the cooling fins. 3. Use a 10 mm, hexagonal-socket wrench to remove the 2 nuts on the internal sheet metal. 4. Pull in the sheet metal to access the inrush resistor. XPR300 Field Service Bulletin 809970...
  • Page 58 8. Use 2 wrenches to install the wires. Tighten to 3 N∙m (25 in∙lb). 9. Align the sheet metal panel with the studs. 10. Use the 2 nuts to install the sheet metal. 11. Install the rear and control-side panel. To inrush contactor 809970 Field Service Bulletin XPR300...

  • Page 59: Plasma Power Supply Panels

    Plasma Power Supply Plasma power supply panels  Keep all nuts and screws that you remove. Remove the front panel Use a 10 mm, hexagonal-socket wrench on the panel screws. XPR300 Field Service Bulletin 809970...

  • Page 60: Remove The Right-Side (Liquid-Cooling-Side) Panel

    Plasma Power Supply Remove the right-side (liquid-cooling-side) panel Use a 10 mm, hexagonal-socket wrench on the panel screws. 809970 Field Service Bulletin XPR300...

  • Page 61: Remove The Left-Side (Control-Side) Panel

    Plasma Power Supply Remove the left-side (control-side) panel Use a 10 mm, hexagonal-socket wrench on the panel screws. XPR300 Field Service Bulletin 809970...

  • Page 62: Remove The Rear Panel

    Plasma Power Supply Remove the rear panel Use a 10 mm, hexagonal-socket wrench on the panel screws. 809970 Field Service Bulletin XPR300...

  • Page 63: Remove The Top Panel

    Plasma Power Supply Remove the top panel Use a 4 mm, hexagonal-key wrench on the panel screws. XPR300 Field Service Bulletin 809970...
  • Page 64 Plasma Power Supply 809970 Field Service Bulletin XPR300...

  • Page 65: Gas Connect Consoles

    Disconnect electrical power before doing any installation or maintenance. All work requiring removal of the gas connect console panels must be done by a qualified technician. See the Safety and Compliance Manual (80669C) for more safety precautions. XPR300 Field Service Bulletin 809970...

  • Page 66: How To Use Push-To-Connect Fittings

    Replace any tubing that is damaged. If you reuse damaged tubing, it can result in leaks.  Used tubing can have an indentation on the end that can cause leaks. To prevent leaks, trim the tubing to remove the indentation. 809970 Field Service Bulletin XPR300...

  • Page 67: Replace The High-Frequency, High-Voltage Transformer

    Keep all nuts and screws that you remove. 2. Disconnect the wire connectors from J1, J2, and J3 from the high-frequency, high-voltage PCB. 3. Remove the wire for the coil from pin 2 on J2. XPR300 Field Service Bulletin 809970...
  • Page 68 J3 - The wire to the primary input of the high-frequency, high-voltage transformer.  10. Install the insulator panel. 11. Install the high-voltage-side panel. 12. Install the top panel. 809970 Field Service Bulletin XPR300...

  • Page 69: Replace The High-Frequency, High-Voltage Pcb

    Keep all nuts and screws that you remove. 2. Disconnect J1, J2, J3, J5, J7, J8, and the wire to the capacitor. 3. Remove the 2 screws. 4. Remove the 2 thumb screws. 5. Use the screws to install the PCB. XPR300 Field Service Bulletin 809970...
  • Page 70 J2 - The wire from the high-frequency, high-voltage transformer and wire from the coil  assembly. J3 - The wires to the primary input of the high-frequency, high-voltage transformer.  9. Install the high-voltage-side panel. 10. Install the insulator panel. 11. Install the top panel. 809970 Field Service Bulletin XPR300...

  • Page 71: Replace The Coil Assembly

    1. Complete the following procedures: a. Remove the power from the cutting system. b. Drain the coolant. See Remove old coolant from the coolant system in the Maintenance section in the XPR300 Instruction Manual (809480). c. Remove the top panel. d. Remove the insulator.
  • Page 72 The wire from J5  4. Remove the 3 mm set screw 5. Remove the pilot lead connection from the insulator panel. 6. Use a short Phillips screwdriver to remove 3 screws 7. Remove the coil assembly 809970 Field Service Bulletin XPR300...

  • Page 73: Install The Coil Assembly

    6. Install the gas connect console to torch connect console coolant lead assembly. 7. Install the high-voltage-side panel. 8. Install the insulator panel. 9. Install the top panel. 10. Install the coolant. See the Coolant Installation section in the XPR300 Instruction Manual (809480). XPR300 Field Service Bulletin...

  • Page 74: Replace The Emi Filter

    2 screws To J6 4. Use the 2 screws to install the EMI filter. 5. Install the wires as shown. 6. Install the high-voltage-side panel. 7. Install the insulator panel. 8. Install the top panel. 809970 Field Service Bulletin XPR300...

  • Page 75: Replace The Control Pcb

    PCB. 5. Connect the wire connectors to the PCB.  Make sure that the pressure transducer wires goes to the correct pressure transducer connector. 6. Install the manifold-side panel. 7. Install the top panel. XPR300 Field Service Bulletin 809970...

  • Page 76: Replace The 24 V Power Source

    7. Install the wires L, N, +, -. Tighten the screws. 8. Install the unlabeled wires. Connect the red wire to + and white wire to -. Tighten the screws. 9. Install the control-side panel. 809970 Field Service Bulletin XPR300...

  • Page 77: Replace The Air Filter Assembly

    7. Use the 2 screws to install the air filter assembly. 8. Connect the hoses to the push-to-connect fittings. See How to use push-to-connect fittings on page 66. 9. Install the top panel. XPR300 Field Service Bulletin 809970...

  • Page 78: Replace A Pressure Transducer

    5. Push the new pressure transducer into the manifold. 6. Connect the pressure transducer wire connectors.  Make sure that you connect the correct pressure transducer to the correct connector on the control PCB. For example, connect pressure transducer P7 to connector P7. 809970 Field Service Bulletin XPR300...
  • Page 79 10. Use the XPR web interface to make sure that the pressures are in the acceptable ranges.  For more information on the XPR web interface, see the Connect for Communication in the XPR300 Instruction Manual (809480). XPR300 Field Service Bulletin...

  • Page 80: Replace A Proportional Valve

    4. Use a 14 mm socket wrench to remove the nut 5. Remove the coil/solenoid 6. Remove the base cover 7. Use a T20 screwdriver to remove the 2 screws 8. Remove the base 809970 Field Service Bulletin XPR300...

  • Page 81: Install A Proportional Valve

    13. Use the XPR web interface to make sure that the pressures are in the acceptable ranges.  For more information on the XPR web interface, see the Connect for Communication in the XPR300 Instruction Manual (809480). XPR300 Field Service Bulletin...

  • Page 82: Replace A Regulator

    2. Disconnect the hoses from the push-to-connect fittings on the regulators. 3. Disconnect the 2 CAN cables from the mixer. 4. Disconnect the air hose from the push-to-connect fitting on the inlet side of the air filter. 809970 Field Service Bulletin XPR300...
  • Page 83 7. Remove the regulator nut from the regulator that you want to replace. 16 mm wrench 12 mm wrench 16 mm wrench 14 mm wrench 8. Remove the regulator from the bracket. 9. Remove the fittings from the regulator.  Keep the fittings. XPR300 Field Service Bulletin 809970...

  • Page 84: Install A Regulator

    How to set the regulators on page 85 to calibrate the regulators.  For more information on the XPR web interface, see the Connect for Communication in the XPR300 Instruction Manual (809480). 809970 Field Service Bulletin XPR300...

  • Page 85: How To Set The Regulators

    This procedure is for when the regulators need to be adjusted in the field. The N and Ar OptiMix gas connect console (078633) regulators are set at Hypertherm before the regulators are installed into the gas connect console. The regulators are set in a dynamic condition, when gas is flowing, with 7.9 bar –...

  • Page 86: Set The Ar Regulator

    4. Pop the Ar regulator knob up so the orange indicator is visible. 5. Go to Gas System in the XPR web interface. 6. Choose TEST PIERCEFLOW. 7. Adjust the regulator until the shield inlet sensor (P4) reads 6.9 bar (100 psi) on the web interface. 809970 Field Service Bulletin XPR300...

  • Page 87: Gas Connect Console Panels

    Gas Connect Consoles Gas connect console panels Use a 3 mm, hexagonal-key wrench on all external panel screws. 4 mm, hexagonal-key wrench XPR300 Field Service Bulletin 809970...
  • Page 88 Gas Connect Consoles 809970 Field Service Bulletin XPR300...

  • Page 89: Torch Connect Console

    Disconnect electrical power before doing any installation or maintenance. All work requiring removal of the torch connect console panels must be done by a qualified technician. See the Safety and Compliance Manual (80669C) for more safety precautions. XPR300 Field Service Bulletin 809970...

  • Page 90: How To Use Push-To-Connect Fittings

    Replace any tubing that is damaged. If you reuse damaged tubing, it can result in leaks.  Used tubing can have an indentation on the end that can cause leaks. To prevent leaks, trim the tubing to remove the indentation. 809970 Field Service Bulletin XPR300...

  • Page 91: Replace The Ohmic Pcb

    9. Use the 3 screws to install the PCB. Tighten to 6.9 kg∙cm (6 in∙lb). 10. Connect the wires J1, J2, J3, and J4.  Make sure that you connect the ohmic wires to where you removed them. The location of the ohmic wires varies by system setup. XPR300 Field Service Bulletin 809970...
  • Page 92 Torch Connect Console 11. Connect the yellow plasma hose. 12. Install the side panels. 13. Install the top panel. 809970 Field Service Bulletin XPR300...

  • Page 93: Replace The Ohmic Relay And Bracket

    Remove the power from the cutting system. b. Drain the coolant. See Remove old coolant from the coolant system in the Maintenance section in the XPR300 Instruction Manual (809480). c. Remove the top panel. d. Remove the torch-side panel.

  • Page 94: Install The Ohmic Relay And Bracket

    5. Install the water hose, coolant hoses, and pilot arc lead. 6. Install the torch-side panel. 7. Install the top panel. 8. Install the coolant. See the Coolant Installation section in the XPR300 Instruction Manual (809480). 809970 Field Service Bulletin...

  • Page 95: Replace A Pressure Transducer

    2. Disconnect the wire connector that goes to the pressure transducer that you want to replace. 3. Use a 10 mm open-ended wrench to remove the pressure transducer. 4. Use a 10 mm open-ended wrench to install the pressure transducer. Tighten to 2.3 N∙m (20 in∙lb). XPR300 Field Service Bulletin 809970...
  • Page 96 9. Use the XPR web interface to make sure that the pressures are in the acceptable ranges.  For more information on the XPR web interface, see the Connect for Communication in the XPR300 Instruction Manual (809480). 809970 Field Service Bulletin XPR300...

  • Page 97: Replace A Solenoid Valve (V4-V10, V12)

    Keep all nuts and screws that you remove. 2. Use the edge of the connector to disconnect the wire from the control PCB.  Be careful not to pull the wires out of the solenoid valve connector. XPR300 Field Service Bulletin 809970...
  • Page 98 Tighten to 2.5 N∙m (22.1 in∙lb).  Rotate the valve as you install it to prevent the O-rings from rolling. 5. Install the top panel. 6. Supply the gas pressure to the cutting system. 809970 Field Service Bulletin XPR300...

  • Page 99: Replace The Solenoid Valve (V11)

    Remove the gas pressure from the cutting system. c. Drain the coolant. See Remove old coolant from the coolant system in the Maintenance section in the XPR300 Instruction Manual (809480). d. Remove the top panel. e. Remove the side panels.
  • Page 100 8. Use a 3 mm, hexagonal-key wrench to remove the 2 screws that hold the manifold assembly in the bottom of the torch connect console. 9. Slide the manifold assembly with control PCB back and lift out. 809970 Field Service Bulletin XPR300...

  • Page 101: Install The Solenoid Valve (V11)

    8. Install the ohmic relay and bracket. See Install the ohmic relay and bracket on page 94. 9. Install the power connector (J19), ohmic board connector (J27) and V1 connector (J7) on the control PCB. 10. Connect the gas supply hoses. 11. Install the side panels. XPR300 Field Service Bulletin 809970...
  • Page 102 Torch Connect Console 12. Install the top panel. 13. Install the coolant. See the Coolant Installation section in the XPR300 Instruction Manual (809480). 14. Supply the gas pressure to the cutting system. 809970 Field Service Bulletin XPR300...

  • Page 103: Replace The Control Pcb

    2. Disconnect and remove the pressure transducers. See Replace a pressure transducer on page 95. 3. Disconnect all of the wires from the PCB. 4. Remove the 5 screws from the PCB. 5. Tilt the end of the PCB up and pull the PCB out. XPR300 Field Service Bulletin 809970...

  • Page 104: Install The Control Pcb

    9. Use the XPR web interface to make sure that the pressures are in the acceptable ranges.  For more information on the XPR web interface, see the Connect for Communication in the XPR300 Instruction Manual (809480). 809970 Field Service Bulletin...
  • Page 105 Torch Connect Console Table 1 – Solenoid valve connectors Valve Connector Table 2 – Pressure transducer connectors Transducer Connector XPR300 Field Service Bulletin 809970...

  • Page 106: Replace A Proportional Valve

    5. Use a 14 mm, hexagonal-socket wrench to remove the nut 6. Remove the coil/solenoid 7. Pull the base cover to remove. 8. Use a T20 screwdriver to remove the 2 screws 9. Pull the base to remove. 809970 Field Service Bulletin XPR300...

  • Page 107: Install A Proportional Valve

    6. Install the nut. Tighten to 3.3 N∙m (29 in∙lb). 7. Install the connector. 8. Install the screw. 9. Install the control PCB. See Install the control PCB on page 104. 10. Install the manifold-side panel. 11. Install the top panel. XPR300 Field Service Bulletin 809970...

  • Page 108: Replace The Manifold Assembly

    Remove the gas pressure from the cutting system. c. Drain the coolant. See Remove old coolant from the coolant system in the Maintenance section in the XPR300 Instruction Manual (809480). d. Remove the top panel. e. Remove the side panels.

  • Page 109: Install The Manifold Assembly

    5. Install the ohmic relay and bracket. See Install the ohmic relay and bracket on page 94. 6. Install control PCB. See Install the control PCB on page 104. 7. Connect the gas supply hoses. XPR300 Field Service Bulletin 809970...
  • Page 110 Torch Connect Console 8. Install the side panels. 9. Install the top panel. 10. Install the coolant. See the Coolant Installation section in the XPR300 Instruction Manual (809480). 11. Supply the gas pressure to the cutting system. 809970 Field Service Bulletin...

  • Page 111: Replace The Bottom Manifold Assembly

    Remove the gas pressure from the cutting system. c. Drain the coolant. See Remove old coolant from the coolant system in the Maintenance section in the XPR300 Instruction Manual (809480). d. Remove the top panel. e. Remove the side panels.
  • Page 112 Be careful not to pull the wires out of the solenoid valve connector. 11. Use a 5 mm, hexagonal-key wrench to remove the 4 screws from the bottom manifold assembly. 12. Remove the bottom manifold assembly 13. Remove the O-ring from the inlet manifold. 809970 Field Service Bulletin XPR300...

  • Page 113: Install The Bottom Manifold Assembly

    10. Install the power connector (J19), ohmic board connector (J27) and V1 connector (J7) on the control PCB. 11. Install the side panels. 12. Install the top panel. 13. Install the coolant. See the Coolant Installation section in the XPR300 Instruction Manual (809480). 14. Supply the gas pressure to the cutting system. XPR300...

  • Page 114: Torch Connect Console Top Panel And Side Panels

    Torch Connect Console Torch connect console top panel and side panels Use a 3 mm, hexagonal-key wrench on all external panel screws. 809970 Field Service Bulletin XPR300...

  • Page 115: Torch

    Torch WARNING ELECTRIC SHOCK CAN KILL Disconnect electrical power before doing any installation or maintenance. See the Safety and Compliance Manual (80669C) for more safety precautions. XPR300 Field Service Bulletin 809970...

  • Page 116: Replace The Solenoid Valve

    Pull the collar away from the torch 3. Remove the torch mounting sleeve: a. Loosen the torch mounting sleeve. b. Pull the torch mounting sleeve away from the torch. 4. Disconnect the plasma valve connector. Plasma valve connector 809970 Field Service Bulletin XPR300...
  • Page 117 9. Reposition the collar on the torch-end of the torch lead: a. Pull the collar towards the torch-end of the torch lead assembly. b. Tighten the hose clamp that holds the collar in position. Tighten the clamp Pull the collar toward the torch XPR300 Field Service Bulletin 809970...
  • Page 118 Torch 809970 Field Service Bulletin XPR300...

  • Page 119: Parts List

    Parts List Plasma power supply Part number Voltage (AC) 078620 078621 078622 078623 078624 078625 078626 078627 078628 078629 XPR300 Instruction Manual 809970...

  • Page 120: Outer Panels

    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 809970 Instruction Manual XPR300...

  • Page 121: Fans

    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 809970...

  • Page 122: Coolant System

    Adapter: 1 inch MNPT X 3/8 inch FNPT X 1/4 inch FNPT Adapter: 3/8 inch hexagonal Coolant solenoid valve assembly 006132 Coolant bypass check valve 229721 Coolant solenoid valve assembly 229654 Thermistor: Copper pipe clip with electrical connector 127559 Coolant pump screen (coarse) 809970 Instruction Manual XPR300...

  • Page 123: Coolant Adapters In The Rear Compartment

    Adapter: 1/2 inch FNPT X 1-1/2 inch length bulkhead 015899 Red ring: 0.87 inch inner diameter (not shown) 015029 Adapter: 1/2 inch NPT X #8 male 015898 Green ring: 0.87 inch inner diameter (not shown) 015902 Green ring: 1.13 inch inner diameter XPR300 Instruction Manual 809970...

  • Page 124: Other Adapters Not Shown

    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 809970 Instruction Manual XPR300...

  • Page 125: Transformers And Inductors

    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. XPR300 Instruction Manual 809970...

  • Page 126: Control Side - View 1

    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 809970 Instruction Manual XPR300...

  • Page 127: Control Side - View 2

    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 229711 XPR300 wire harness – XPR300 Instruction Manual 809970...

  • Page 128: Rear Compartment Of The Plasma Power Supply

    Main contactor (200 V, 208 V, 220 V, 240 V) M_CON Main contactor (380 V, 400 V, 415 V, 440 V, 003268 480 V, 600 V) VDC3 PCB (Optional, for use with RS-422 141511 – and discrete cutting systems) 809970 Instruction Manual XPR300...

  • Page 129: Gas Connect Consoles

    Parts List Gas connect consoles Core OptiMix Part number Description 078631 Core gas connect console 078632 VWI gas connect console 078633 OptiMix gas connect console XPR300 Instruction Manual 809970...

  • Page 130: Gas Connect Console High-Voltage Side Parts

    Core, VWI, OptiMix high-voltage transformer 009045 EMI filter Core, VWI, OptiMix – High-frequency, 141354 Core, VWI, OptiMix PCB2 high-voltage ignition PCB Socket head cap screw: 075678 M5 – 0.8 X 10 mm Core, VWI, OptiMix – hexagonal 809970 Instruction Manual XPR300...

  • Page 131: Gas Connect Console Manifold Side Parts

    #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 – XPR300 Instruction Manual 809970...

  • Page 132: Core Gas Connect Console Manifolds And Adapters

    1/4 inch NPT X #6 male (air output and input) 015103 1/4 inch NPT X RH ‘B’ inert female (nitrogen output and input) 015116 1/8 inch NPT X RH ‘A’ male (oxygen output) 015009 1/4 inch NPT X RH ‘B’ male (oxygen input) 809970 Instruction Manual XPR300...
  • Page 133 Parts List XPR300 Instruction Manual 809970...

  • Page 134: Vwi Gas Connect Console Input And Output Manifolds And Adapters

    Parts List VWI gas connect console input and output manifolds and adapters 809970 Instruction Manual XPR300...
  • Page 135 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 809970...

  • Page 136: Optimix Gas Connect Console Input And Output Manifolds And Adapters

    Parts List OptiMix gas connect console input and output manifolds and adapters 809970 Instruction Manual XPR300...
  • Page 137 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 809970...

  • Page 138: Vwi And Optimix Gas Connect Console Mixer, Transducers, And Valves

    Designator Quantity Mixer (You cannot purchase – this part. Shown for OptiMix – reference only.) 011101 Regulator OptiMix – 223398 Pressure transducer VWI and OptiMix P6 – P9 006167 Solenoid valve VWI and OptiMix B4, B5 809970 Instruction Manual XPR300...

  • Page 139: Gas Connect Console Wire Harness, Hose Kit, And Can Cables

    CAN cable 0.48 m (1.6 ft) male-female Core, VWI 223711 CAN cable 0.5 m (1.6 ft) male-female OptiMix 223712 CAN cable 0.39 m (1.3 ft) male-female OptiMix Torch connect console Part number Description 078618 Torch connect console XPR300 Instruction Manual 809970...

  • Page 140: Torch Connect Console Easy Connect Side

    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 – 809970 Instruction Manual XPR300...

  • Page 141: Torch Connect Console Manifold Side - View 1

    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 809970...

  • Page 142: Torch Connect Console Manifold Side - View 2

    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 809970 Instruction Manual XPR300...

  • Page 143: Front Adapters And Valves

    1/8 inch NPT X #6 male – 015103 1/4 inch NPT X RH ‘B’ inert female – 015007 1/4 inch NPT X #5 male – 015922 1/4 inch hexagonal collar – 015210 1/8 inch NPT X LH ‘A’ male – XPR300 Instruction Manual 809970...

  • Page 144: Torch Assembly

    Torch solenoid valve (V1) tool 006169 Torch solenoid valve connector 428488 Torch assembly, 300 A mild steel consumables 104879 2.25 inch spanner wrench Torch bracket Part number Description 428646 Torch lifter bracket: 2.25 inch diameter sleeve 809970 Instruction Manual XPR300...

  • Page 145: Consumable Starter Kits

    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 XPR300 Instruction Manual 809970...

  • Page 146: Stainless Steel And Aluminum Consumable Starter Kit (428617)

    Swirl ring: 40 A – 170 A multiple processes 420323 Swirl ring: 60 A – 300 A multiple processes 420368 Water tube 420200 Shield retaining cap 420365 Nozzle retaining cap 104879 2.25 inch spanner wrench 104119 Consumable tool 027055 Silicone lubricant, 1/4 ounce 809970 Instruction Manual XPR300...

  • Page 147: Mild Steel Consumable Starter Kit With Torch (428618)

    Nozzle: 300 A 420491 Shield: 300 A 420406 Swirl ring: 300 A 420368 Water tube 420200 Shield retaining cap 420365 Nozzle retaining cap 104879 2.25 inch spanner wrench 104119 Consumable tool 027055 Silicone lubricant, 1/4 ounce XPR300 Instruction Manual 809970...

  • Page 148: Stainless Steel And Aluminum Consumable Starter Kit With Torch (428619)

    Swirl ring: 40 A – 170 A multiple processes 420323 Swirl ring: 60 A – 300 A multiple processes 420368 Water tube 420200 Shield retaining cap 420365 Nozzle retaining cap 104879 2.25 inch spanner wrench 104119 Consumable tool 027055 Silicone lubricant, 1/4 ounce 809970 Instruction Manual XPR300...

  • Page 149: Other Consumable And Torch Parts

    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 XPR300 Instruction Manual 809970...

  • Page 150: Plasma Power Supply To Gas Connect Console Connections

    25 m (82 feet) 223555* 15 m (49. 2 feet) 223525 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. 809970 Instruction Manual XPR300...

  • Page 151: Power Cable

    7.5 m (24.6 feet) 428483 45 m (147.6 feet) 428478 10 m (32.8 feet) 428484 60 m (196.9 feet) 428479 15 m (49.2 feet) 428485 75 m (246.1 feet) 428480 20 m (65.6 feet) – – XPR300 Instruction Manual 809970...

  • Page 152: Can Cable

    Part number Length Part number Length 428464 3 m (9.8 feet) 428467 7.5 m (24.6 feet) 428465 4.5 m (14.8 feet) 428468 10 m (32.8 feet) 428466 6 m (19.7 feet) 428469 15 m (49.2 feet) 809970 Instruction Manual XPR300...

  • Page 153: Pilot Arc, Coolant Hose Set, And Shield Water Assembly (Vwi Or Optimix)

    Part number Length Part number Length 428363 3 m (9.8 feet) 428366 7.5 m (24.6 feet) 428364 4.5 m (14.8 feet) 428367 10 m (32.8 feet) 428365 6 m (19.7 feet) 428368 15 m (49.2 feet) XPR300 Instruction Manual 809970...

  • Page 154: Plasma Power Supply To Cnc Connections

    12 m (39.4 feet) 223705 37.5 m (123 feet) 223697 13.5 m (44.3 feet) 223706 45 m (147.6 feet) 223698 15 m (49.2 feet) 223707 60 m (196.9 feet) 223699 16.5 m (54.1 feet) 223708 75 m (246.1 feet) 809970 Instruction Manual XPR300...

  • Page 155: Serial Cnc Interface Cable

    25 m (82 feet) 223665* 15 m (49.2 feet) 223646 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. XPR300 Instruction Manual 809970...

  • Page 156: Torch Connect Console To Torch Receptacle Connection

    3 m (11.5 feet) 0.5 m (20 inches) 428833 3 m (11.5 feet) 1.2 m (48 inches) 428828 3.5 m (11.5 feet) 428834 3.5 m (11.5 feet) 428830 4.5 m (14.8 feet) 428836 4.5 m (14.8 feet) 809970 Instruction Manual XPR300...

  • Page 157: Supply Hoses

    7.5 m (24.6 feet) 124033 45 m (147.6 feet) 124028 10 m (32.8 feet) 124034 60 m (196.9 feet) 124029 15 m (49.2 feet) 124035 75 m (246.1 feet) 124030 20 m (65.6 feet) – – XPR300 Instruction Manual 809970...

  • Page 158: Hydrogen Or Nitrogen-Hydrogen (F5) (Red)

    Preventive maintenance kits Part number Length 428639 Kit: Filter, torch rebuild without coolant 428640 Kit: Filter, torch rebuild with coolant 428641 Kit: Electronics (200 V – 240 V) 428642 Kit: Electronics (380 V – 600 V) 809970 Instruction Manual XPR300...

  • Page 159: Tools

    3-phase, 120 VAC 003276* Main contactor (200 V, 208 V, 220 V, 240 V) M_CON Main contactor (380 V, 400 V, 415 V, 440 V, 003268* 480 V, 600 V) * Voltage dependent - Select accordingly XPR300 Instruction Manual 809970...

  • Page 160: Gas Connect Consoles - Recommended Spare Parts

    Pressure transducer with wire and connector P1 – P5, P14 Torch – recommended spare parts Part number Description Designator Quantity 420220 Quick-disconnect/torch receptacle – 420221 Quick-disconnect torch – 420368 Water tube – 006155 Torch solenoid valve – 809970 Instruction Manual XPR300...

  • Page 161: Descriptions Of Warning Label Icons

    110647 Rev. B personnel should operate this www.hypertherm.com/weee www.hypertherm.com/weee 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 809970...
  • Page 162 Parts List 809970 Instruction Manual XPR300...

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