Hypertherm XPR170 Preventive Maintenance Program
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Hypertherm XPR170 Preventive Maintenance Program

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XPR
™
Preventive maintenance program
809490 – REVISION 2
ENGLISH

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  • Page 1 ™ Preventive maintenance program 809490 – REVISION 2 ENGLISH...
  • Page 2 XPR, TorchConnect, and Hypertherm are trademarks of Hypertherm, Inc. and may be registered in the United States and other countries. All other trademarks are the property of their respective holders. Environmental stewardship is one of Hypertherm’s core values. www.hypertherm.com/environment 100% Associate-owned...
  • Page 3 Instruction Manual 809490 REVISION 2 English Original instructions October 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 DE (DEUTSCH/GERMAN) www.hypertherm.com. 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 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......................14 Do a check of the coolant level and condition..............14 Examine and lubricate O-rings....................
  • Page 10 Every 6 months ............................24 Replace the coolant and coolant filter, and clean and examine the pump screen..24 Component replacement schedule......................... 28 Cutting area and operation effects ..................... 31 External cutting area ........................31 Incoming air supply quality......................32 Metal dust inside the plasma power supply cabinet............

  • 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

    (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 14: Examine All Of The Air Filters

    Preventive Maintenance Program Examine all of the air filters Examine all of the air filters for contamination. If you find moisture replace the air filter.  If you find a moderate quantity of solid  contamination, such as dust, blow air through it or use suction to clean the filter.

  • Page 15: Examine And Lubricate O-Rings

    Preventive Maintenance Program Examine and lubricate O-rings 1. Remove the consumables from the torch. 2. Examine all of the O-rings on the torch and consumables for damage or excess wear. 3. If you find damage or excess wear, replace the O-ring.

  • Page 16: 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 17: Weekly

    Preventive Maintenance Program 6. Use compressed air to remove any remaining particles from the torch main body. 7. Install the consumables on the torch. 104119 429013 Pre-calibrated: 2.3 N∙m – 2.8 N∙m (20 in∙lbf – 25 in∙lbf) “Click” “Snug-tight” Weekly Examine hoses, cables, and leads 1.

  • Page 18: 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 19: Monthly

    Preventive Maintenance Program Monthly WARNING ELECTRIC SHOCK CAN KILL Disconnect electric power before doing installation or maintenance. You can get a serious electric shock if electric power is not disconnected. Electric shock can seriously injure or kill you. All work that requires removal of the plasma power supply outer cover or panels must be done by a qualified technician.

  • Page 20: 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  XPR300 XPR170 2. If you find too much of this condition, replace the contactor.

  • Page 21: Examine The Pilot Arc Relay

    Preventive Maintenance Program Examine the pilot arc relay 1. Remove the cover of the pilot arc relay.  Shown for reference only. 2. Examine the contacts inside the relay for black or rough surfaces. 3. If you find too much of this condition, replace the pilot arc relay.

  • Page 22: Do The Coolant Flow Test

    5. If the coolant flow remains slow, refer to 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. 809490 Instruction Manual...

  • Page 23: 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. Refer to the Parts List section of your system’s instruction manual. CAUTION Do not clean brass connections with ammonia-based cleaners.

  • Page 24: 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. Refer to Estimate the total coolant volume for your cutting system in your system’s instruction manual. 2.
  • Page 25 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 Green b.
  • Page 26 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 27 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.

  • Page 28: 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 29 Kit: Torch rebuild and filter with coolant 028872 6 – 12 Coolant (in US gallons)** Kit: Electronics*** 428878 200 V – 240 V (XPR170 only) 428879 380 V – 600 V (XPR170 only) 428641 200 V – 240 V (XPR300 only) 428642 380 V –...
  • Page 30 * 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. Refer to your system’s instruction manual for more information, then record this number in Coolant requirements on page 36.

  • Page 31: 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 32: Incoming Air Supply Quality

    Also, unwanted material in pressure sensors can cause false pressure readings. 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 33: Metal Dust Inside The Plasma Power Supply Cabinet

    Preventive Maintenance Program Metal dust inside the plasma power supply cabinet Plasma cutting makes metal dust. If metal dust collects inside the plasma power supply, it can decrease the life of the fans. The main power supply, chopper, or heat exchanger fans can operate more slowly, or failure of the fans can occur.

  • Page 34: 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 35: 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 36: 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 37: Notes

    Preventive Maintenance Program Notes Instruction Manual 809490...

  • Page 38: Maintenance Log For Xpr Cutting Systems

    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...

This manual is also suitable for:

Xpr300

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