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Related Manuals for Hypertherm XPR Series
Summary of Contents for Hypertherm XPR Series
- Page 1 plasma ™ Preventive maintenance program 809490 – REVISION 1 ENGLISH...
- 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 Instruction Manual 809490 Revision 1 English Original instructions October 2018 Hypertherm, Inc. Hanover, NH 03755 USA www.hypertherm.com...
- Page 4 México, D.F. C.P. 01780 (Technical Service Email) 52 55 5681 8109 Tel 52 55 5683 2127 Fax South America & Central America: Hypertherm Brasil Ltda. Soporte.Tecnico@hypertherm.com (Technical Service Email) Rua Bras Cubas, 231 – Jardim Maia Hypertherm Plasmatechnik GmbH Guarulhos, SP – Brasil...
- Page 5 한국어 / KOREAN product worden meegeleverd. De handleidingen, elke handleiding 경고! Hypertherm 장비를 사용하기 전에 제품 설명서와 안전 및 규정 beschikbaar in alle talen, zijn ook verkrijgbaar via de “Documentenbibliotheek” 준수 설명서 (80669C)에 나와 있는 안전 지침을 읽으십시오. 안전 지침을...
- Page 6 Kópia návodu, ktorá je dodávaná s produktom, môže mať elektronickú alebo tlačenú podobu. Kópie návodov, vo všetkých dostupných jazykoch, sú k dispozícii aj v sekcii z „knižnice Dokumenty“ na www.hypertherm.com.
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Page 7: Table Of Contents
Contents Preventive Maintenance Program..................11 Overview ................................11 Cleaning and inspection schedule........................12 Daily................................13 Do a test of the inlet pressures....................13 Examine all of the air filters......................13 Do a check of the coolant level and condition..............13 Examine and lubricate O-rings.................... - Page 8 Every 6 months ............................21 Replace the coolant and coolant filter, and clean and examine the pump screen..21 Component replacement schedule......................... 25 Cutting area and operation effects ..................... 28 External cutting area ........................28 Incoming air supply quality......................29 Metal dust inside the power supply cabinet .................
- Page 9 Notes..................................40 Maintenance log for XPR cutting systems ....................41 Instruction Manual 809490...
- Page 10 809490 Instruction Manual...
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Page 11: Preventive Maintenance Program
Preventative Maintenance Program (PMP). Hypertherm made this PMP specifically for your plasma system. The PMP has two parts: a cleaning and inspection schedule and a component replacement schedule. -
Page 12: Cleaning And Inspection Schedule
Preventive Maintenance Program Cleaning and inspection schedule This is a daily, weekly, and monthly schedule for cleaning and inspections. The PMP has instructions for each task. These instructions help your personnel understand what to do and what to look for during each task. -
Page 13: Daily
Preventive Maintenance Program Daily Do a test of the inlet pressures 1. With the gas flowing in test preflow mode, make sure that the pressure at the regulator is set to 7.5 bar (110 psi). 2. Repeat the test in cutflow mode, and make sure that the regulator is set to 7.5 bar (110 psi). 3. -
Page 14: Examine And Lubricate O-Rings
Preventive Maintenance Program Examine and lubricate O-rings 1. Examine all of the O-rings on the torch and consumables for damage or excess wear. 2. If you find damage or excess wear, replace the O-ring. Receptacle O-rings and torch O-rings for the torch main body are available as part of the torch rebuild and filter kit (428639 or 428640). -
Page 15: Examine The Water Tube And Torch
Replace the O-ring if you find damage or excess wear. Torch rebuild kits are available from Hypertherm. b. Apply a thin film of silicone lubricant (027055) if replacement is not needed. -
Page 16: Do Tests For Gas Leaks
Tighten loose connections if found, but do not make the connections too tight. b. Order a replacement hose, cable, or lead set if you find its fitting has damage or excess wear. Replacement hoses, cables, and leads are available from Hypertherm. ... -
Page 17: Monthly
Preventive Maintenance Program Monthly WARNING ELECTRIC SHOCK CAN KILL 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. -
Page 18: Examine The Contactors
Preventive Maintenance Program Examine the contactors 1. Examine the contacts for black or rough surfaces: For the XPR170 (left), examine the main contactor For the XPR300 (right), examine the main contactor and inrush contactor 2. If you find too much of this condition, replace the contactor. Examine the pilot arc relay 1. -
Page 19: Examine The Coolant System
5. If the coolant flow remains slow, see How to measure coolant flow in your system’s instruction manual. 6. If you cannot find or resolve the problem with these corrective actions, contact your cutting machine supplier or regional Hypertherm Technical Service team. Instruction Manual 809480... -
Page 20: Examine The Gas Line Connections
Preventive Maintenance Program Examine the gas line connections Spray all of the gas line connections with soapy water. If bubbles appear on a gas line, tighten or replace it as necessary. See Part numbers for hoses, cables, and leads on page 32 for lengths and part numbers. -
Page 21: Every 6 Months
Preventive Maintenance Program Every 6 months Replace the coolant and coolant filter, and clean and examine the pump screen 1. Estimate the total coolant volume for your cutting system. See Estimate the total coolant volume for your cutting system in your system’s instruction manual. 2. - Page 22 Preventive Maintenance Program 5. Remove old coolant from the heat exchanger: a. Keep the 3/8-inch inner diameter tube connected to the outlet of the valve on the bottom of the reservoir on one end and the other end in the container. Green b.
- Page 23 Preventive Maintenance Program f. Leave the coolant return hose (red band) disconnected from the rear of the plasma power supply. g. Put a container under the pump plug. h. Remove the plug and coolant pump screen and set them aside. i.
- Page 24 Preventive Maintenance Program 7. Remove old coolant from the filter housing and replace the coolant filter: a. Remove the filter housing from inside of the plasma power supply. b. Discard all of the coolant from inside of the filter housing. c.
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Page 25: Component Replacement Schedule
If you do not have a Hypertherm CNC and your CNC cannot track arc hours, use the guide below to estimate arc hours per year. This guide uses the average number of 8-hour shifts that the system operates on an average work day. - Page 26 Table 2 Cumulative number of arc hours Item Number Quantity Component 500 1,000 1,500 2,000 2,500 3,000 3,500 4,000 4,500 5,000 5,500 6,000 428639* Kit: Torch rebuild and filter without coolant 428640* Kit: Torch rebuild and filter with coolant 028872 6 –...
- Page 27 * This kit includes the air filter (011110), coolant filter (027005), and torch rebuild components. ** The number of gallons you need depends on the length of the leads. See your system’s instruction manual for more information, then record this number in Coolant requirements on page 39.
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Page 28: Cutting Area And Operation Effects
If any of these conditions or operations apply, change your replacement schedule as suggested. How much you need to change your schedule depends on how bad the condition is. If you have questions about your replacement schedule, contact your OEM or regional Hypertherm Technical Service team. -
Page 29: Incoming Air Supply Quality
The best solution, if possible, is to improve the quality of the air supply. Contact your OEM or regional Hypertherm Technical Service team if you need advice on how to improve the quality of your air supply. -
Page 30: Consumable Use
Preventive Maintenance Program Consumable use If you let consumables reach complete failure, they can melt. Copper pieces can then break off and go into the coolant. In the coolant, these pieces can cause the following problems: Decrease coolant flow Increase coolant flow errors ... -
Page 31: Cut-Cycle Time
Preventive Maintenance Program Cut-cycle time When the cut-cycle is very short, relays operate more frequently. The system also pierces more frequently. Examples of this type of cycle are when you cut many small holes or make markings for numbers and letters. These types of operations can cause the following problems: Increase wear on pilot arc relay contact pads ... -
Page 32: Part Numbers For Hoses, Cables, And Leads
Preventive Maintenance Program Part numbers for hoses, cables, and leads Plasma power supply to gas connect console connections Pilot arc lead with strain relief Part number Length Part number Length 223529 3 m (9.8 feet) 223535 25 m (82 feet) 223530 4.5 m (14.8 feet) 223536... -
Page 33: Power Cable
Preventive Maintenance Program * Leads labeled with CCC mark only. Power cable Part number Length Part number Length 223436 3 m (9.8 feet) 223446 25 m (82 feet) 223437 4.5 m (14.8 feet) 223447 35 m (114.8 feet) 223439 7.5 m (24.6 feet) 223448 45 m (147.6 feet) 223441... -
Page 34: Power, Can, And 3-Gas Assembly (Core)
Preventive Maintenance Program Power, CAN, and 3-gas assembly (Core) 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) Pilot arc, coolant hose set, and shield water assembly (VWI or OptiMix) -
Page 35: Plasma Power Supply To Cnc Connections
Preventive Maintenance Program Plasma power supply to CNC connections EtherCAT CNC interface cable Part number Length Part number Length 223506 0.3 m (1 foot) 223512 10 m (32.8 feet) 223507 0.6 m (2 feet) 223513 15 m (49.2 feet) 223508 1.5 m (4.9 feet) 223514 22.5 m (73.8 feet) -
Page 36: Plasma Power Supply To Cutting Table Connection
Preventive Maintenance Program Plasma power supply to cutting table connection Work lead (XPR170 only) Part number Type Length Part number Type Length 223617 3 m (9.8 feet) 223650* 3 m (9.8 feet) 223618 4.5 m (14.8 feet) 223651* 4.5 m (14.8 feet) 223619 7.5 m (24.6 feet) 223652*... -
Page 37: Supply Hoses
Preventive Maintenance Program Supply hoses Oxygen hose (blue) Part number Length Part number Length 124003 3 m (9.8 feet) 124009 25 m (82 feet) 124004 4.5 m (14.8 feet) 124010 35 m (114.8 feet) 124005 7.5 m (24.6 feet) 124011 45 m (147.6 feet) 124006 10 m (32.8 feet) -
Page 38: Water (Optional Shield Fluid) (Blue)
Preventive Maintenance Program Water (optional shield fluid) (blue) Part number Length Part number Length 124047 3 m (9.8 feet) 124053 25 m (82 feet) 124048 4.5 m (14.8 feet) 124054 35 m (114.8 feet) 124049 7.5 m (24.6 feet) 124055 45 m (147.6 feet) 124050 10 m (32.8 feet) -
Page 39: System Information
Preventive Maintenance Program System information Model number Serial number System voltage 200 V/208 V 220 V 240 V 380 V (CCC) 400 V (CE) 415 V (CE) 440 V 480 V (CSA) 600 V (CSA) ... - Page 40 Preventive Maintenance Program Notes 809490 Instruction Manual...
- Page 41 Maintenance log for XPR cutting systems Daily tasks 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Do a test of the inlet pressures Examine all of the air filters Do a check of the coolant level and condition Examine and lubricate O-rings Examine the water tube and torch...
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